Acrobat Distiller, Job 7

Transcription

Instruction Manual
For Power Monitor
(PM) Series
14845 WEST 64th AVENUE • ARVADA, COLORADO 80007 USA
PHONE: (1+) 303-425-0800 • FAX: (1+) 303-425-0896 • WEBSITE: WWW.SUNDYNE.COM
PM Series_MANUAL_1/07/04
Page 1
Table of Contents
Description
Page
Legal Declarations
3
Model Number Definitions
3
Introduction
4
Basic Power Monitor
Product Specifications
4
Wiring Diagrams
3-Phase Models Using Internal CT Only
5
3-Phase Models Using External CT
6
1-Phase Model Using Internal CT Only
7
Terminal Block Connections and Definitions
8
Mounting Information
9
Panel Function Definitions
10
Determining Low and High Trips Limits
11
Application Notes
Using an External CT
13
Automatic Reset
13
Utilizing the Analog Output
13
Inverted Relay Operation
13
Troubleshooting
14
Optional Display Panel
Product Specifications
15
Wiring Diagram
16
Terminal Block Connections and Definitions
16
Mounting Information
17
Panel Definitions
18
Panel Programming Steps and Function Definitions
19
Application Notes:
Using an External CT
20
Automatic Reset
20
Utilizing the 4-20 mA Output
20
Hardware and Software Lock
20
Troubleshooting
Set-Up Examples
21
22
Page 2
WARRANTY
Sundyne Corporation warrants to Buyer for a period of twenty-four
(24) months that equipment at the time of shipment will be free from
defects of design, material and workmanship. If any defects or
malperformance occur during the warranty period, Sundyne’s sole
obligation shall be limited to alteration, repair or replacement at
Sundyne’s expense, F.O.B. Factory, of parts or equipment, which
upon return to Sundyne and upon Sundyne’s examination prove to be
defective. Equipment and accessories not manufactured by Sundyne
are warranty only to extend of and by the original manufacturers’
warranty. Sundyne shall not be liable for damage or wear to
equipment caused by abnormal conditions, vibration, failure to
properly prime or operate equipment without flow or caused by
corrosives, abrasives or foreign objects. THE FOREGING WARRANTY
IS EXCLUSIVE AND INLIEU OF ALL OTHER WARRANTIES WHETHER
EXPRESSED OR IMPLIED INCLUDING ANY WARRANTY OF
MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.
In no even shall Sundyne be liable for consequential or incidental
damages.
EUROPEAN UNION MACHINERY DIRECTIVE
This document incorporates information relevant to the Machinery
Directive 98/37/EC. It should be read prior to the use of our
equipment. Individual maintenance manuals that also conform to the
EU Directive should be read when dealing with all models. Although
PM Series power monitor complies with the EMC and Low Voltage
Directives, satisfactory performance cannot be guaranteed in high
noise environments that are outside the EMC limits.
THIRD PARTY APPROVALS
The PM Series products are designed to meet the industrial control
equipment guidelines outlined by Underwriter’s Laboratories (UL)
Bulletin 508 and Canadian Standards Association (CSA) Standard
22.2. Please consult the factory for the specific model approval
status.
COPYRIGHT
All rights reserved. No part of this publication may be reproduced,
stored in a retrieval system or transmitted in any form or by any
means, electronic, mechanical, photo copying, recording or otherwise
without the prior permission of Sundyne Corporation.
 2003 Sundyne Corporation
Page 3
Introduction:
INPUT
POWER
MOTOR INPUTS
The relationships between AC motor current and AC motor input
power with respect to motor load are shown in figure 1. The motor
current remains almost constant between 0 to 50% of motor load
while the motor power increases uniformly with increasing load. Using
this linear relationship between input power, the user has a method of
linking motor power to the pump performance curve to predict flow
rate as long as the motor speed remains constant. Motor output
power is calculated by multiplying the measured input power by the
motor efficiency marked on the motor nameplate. This motor
efficiency can fluctuate by several percentage points over the entire
motor load range depending on the motor manufacturer standards.
CURRENT
0
50
100
PERCENTAGE OF MOTOR LOAD
FIGURE 1
A power monitor is a simple flow indicator that associates a digital (input or calculated output
power) value to a specific pump flow rate. The decision-making capability inside the power monitor
permits the user to setup a power window of pump operation. This window has a programmable
low limit (value just above minimum flow) and a programmable high limit (value equal to the point
just prior to end of curve/cavitation). If the pump motor operates outside of this window longer than
a defined time period, then the monitor will open a relay contact (electrical mechanical switch) that
will cause a controller to remove power from the pump motor, thus stopping the pump operation
before damage can occur.
-Basic Power MonitorProduct Specifications:
Model No.
PM 1200
PM 1300
PM 1100
Description - Voltage Sampling Range
3-PH Power Monitor, 230 to 575 VAC
3-PH Power Monitor, 600 to 660* VAC (Optional)
1-PH Power Monitor, 100 to 250 VAC (Optional)
*Note: Underwriters Laboratory has a maximum voltage limit of
600 VAC, model PM1300 cannot be UL listed.
Motor Current Sampling Range (All Models)
0 – 65 Amp
Internal CT
N Amp with CT ratio of N: 5 Amp
External CT
High Trip Limit
Low Trip Limit Range
Start-Up / Low Trip Delay
High Trip Delay
Frequency Range
Control Supply
Relay Output:
Rating
Type
Analog Output
Activation Voltage - K Inputs
Environment Restriction
Operating Temperature
Enclosure:
Material
Mounting
Rating
Dimensions
Third Party Approvals
FIGURE 2
High Trip = kW range set (adjustable from panel pot)
20 to 80% of kW Power Range (adjustable from panel pot)
1 - 30 seconds (adjustable from panel pot)
1 - 10 seconds (adjustable from panel pot)
45 - 65 Hz
115/230 VAC ± 10%, 50/60 Hz, 1-Ph
5 Amp @ 250 VAC (non-inductive)
SPDT, Normally Close
0 –10 VDC (directly proportional to kW range selected).
