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NOTE FOR CONDUIT SIZES AND DETAILS REFER OWE. 486/4/7-80053

900

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CRANE RAIL BEA

ACOUSTIC LOUVRES

CONCRETE iTHRUST

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R.L. 49.650

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R.L. 50.150

BLOCKOUTS FOR CONDUITS

500 0 500 1000 1500 2000 2500 1,,I I I I I I

SCALE OF MILLIMETRES 1 50

A 4.4.95

DATE PUMP REMOVE:

AMETIXENT

°RECTOR OF PD. G. PS.

DATE

1343,4EEp ORIGINAL SII:NED DATE CHARGE R. .BOWERPV.:

SLPERVISM ORIG. SIGN. RPE.12 , DATE EN2INEE4 P. GAW 3727 2: /: '

NANE I DATE

S. MOBBS 1997

CHECKED

UCB FLE

DRAWN

0-EOCED

CADD FLE

SURVEYS)

Mery at,

JJV SEPT. '..;";r

J E F OCT .9

47PD345 iSLRVEY Na

RID BCCK

Brisbane =

Water PROJECT

MAJOR DISTRIBUTION MAINS LOGAN CITY TRUNK MAIN AMPLIFICATION

TITLE

LEAROYD ROAD PUMPING STATION GENERAL ARRANGEMENT OF MECHANICAL PLANT TENDER DRAWING

SCALE AS 9-DAN N' 1 OF 4 SHEETS

0AWGM JAS .43,11

486/4/7-PD045

A.FL DATUM



B

DIA. 1220 M.S.C.L. INLET MAIN

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LIMIT ' OF CONTRACT

STUB PIPE 762 OD

di4 4,4411

6.T

Pfd.:

DN 25 SYSTEM DRAIN

ON 450 . 400 ECCENTRIC F ENLARGER

R.L. 49.800 C I

L

DN 25 SYSTEM DRAIN

STUB PIPE 635 OD

COLLAR JOINT PRESSURE TAPPING (D)

ON 700 BUTTERFLY VALVE

ON 455 . 700 ECCENTRIC REDUCER

DN450 TIED DISMANTLING JOINT (REFER DETAIL DwG. 466/4/7-P004BI

PUMP

DN400 TIED DISMANTLING JOINT (REFER DETAIL DWG. 486/4/7-P0048/

HANOI-IDLE (REFER DETAIL DWG. 486/4/7-P0048)

DN 450 OEMAG ORV-G OR DRV-B CHECK VALVE

ON 450 600 ECCENTRIC ENLARGER

ON 600 BUTTERFLY VALVE

PRESSURE TAPPING (D)

COLLAR JOINT

LIMIT Or-tONYRWt7-

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THRUST WALL

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ON 910 M.S.C.L. OUTLET MAIN I

PLAN SCALE 125

TYPICAL PUMP LAYOUT

RL 50.655

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5755

7) ENDS 3F STUB riPES

CATHODIC PROTECTION ISOLATION GASKET (SUPPLIED BY C.P. CON7RACTOR)

ON 25 DRAIN

COMMISSIONING STRAINER

-PRESSURE TAPP:NG (A)

RL 50.750

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PRESSURE TAPPING (6)

ON 25 DRAIN

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ON 25 DRAIN

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PRESSURE TRANSMITTER FOR HEADER- (D) PRESSURE ON PUMP 2 ONLY

5 0 10 20 30 40

'/' SECOND STAGE CONCRETE

NOTE EXISTING BENDS SUPPLIED WITH EXTRA LENGTH. CUT TO SUIT DURING INSTALLATION OF PIPEWORK AND VALVES.

OA

PFCLECT T a E %I SCALE

MAJOR DISTRIBUTION MAINS LEAROYD ROAD PUMPING STATION AS SHOWN

LOGAN CITY TRUNK MAIN AMPLIFICATION TENDER DRAWINGS

LAYOUT OF PUMPS AND PIPEWORK DIAwN3w

0

200 0 200 400 600 800 1000

SCALE OF MILLIME-PES 1 : 25

I

60 70 lk I 90 100 110 120 .130 140 150

AR DATUM IY 2 CF 4 HHEETS

AA4341

486/4/7-PD046 0



KelairPumps

Head Office Sydney Gateway Estate 215 yValters'Ficrad Amdell Park NSW 2148 Telephone: 61 2.9678 9466 Facsimile: 61:2 9678 9455 Omit [email protected] (Amin)

[email protected] MSW Sales)

Queensland Office 5/89 dijaWs Street' Suniner Park GILD 4074 Telephone: 07 3279 5700 Facsimile: 07 3279 5711 Ernst: [email protected]

1. .nian Office 1/12 South Street Invermay TAS 7248 Telephone: 03 6331 6733 Facsimile: 03 6331 9102 Email: [email protected]

Victorian Office 19 Edward Street Oakteigh VIC 3166 Telephone: 03 9569 7855 Facsimile: 03 9569 7866 Email: [email protected]

Western Australia Office Coma Corporate Centre 11 Preston Street Como WA 6152 Telephone: 08 9367 0633 Facsimile: 08 9474 5636 Email: [email protected]

,elair Pumps Australia Pty Ltd

A.C.N. 001 308 381

Website: http://www.kelairpumps.com.au

OPERATION & MAINTENANCE

MANUAL

CLIENT : Kilpatrick Green Pty Ltd

ORDER No. : 441/843941

SITE/PLANT : Learoyd Road - Brisbane '

PUMPSET :- Water Transfer Pumps: LP - 110015 - BM (Kelair / ABS)

JOB No. : 110015

CONTRACT : CQ5121/8

Standard conditions of sale and warranty available on request



KelairPumps

PAGE Rev i

REVISIONS

Revision 1: As per Clients Request ( Fax Dated 13/05/99 )



1[4. KelairPumps

PAGE Contents i

CONTENTS

1: Introduction 2: Description of Equipment 3: Design Criteria & Process Description 4: Installation and Precommissioning 5: Start Up and Shut Down Procedures 6: Commissioning 7: Operations 8: Maintenance 9: Fault Protection and Rectification

10: Isolation and Restoration Procedures 11: List of Sub-Contractor and Proprietary Equipment 12: Recommended Spare Parts and Special Tools 13: List of Engineering Drawings 14: Training 15: List of Contract Variations and Plant Modifications 16: Commissioning and Test Reports 17: Appendix 1 - Fan Monitor 18: Appendix 2 - Motor Installation & Maintenance Instructions 19: Appendix 3 - Variable Speed Drive



1: Introduction

CONTENTS: INTRODUCTION & CONTACT DETAILS

KelairPumps

PAGE 1.00

PAGE Page 1.01



Kelair Pumps Australia