12 – 30 VDC
The unit must be kept away from moisture.
+5 to +122°F (-15 to +50 °C)
Upper:White Lexan (UL94-V0), Lower:Black Noryl (UL94-V0)
35 mm DIN Rail
NEMA 1 Type (IP 20)
2.76 in. x 3.38 in. x 2.28 in. (70 mm x 86 mm x 58 mm)
CE (UL and C-UL pending)
Page 4
Wiring Diagram: 3-Phase Unit with Internal CT Only
PHASE L3
PHASE L2
PHASE L1
INTERNAL CURRENT SENSOR
1
L1
2
3
L2
NC
13
C
14
NO
15
16
4
5
L3
6
7
230 VAC
8
CONTROL
VOLTAGE
9
115 VAC
10
11
STARTING COIL
VOLTAGE
N
12
+12V
17
K1
18
K2
19
K3
20
GND
21
VD +
22
VP
23
VN
24
STOP
OPTIONAL
DISPLAY
0 - 10 VDC
START
AUX.
MOTOR STARTER
OL
M
M
M
M
AC
3-PHASE
MOTOR
FIGURE 3
Note: The normally closed (NC) relay contact is closed when the unit is powered and no
trip condition exists.
!
CAUTION
The PM Series power monitor is directly connected to the AC supply
that powers the motor. Dangerous voltage potentials are present.
Qualified personnel must perform all installation and servicing with the
AC supply disconnected and locked out.
Page 5
Wiring Diagram: 3-Phase Unit with External CT
PHASE L3
PHASE L2
HI
PHASE L1
X2
X1
EXTERNAL CURRENT TRANSFORMER
1
L1
NC
C
NO
2
3
L2
+12V
K1
K2
K3
GND
VD +
VP
VN
L3
6
7
230 VAC
8
CONTROL
VOLTAGE
9
115 VAC
10
11
N
12
STARTING COIL
VOLTAGE
14
15
16
4
5
13
STOP
17
18
19
20
21
OPTIONAL
DISPLAY
22
23
24
0 - 10 VDC
START
AUX.
MOTOR STARTER
OL
M
M
AC
3-PHASE
MOTOR
M
M
FIGURE 4
Note:
The normally closed (NC) relay contact is closed when the unit is powered and no
WIRE WITH MOTOR
CURRENT FLOWING
Using an External Current Transformer
1. The external CT must be rated for wattmeter usage to
obtain correct power reading.
2. The “XI” wire lead from the transformer is passed through
the internal CT and is connected to the other wire lead, X2.
3. To maintain proper current direction, the wire from the
power supply must enter the core of the external CT from
the side marked “HI”.
4. Refer to the page 13 in application notes for further details.
!
FIGURE 4
SECONDARY WIRES
CONNECT THRU
INTERNAL CT
EXTERNAL CT WITH ONE TURN
FIGURE 5
CAUTION
Page 6
Wiring Diagram: 1-Phase Unit with Internal CT
PHASE L2
PHASE L1
1
L1
2
3
L2
NC
13
C
14
NO
15
16
4
5
+12V
17
6
K1
18
K2
19
K3
20
GND
21
VD +
22
VP
23
VN
24
7
230 VAC
8
CONTROL
VOLTAGE
9
115 VAC
10
11
STARTING COIL
VOLTAGE
N
12
STOP
OPTIONAL
DISPLAY
0 - 10 VDC
START
AUX.
MOTOR STARTER
OL
M
M
M
AC
1-PHASE
MOTOR
FIGURE 6
Note:
The normally closed (NC) relay contact is closed when the unit is powered and no
!
CAUTION
Page 7
Terminal Block Connections and Definitions:
INTERNAL RELAY
CONTACTS (NO, NC)
REMOTE RESET AND
TRIP INHIBIT INPUTS
EXTERNAL DISPLAY SIGNAL
ANALOG OUTPUT
SIGNAL (0 - 10 VDC)
1. It is strongly recommended that all
wiring be done according to local
electrical codes.
24
13
13 14 15 16 17 18 19 20 21 22 23 24
4 5 6
.
4 5 6
2. The terminal block will accept a
maximum of 12-gauge wire (2 mm).
5
4 5 6
Loa d
73
7
73
82
8 0
82
10
Ts
9
9
1
9
1
HighDelay(s)
0
0
Hig h
Limit / Range (kW)
15
Sta rt- T
Hig h T rip
Low
Lo w T rip
0
30
PM Seri es
Ts Delay(s)
Limit (% )
In t. C T
52
15
44
M ax65A
60
Reset
36
68
0
30
28
76 Low Delay(s)
L1
L2
L3
20
3
2
x10
1
1
0
2
3
4
5
6
7
8
3. Maximum recommended installation
torque for the terminal block screws is
7 lb-in (0.79 N-m).
4. The internal CT opening has maximum
opening of 0.39 in. (10 mm) that limits
the wire size to #6 (4.1 mm).
9 10 11 12
1
Field Wiring Guidelines
12
5. Use copper wire only.
CONTROL VOLTAGE
(115 /230 VAC, 50/60 Hz, PH 1)
MOTOR SAMPLE VOLTAGE INPUT
No.
1
2
3
4
5
6
7
8
9
10
11
12
FIGURE 7
Description
Phase Voltage L1 Input
Do not use
Do not use
Do not use
230 VAC
Do not use
115 VAC
Do not use
N
Do not use
No.
13
14
15
16
17
18
19
20
21
22
23
24
Description
Relay Contact, Normally Closed
Relay Contact, Pole
Relay Contact, Normally Open
Do not use
+12 VDC Unregulated (For ”K” Inputs Only)
K1, External and Automatic Reset
K2, Disable Low Trip Function
K3, Disable High Trip Function
Isolated DC Ground
VD+, Display input
VP, Analog Output
VN, Analog Output
Remote Reset and Inhibit Inputs:
The control inputs are isolated (2500 Vrms) by
means of opto-couplers. Connecting terminal 17
(isolated 12 VDC, unregulated supply) to one of the
inputs will activate it. The inputs can also be wired for
PLC operation:
Analog Output:
A non-isolated monitoring signal (0 – 10 VDC) is
available at terminals 23 (VP) and 24 (VN) that can
be connected to a voltmeter for digital visualization of
the measured input power.
Zero kW Power
High Trip (kW Range Setting)
Minimum Load Impedance
0V
10 V
1 Meg. Ohms
12 - 30 VDC
16
+12V
17
K1
18
K2
19
K3
20
GND
21
VD +
22
VP
23
VN
24
PLC
DC SUPPLY
COMMON
0 - 10 VDC
FIGURE 8
Page 8
Mounting Information:
The power monitor must be installed inside either a motor starter control cabinet or a similar
electrical enclosure to shield it from moisture. The unit attaches to a standard 35 mm DIN rail (not
supplied by Sundyne).
2.28 IN. (58 MM)
13
24
1 3 1 4 15 1 6 1 7 18 19 20 21 2 2 23 24
4
5
6
.
4
5
4
6
5
5
6
3
7 3
7 3
7
2
8 2
8 2
8
x10
1
0
Hi gh Trip
9
1 0 9
0
L imit / Ran ge ( kW)
9
1
S tart-T
Lim it (% )
52
60
44
Int. CT
Ma x 65A
36
68
28
L2
1
2
Ts
High
15
3.38 IN. (86 MM)
Low
Low Tri p
PM Series
L1
Load
0
10
Hig h De lay(s )
L3
3
4
5
6
20
76
7
0
30
T s De lay(s )
15
Reset
0
30
Low Delay (s)
8
9 1 0 11 12
1
12
2.76 IN. (70 MM)
0.39 IN. (10 MM)
MOUNT
RELEASE
CORE OF INTERNAL
CURRENT TRANSFORMER
FIGURE 9
The unit must be kept away from moisture.
+5 to +122°F (-15 to +50 °C)
Upper: White Lexan (UL94-V0), Lower: Black Noryl (UL94-V0)
35 mm DIN Rail
NEMA 1 Type (IP 20)
2.76 in. x 3.38 in. x 2.28 in. (70 mm x 86 mm x 58 mm)
Enclosure:
Material
Mounting
Rating
Dimensions
!
Warning
The PM Series products are not to be located in Hazardous Areas,
which are defined as areas where there is a presence or possible
presence of a flammable gas/air mixture.
Page 9
Panel Function Definitions:
HIGH LIMIT MULTIPLIER
HIGH LIMIT SETTING (3-DIGIT)
13
24
13 14 15 16 17 18 19 20 21 22 23 24
4
3
2
x10
5
6
.
4
5
4
6
7 3
8 2
5
5
6
1 0 9
1 0 9
1 0 9
Limit / Rang e (kW)
36
1 2
3 4
5
15
Rese t
68
28
L3
6
20
High
0
30
T s Delay(s)
Limit ( %)
52
60
44
In t. CT
Max 65A
15
Ts
Lo w
Low Trip
P M Se rie s
L2
0
10
High Delay(s)
St art-T
High Trip
L1
L oad
7
8
73
82
30
0
76 Low Delay( s)
7 8
HIGH TRIP TIME DELAY SETTING
LOAD MEASURED LED
START TIME DELAY STATUS
HIGH TRIP STATUS
LOW TRIP STATUS
RELAY CONTACT STATUS
START-UP TIME DELAY SETTING
LOCAL RESET BUTTON
9 10 11 12
12
1
LOW TRIP TIME DELAY SETTING
LOW LIMIT SETTING
FIGURE 10
Marking
Function Description
X1 - X10
High Limit Multiplier: Adjusts the High Trip limit setting value by a factor of 10.
High Trip
Limit
High Limit Setting: Upper power limit of the operating window is defined by this
value. If the measured power is higher than this value, then a trip condition is
recognized.
High Trip
Delay
High Trip Delay Time Setting: When the measured power exceeds the High
Trip setting, an internal timer is activated. The measured power must return
below this limit within a defined time period or a trip condition will be accepted.
This time period is defined as the High Trip Delay.
Load
Load Measured LED: Will be on when the measured load is higher than 5% of
kW setting, otherwise it will flash at 1/2-second intervals.
Ts
Start Time Delay Status: The LED is on when start-up timer is active.
High
High Trip Status: The LED is on when High Trip condition is recognized, and
the LED flashes (0.5 second on-off) when High Trip condition is accepted.
Low
Low Trip Status: The LED is on when High Trip condition is recognized, and
the LED flashes (0.5 second on-off) when High Trip condition is accepted.
Relay Contact Status: The LED is on when the internal, normally closed relay
contact is closed.
Ts(s)
Start Up Time Delay Setting: The High and Low trip functions are disabled
during motor start-up (power-up) for a fixed period of time.
Reset
Local Reset Button: Push to clear all trip functions to close relay contact
Low Trip
Delay
Low Trip Delay Time Setting: When the measured power falls below the Low
Trip setting, an internal timer is activated. The measured power must return
above this limit within a defined time period or a trip condition will be accepted.
This time period is defined as the Low Trip Delay.
Low Trip
Limit
Low Limit Setting: Lower power limit of the operating window is defined by this
value. If the measured power is lower than this value, then a trip condition is
recognized.
Page 10
Determining the Low and High Trip Limits:
The basic power monitor performs three tasks once it is connected to a pump drive motor:
•
•
•
Measure the electrical input power in kW
Compare the measured power value to a minimum and maximum power settings
Set and latch an internal relay contact (open or close) based on the comparison result
The minimum (Low) limit is the input power measurement setting that is associated with:
•
•
Low Flow
Severe Cavitation
•
•
Magnetic Decoupling (Magnetic Drive Pumps)
Reduction in Fluid Viscosity
The maximum (High) limit is the input power measurement setting that is associated with:
•
•
•
Seizure of Rotating Parts
High Flow Operation (Operating at the end of pump curve)
Increase in Fluid Viscosity
The High and Low limits (trips) can be estimated from the pump performance curve:
1. Write down the motor output power (POUT @ min. and POUT @ max.) values for the
minimum and maximum flow points that are defined by application sheet.
2. Calculate the percentage ratio of minimum power to the maximum power:
(POUT @ Min / POUT @ Max) x 100
3. Set the Low Limit (%) dial to this percentage value or to the nearest percentage value
above it. (for example, if 41.5 % is calculated, then choose 44%)
4. Multiply the POUT @ Max by the specific gravity (S.G.) of the fluid to be pumped.
5. Add any magnetic coupling (PMC) losses (if any) to this value.
HIGH LIMIT
6. Determine what motor size (or rating) is needed to
operate the pump for the maximum flow.
Load
7. Select a motor from a manufacturer’s catalog, and record
Ts
the motor efficiency value at full load.
High
St art -T
High Trip
Low
8. Divide the adjusted maximum power value by the motor
Low T rip
PM Series
efficiency value. (Note: If this power value is not in kW,
Reset
then convert it)
9. Set the High Limit (3-digit) to this value.
x1
4
5
3
2
x1 0
6
.
4
5
73
82
1
0
6
4
5
7
8
9
1
9
9
1
0
0
Lim it / Ra ng e ( kW)
0
30
T s Dela y(s)
15
44
36
Note: The motor power required by the pump can change if
the fluid property (specific gravity, viscosity,
temperature) changes in the application.
0
10
High Dela y(s)
15
Limit (%)
52
60
Int. CT
Max 6 5A
L1
5
6
7 3
8 2
L2
LOW LIMIT
L3
28
68
20
76
0
30
Low Delay( s)
FIGURE 11
To operate the monitor when the limits are not known, it is recommended to set the pots to values
shown and/or calculated from this table:
Marking
Ts(s)
High - Tr(s)
Low - Tr(s)
Low Limit
High Limit
Adjust Monitor Panel Pots for Initial Start-Up as Follows
Definition
Initial Set Value
Start Time Delay
5 Seconds (Approximately)
High Trip Delay
Low Trip Delay
Low Trip Value
20%
Motor rated power (hp) x 0.746 / 0.81
High Trip Value2
Motor rated power (kW) / 0.81
Note:
1. The monitor measures input power in kW, so this equation estimates the
input power value in kW of the pump motor at 100% of rated load. The
equation assumes that the motor is 80% efficient.
2. If external CT is to be used, then refer to application section on page 13 for
kW range setting limits on the monitor.
Page 11
A simple way to set the Low and High Trip values is to operate the pump at the two extreme flow
rates (maximum and minimum) defined in application parameters.
1. Make sure that the suction pipe and the pump are filled with liquid, and the suction valve is
completely open.
2. Start the pump, and adjust the discharge valve until the application maximum flow is reached.
!
PUMP OPERATION
Do not run out on the pump curve if throttling is necessary because
cavitation may occur.
3. Decrease kW setting value slowly until the HIGH LED turns on. The motor starter can and will
switch off at this point after the time delay is completed. (Press the Reset button on monitor
panel to clear any trips.)
DELAY TIMERS SETTINGS
4. Start the pump again and verify that the pump does shut-off at
this point. The HIGH LED will be on, and Contact LED is off.
Note: The time to shut-off the pump from a start-up
condition is equal to the sum of start time (Ts) and
the High Limit Delay Setting (High-Tr).
5. If the pump does not shut off, then repeat steps 3 and 4 until
the pump does shut off at this flow point.
x1
4
5
3
2
x1 0
6
.
4
5
6
4
5
5
6
73
7 3
7
82
8 2
8
1 0 9
1 0 9
1 0 9
Lim it / Ra ng e ( kW)
St art -T
High Trip
Limit (%)
52
60
44
Int. CT
Max 6 5A
36
L2
Ts
High
15
Low
Low T rip
PM Series
L1
Load
0
10
High Dela y(s)
L3
28
68
20
76
6. Press the Reset button on the monitor panel to clear any trips.
0
30
T s Dela y(s)
15
Reset
0
30
Low Delay( s)
FIGURE 12
7. Start the pump again and adjust the discharge value for the normal operating flow point.
Note:
Only two LEDs (LOAD and Contact) should be on after Ts LED is off.
8. Adjust the discharge valve to the minimum flow point required in the application. If this value is
very close to no flow condition, then consult with the pump manufacturer for cautionary advice.
!
PUMP OPERATION
Try to limit pump operation time at minimum flow for no more than a few
seconds until the Low Trip Limit is set. Do not exceed 5-10 seconds at
any one time.
9. Increase the LOW Trip limit setting until the LOW LED is on. The motor starter can and will
switch off at this point after the time delay is completed. (Press the Reset button on monitor
panel to clear any trips)
10. Start the pump again and adjust the discharge valve until the normal operating flow is reached.
Only two LEDs (Load and Contact) should be on after Ts LED is off.
11. Verify the limits by adjusting the discharge valve for the two flow conditions. Fine-tune the trip
limits where it is needed. (Time delays may also need tuning to reduce nuisance tripping.)
Note: Let the pump run for a few hours to allow the AC motor to warm-up. The trip
values may need to be fine-tuned to compensate for power variation between
cold (not used for 24 hours) motor and hot (operating for 2 hours or more) motor.
Page 12
Application Notes:
Using an External CT with the Power Monitor
The kW range on the monitor must be adjusted to accept
only the 0 – 5 amps current range from the CT secondary.
The recommended kW value is shown in this chart for the
nominal line voltage or a value can be calculated from the
basic power equation given:
The maximum kW range with external CT (N:5) is defined:
Max. kW = N (primary value) x kW Setting (monitor) x 0.2
Note: The nominal motor voltage can influence this
maximum kW setting for the Monitor. If the
calculated kW value is higher than the kW
setting shown for the voltage indicated, then
use the kW setting shown for the voltage as the
maximum kW setting.
Nominal Voltage
208 VAC
230 VAC
380 VAC
415 VAC
460 VAC
575 VAC
600 VAC
kW Setting
1.80
1.99
3.29
3.59
3.98
4.98
5.20
Basic Power Equation
kW Setting = Nom. Volt x .00866
Automatic Reset
Connecting a wire jumper between terminals 17 and 18 will enable
the Automatic Reset feature. This reset feature will automatically
clear a trip condition after a trip has been recognized.
WIRE JUMPER
16
+12V
17
K1
18
K2
19
K3
20
GND
21
Utilizing the Analog Output
VD +
22
A non-isolated monitoring signal (0 – 10 VDC) is available at
terminals 23 (VP) and 24 (VN) that can be connected to a
voltmeter (or a process meter with scaling) for digital visualization
of the measured power. The linear relationship of signal to the
measured power is defined by this equation:
VP
23
VN
24
Note: When this feature is used, it is strongly recommended
that a separate start command be required to start the
motor thus preventing unexpected system start-up.
0 - 10 VDC
FIGURE 13
Measured kW = analog output value (from monitor) x kW setting value (from monitor) x 0.1
Note: Terminal 24 (VN) is connected to the measured ground reference formed by (3) Mega
ohm resistors arranged in Y-configuration across three-phase line. The voltage
potential is relative low, but connecting this terminal to external equipment may result
in measurement errors.
Inverted Relay Operation
Depending on the specific control logic requirements, the
internal relay contact action may need to be reversed where a
close contact will indicate a trip condition instead of an open
contact. To obtain this inverted relay operation, the user is
advised to use the normally open relay contact (terminal 15)
instead of normally closed contact (terminal 13).
Note: When control power is applied to the monitor and
no trip condition exists, terminal 15 will be open.
NC
C
NO
13
14
15
16
+12V
17
FIGURE 14
Page 13
Troubleshooting:
Condition
Suggestion
The wire direction for the current sampling is reversed through
the internal CT in the Monitor. The wire from the power supply
side must enter the internal CT core from the top (terminal
block side marked 13-24) of the Monitor.
The Monitor Load LED is
not on when the motor is
running.
The current sampling is not done on the same phase wire that
is connected to terminal 1 (L1) on Monitor. Have a qualified
person check the wiring.
The measured power is less than 5% of kW setting, so the kW
setting must be lowered. Adjust the kW setting to equal the
motor rating (in kW) times 1.25 (assuming an 80% motor
efficiency). Contact Sundyne for further assistance.
No LEDs are on when the
monitor is powered up.
The control power supply at terminals 7 and 9 or 8 and 9 of the
Monitor does not have the proper voltage. Have a qualified
person check the fusing and wiring. Contact Sundyne for
further assistance.
The High Trip limit may be set too high. Lower the High Trip
setting until the High Trip LED goes on.
The motor does not trip on
the High Trip setting.
The High Trip time delay is set too high, and may need to be
lowered.
The K3 input (High Trip Inhibit) at terminal 20 is activated.
The Contact LED is off,
but the motor is still
running.
The trip contact may be welded together. Have a qualified
person check the continuity of the contact. Contact Sundyne
for further assistance.
The Low Trip limit may be set too low. Increase the Low Trip
setting until the Low Trip LED goes on.
the Low Trip setting.
The Low Trip time delay is set too high, and may need to be
lowered.
The K2 input (Low Trip Inhibit) at terminal 19 is activated.
The unit trips the motor
during short underload or
overload conditions.
Remote Reset and Trip
Inhibits do not operate
properly.
Increase the trip time delays or adjust the trip limits to
compensate for the intermittent load surges.
The remote switch contact may be rated for 10 A. or higher,
and this contact may have oxidized causing high circuit
resistance. Replace the switch with one that has a low current
(1A. or less) rating.
The DC common of an external driver (PLC or other control
device) is not connected to the monitor common (terminal 21).
Page 14
- Optional Display PanelModel
Description
Number
PM-2000 Display Panel Only
PM-2011 Display Panel with Model PM-1100 Monitor
Note: The power monitor specifications are listed on
page 4 of this manual.
Product Specifications:
FIGURE 15
Product Type
Display Panel
Digital Screen
LED, 3 digit, 0.3 in. (7.62 mm) High
Power Requirements
10 VDC / 50 mA (Provided from Power Monitor)
Analog Output
(Passive)
Range
Input Voltage Range
Maximum Load Resistance
Short Circuit Protection
Reverse Voltage Protection
4 –20 mA ± 1% @ 24 VDC (proportion to power range set)
15 to 30 VDC
R= (Vp-12)/0.022, Vp=Input Voltage (i.e. 545 Ohms @ 24VDC)
Yes
Yes
Activation Voltage - K Inputs
12 – 30 VDC
Start-Up Timer
1 – 999 seconds
High and Low Trip Delays
1 – 99 seconds
Trip Range
5% to 100% of Maximum Power Value
Display Power Units
HP, kW, or % kW
Parameter Program Lock
Software
Hardware
Embedded command entered from keypad
Closed connection between terminals 6 and 7
Communication Distance
The maximum wire distance between the Power Monitor and
the Display Panel is 25 ft (7.62 m). A twisted wire pair is
recommended for the distance between 1 ft (0.3 m) to 6 ft
(1.82 m), and shielded wire for distance over 6 ft (1.82 m)
Keep the unit out of direct sunlight
+5 to +122°F (-15 to +50 °C)
Enclosure:
Flame Resistant Noryl
Panel
2.83 in. x 2.83 in. x 2.70 in. (72 mm x 72 mm x 68.6 mm)
NEMA-12 Type (IP- 54)
NEMA-4X (IP- 66) with optional translucent, plastic hood*
Material
Mounting
Dimensions
Rating
Third Party Approvals
*Note:
CE (UL and C-UL is not required if supply is under 32 VDC)
Contact the factory for further information on the optional translucent, plastic hood.
Page 15
Wiring Diagram:
OPTIONAL DISPLAY PANEL
NC
C
NO
+12V
K1
K2
K3
GND
VD +
VP
VN
13
14
1
15
2
16
3
17
4
18
5
19
6
20
7
21
8
22
9
23
10
24
DV+
GND
PM 2000
K1
K2
K3
V+
K GND
Iout
Vin
VOLTAGE INPUT FOR 4-20 mA
4-20 mA OUTPUT
FIGURE 16
POWER MONITOR
Terminal Block Connections and Definitions:
Field Wiring Guidelines
BACK OF DISPLAY
1. The terminal block will accept a maximum of
12-gauge wire (2 mm).
1 2 3 4 5 6 7 8 9 10
FIGURE 17
No.
2. Maximum recommended installation torque for
the terminal block screws is 4 lb-in (0.6 N-m).
3. Use copper wire only.
Description
No.
Description
1
DV+, Supply Signal from Monitor
6
K3, Hardware Parameter Lock
2
GND, DC Common
7
V+, DC Supply (For K Inputs Use Only)
8
K GND, DC common for K Inputs Only
3
, Cable Shield Connection
4
K1, Remote Reset
9
Iout, 4-20 mA Output
5
K2, Do Not Use
10
Vin, Voltage Input for 4-20 mA
Note: The I/Os on Monitor are internally switch-off when the Display Panel is connected:
• Control Inputs (K1, K2, K3)
• High / Low Limit Pots
• Panel LEDs (Start-T, Low, High)
• Delay Timer Pots
Remote Reset and Control Inputs:
The control inputs are isolated (2500 Vrms) by means
of opto-couplers. Local operation is accomplished by
connecting terminal 7 (V+) to inputs (K1 or K3) to
activate them, but terminal 8 (K GND) must be
connected to terminal 2 (GND). The inputs can also be
wired for PLC operation:
Analog Output:
DC SUPPLY
COMMON
12 - 30 VDC
1
2
PLC
Zero Measured Power
Max. Measure Power
4 mA
20 mA
136
Ohms@
15V
Maximum Load Impedance
818 Ohms@ 30V
Note: See the application notes on page 20.
3
4
An isolated (2500 VAC to measured voltage), passive
monitoring signal (4-20 mA) is available at terminals 9.
5
6
7
8
4-20 mA OUTPUT
DV+
GND
9
10
K1
K2
K3
V+
K GND
Iout
Vin
FIGURE 18
Page 16
Mounting Information:
2.83 IN. (72 MM)
TM
0.25 IN. (6.35 MM)
PM Series
2.50
HP
PRGM
PWR Max
Ext. CT
MTR Eff
PTR kW
kW
kW %
Aux
Locked
Start-T
Trip Pt.
T-Delay
HIGH
LOW
DETACHABLE
TERMINAL
BLOCK
Mode
2.63 IN. (66.5 MM)
Reset
PM-2000
2.70 IN. (68.6 MM)
2.83 IN. (72 MM)
FIGURE 19
The Display Panel is normally mounted to a control cabinet door or a similar electrical enclosure.
The supplied neoprene rubber gasket or a similar sealing device is required to seal the air gap
between the cutout opening and the enclosure from the outside environment. To obtain NEMA-4X
rating, an optional translucent plastic hood is fitted over the front panel before it is mounted to the
panel door.
ADJUSTABLE BRACKET
(TWO ARE SUPPLIED)
2.68 IN. (68 MM)
RECOMMENDED 2.68 IN. (68 MM)
CUTOUT
DIMENSIONS
OPTIONAL
TRANSLUCENT
PLASTIC HOOD
Enclosure:
Material
Mounting
Dimensions
Rating
NEOPRENE RUBBER GASKET
SUPPLIED WITH THE UNIT
PANEL WALL
FIGURE 20
Keep away from direct sunlight
+5 to +122°F (-15 to +50 °C)
Flame Resistant Noryl
Panel
2.83 in. x 2.83 in. x 2.70 in. (72 mm x 72 mm x 68.6 mm)
NEMA-12 Type (IP - 54)
NEMA-4X (IP- 66) with optional translucent, plastic hood*
* Note: Contact the factory for further information on the optional translucent, plastic hood.
!
Warning
The PM Series products are not to be located in Hazardous Areas,
which are defined as areas where there is a presence or possible
presence of a flammable gas/air mixture.
Page 17
Panel Definitions:
PM Series
2.50
HP
PRGM
PWR Max
Ext. CT
MTR Eff
PTR kW
kW
kW %
Aux
Locked
Start-T
Trip Pt.
T-Delay
HIGH
LOW
DISPLAY SCREEN
UP ARROW KEY
DOWN ARROW KEY
Mode
MODE ARROW KEY
Reset
RESET ARROW KEY
PM-2000
FUNCTION LEDS
Function
LEDs
Notes
HP
The power reading is shown in horsepower.
kW
The power reading is shown in kilowatt.
% kW
Aux
FIGURE 21
The power reading is shown in percent of kilowatt.
Not used.
Locked
The parameters settings are protected by either software or hardware lock.
Start-T
The start-up time delay (1 to 999 seconds) entered.
Trip Pt
The displayed power value is a trip point.
T- Delay
The time delay (1 to 99 seconds) entered for a trip (limit) point.
PRGM
The monitor is in the program mode.
PWR Max
The maximum motor rating entered.
Ext. CT
The external current transformer (CT) ratio (off, 50 to 500) entered.
MTR Eff
The motor efficiency value (50 to 100%) entered.
PTR kW
The recommended kW value for Monitor Range is shown on display screen.
High
The displayed value is a High Trip (limit) point.
Low
The displayed value is a Low Trip (limit) point.
Buttons
Notes
f
Up Arrow Button:
Push to increase value.
g
Down Arrow Button:
Push to decrease value.
Mode
Mode Switch Button:
Push to advance to next function in program mode.
Reset
Local Reset Button:
Push to clear all trip functions and to close relay contact.
Program Exit Button: Push to exit from program mode.
Page 18
Panel Programming Steps and Function Definitions:
Step
Press
Button
LEDs On
1
Mode
PRGM, Locked
On or Off An internal software lock can be engaged to prevent unwanted
parameter changes. This software lock will automatically be
switched on, if no button is pushed within a 60-second time period.
PRGM, Locked
On or Off Press T and S together to toggle the lock on or off. (Default=On)
2
T
and S
Display
Value
Function Definition
The High and Low trips are disabled during motor start-up for a
fixed period of time (start-up delay). (Default =15 seconds)
The T or S are used to enter a value from 1 - 999 seconds.
3
Mode
PRGM, Start-T
#Value
4
T
or S
PRGM, Start-T
#Value
5
Mode
PRGM,
Trip Pt., High
#Value
Upper power limit of the operating window is defined by this value.
If the measured power is higher than this value, then a trip
condition is recognized. (Default value = max. power value)
6
T
#Value
The T or S are used to enter a value.
7
Mode
#Value
Lower power limit of the operating window is defined by this value.
If the measured power is lower than this value, then a trip condition
is recognized. (Default value = 5% of max. power value)
8
T
or S
PRGM
Trip Pt., Low
#Value
9
Mode
PRGM
T-Delay, High
#Value
When the measured power exceeds the High Trip setting, an
internal timer is activated. The measured power must return below
this limit within a defined time period or a trip condition will be
accepted. This period is the High Trip Delay. (Default =5 seconds)
or S
PRGM
T-Delay, High
or S
10
T
11
Mode
12
T
or S
13
Mode
14
T
15
16
T
17
18
T
or S
19
Mode
PRGM,
Trip Pt., High
PRGM
Trip Pt., Low
PRGM
T-Delay, Low
PRGM
T-Delay. Low
#Value
#Value
When measured power falls below this Low Trip setting, an internal
timer is activated. The measured power must return above this limit
within a defined time period or a trip condition will be accepted.
This period is the Low Trip Delay. (Default =15 seconds)
#Value
PRGM
Hp or kW or %kW
PRGM
Hp or kW or %kW
P.Un
Select the power units (horsepower, kilowatt, or % of kW) that
measured electrical power will be displayed in.
P.Un
The T or S are used to select the power units.
Mode
PRGM, PWR Max.
#Value
Enter motor output rating. The decimal point can be repositioned in
the step 18, if required.
or S
PRGM, PWR Max
#Value
Mode
PRGM, PWR Max
#Value
Place the decimal point in PWR Max. value.
PRGM, PWR Max
#Value
The T or S are used to shift the decimal point. (X.xx, XX.x, or XXX)
PRGM, Ext. CT
#Value
When the motor current is higher than 65 amps, an external CT is
required. The unit will work with external CTs with ratio of xxx: 5.
PRGM, Ext. CT
#Value
The T or S are used to select the external CT setting:
Off =No Ext. CT, 50 =50:5 CT, 60 =60:5 CT, 75 =75:5 CT,
100 =100:5 CT, 125 = 125:5 CT, 150 =150:5 CT, 200 =200:5 CT,
250 =250:5 CT, 300 =300:5 CT, 400 =400:5 CT, 500 =500:5 CT.
(Default = Off)
or S
20
T
or S
21
Mode
PRGM, MTR Eff.
#Value
22
T
or S
PRGM, MTR Eff.
#Value
#Value
This is the maximum kW range value (calculated internally by the
3
panel display) that should be entered on the power monitor.
#Value
Reads measured motor power.
23
Mode
PRGM,
PTR kW, kW
24
Mode
Hp or kW or %kW
Notes:
1.
2.
3.
The efficiency value for 100% of motor full load is used to internally
calculate the maximum input power range in kW.
The T or S are used to enter a value from 50 to 100. (Default=100)
Press the Reset button on Display Panel to exit any time from the Program Mode.
An automatic “exit” signal is generated internally, if no buttons are pushed within 30 seconds while
in the Program Mode.
When an external CT is used, the nominal motor voltage influences the maximum kW setting for
the Monitor. The maximum kW range value for the monitor cannot be higher than the kW setting
listed on page 20 in the application notes for that nominal motor voltage.
Page 19
Application Notes:
Using an External CT with Display Panel
Nominal Voltage
208 VAC
230 VAC
380 VAC
415 VAC
460 VAC
575 VAC
600 VAC
The Display Panel calculates a maximum kW value for the
Monitor under the PTR kW function. When an external CT
is used, the nominal motor voltage can influence this
maximum kW setting. If the calculated kW value is higher
than the kW setting shown for the voltage indicated, then
use the kW setting shown for the voltage as the maximum
kW setting.
Note: If the specific motor voltage is not shown, then
use the basic equation to calculate the
maximum kW setting.
kW Setting
1.80
1.99
3.29
3.59
3.98
4.98
5.20
Basic Power Equation
kW Setting = Nom. Volt x .00866
Automatic Reset
Connecting a wire jumper between terminals 4 and 7 on
the Display will enable the Automatic Reset feature. This
reset feature will automatically clear a trip condition after a
trip has been recognized.
1
2
Note: When this feature is used, it is strongly
recommended that a separate start command
be required to start the motor thus preventing
unexpected system start-up.
WIRE JUMPER
DV+
GND
3
4
5
6
Utilizing the 4-20 mA Output
7
An isolated (2500 VAC from the Power Measuring side)
monitoring signal (4 – 20 mA) is available at terminals 9
(Iout) that can be connected to a process meter or to a
PLC for a process feedback signal. This signal requires an
external DC supply (15 to 30 VDC) to be connected to
terminal 10 (Vin) for the output to work. The linear
relationship of 4-20 mA signal to the measured power is
defined by this equation:
9
8
10
K1
K2
K3
V+
K GND
Iout
Vin
4-20 mA OUTPUT
FIGURE 22
Equation Definitions
Notes
Measured power = Current value (mA) x Slope + Intercept
Slope = Power Max. (Value entered at PWR Max. Step) / 16
Intercept = Power Max. – (20 x Slope)
Current value = 4-20 mA signal from the Display
In a trip condition, the output
current value is less than 1 mA.
Hardware and Software Lock
To prevent unwanted changes to the parameter values entered into the Display, a software or
hardware lock is used. The software lock will automatically be switched on, if no button is pushed
within a 60-second time period.
Software (Panel Entered) Lock
Hardware (Terminal Block) Lock
• Press the Mode button once
• Press T and S buttons together each time to
change the lock state.
Connect terminal 6 and 7 together to switch
on the parameter lock. To use terminal 7,
terminal 8 (K Gnd) must be connected to
terminal 2 (Gnd)
Note: The parameter lock status will be
displayed on LED screen.
Note:
The hardware lock cannot be turned
off from the front panel.
Page 20
Troubleshooting:
Condition
Suggestion
The wire direction for the current sampling is reversed through
the internal CT in the Monitor. The wire from the power supply
side must enter the internal CT core from the top (terminal
block side marked 13-24) of the Monitor.
The Display Panel does
not read motor power
when the motor is running.
The current sampling is not done on the same phase wire that
is connected to terminal 1 (L1) on Monitor. Have a qualified
person check the wiring.
The measured power is less than 5% of kW setting, so the kW
setting must be lowered. Adjust the kW setting to equal the
motor rating (in kW) times 1.25 (assuming an 80% motor
efficiency). Contact Sundyne for further assistance.
Display Panel does not
light up when power is
applied to Monitor.
the High Trip setting.
The Display Panel reads
power when High or Low
LEDs indicated a Trip.
the Low Trip setting.
The T and S buttons do
not work in Program Mode.
The remote Reset and
Hardware Lock inputs do
not operate properly.
The two wire connections from the Monitor to the Display
Panel maybe reversed.
Have a qualified person check the control power wiring to
power monitor.
The High Trip limit may be set too high. Lower the High Trip
setting until the High and Trip Pt. LEDs go on.
The High Trip time delay is set too high, and may need to be
lowered.
The trip contact on the monitor may be welded together. Have
a qualified person check the continuity of the contact. Contact
Sundyne for further assistance.
The trip contact on the Monitor may not be wired properly to
the motor starter control circuit. Have a qualified person check
the control wiring from starter to Monitor.
The Low Trip limit may be set too low. Increase the Low Trip
setting until the Low and Trip Pt. LEDs go on.
The Low Trip time delay is set too high, and may need to be
lowered.
A parameter lock command is on. Turn software lock off and
make sure terminals (6 and 7) on the Display Panel are
disconnected. Contact Sundyne for further assistance.
The remote switch contact may be rated for 10 A. or higher,
and this contact may have oxidized causing high circuit
resistance. Replace the switch with one that has a low current
(1A. or less) rating.
The DC common of an external driver (PLC or other control
device) is not connected to the Display K GND (terminal 8).
Page 21
Setup Example:
Pump Model
Type
Ansimag K326
Diameter
6.00 in.
Speed
3500 rpm
Max. Flow
265 gpm
Min. Flow
15 gpm
AC Motor
Power Rating
15 hp
Nominal Voltage
460 VAC
Full Load Amp
17.6
Efficiency
88.2
Phase
3
Pump Performance Curve
Performance
BHP
Chart Definitions:
180
160
BHP = Brake Horsepower
TDH = Total ∆ Head
10 hp
TDH (ft)
140
13 hp
120
Notes:
This pump curve is derived from
Ansimag K+ performance catalog
sheet of K326 pump with the
following conditions:
7.5 hp
100
2.5 hp
80
5 hp
60
40
20
0
0
25
50
75
100
125
150
175
200
225
250
275
300
Liquid S.G. = 1.00
Motor Speed = 3500 rpm
Impeller Trim = 6.00 in.
Capacity (gpm)
LOW TRIP
FIGURE 23
HIGH TRIP
Before starting the pump drive motor, data (parameter information) must be entered into the
Display’s memory for it to operate correctly. For our example, the following information will be
entered into the Display’s memory:
Data Entry
HP
Start-T3
Trip Pt. – High2
Trip Pt. – Low2
T-Delay – High3
T-Delay – Low3
PTR Max.
Ext. CT
MTR Eff
PTR kW
Display
P. un
15
10.5
4.9
5
10
15.0
15.0
Off
88
12.74
Comments
Select HP for power Units
Start-Up Timer Delay Value in Seconds (1 – 999)
High Trip Value in HP
Low Trip value in HP
High Trip Delay Value in Seconds (1 – 99)
High Trip Delay Value in Seconds (1 – 99)
Enter Motor Horsepower Rating
Use T and S buttons to position the Decimal Point, if required
Set external CT value to off.
Enter motor efficiency value of 88
Internal calculated input kW value for Monitor
Notes:
1. If the parameters cannot be changed, then the Locked function is on. The procedure to switch
off the parameter lock is listed on page 19 in the application notes.
2. The estimated BHP values (4.9 hp @ 15 gpm and 10.5 hp @ 265 gpm) from a pump curve are
normally used, but the trips values are adjusted further after running the pump in the
application. Specific gravity must be factored into the data derived from the standard
pump curves.
3. The time values are practical times that can be adjusted according to the application needs.
4. The kW range on the Monitor is set to this value before operating the pump.
Page 22
Notes
Page 23

Acrobat Distiller, Job 7

Transcription

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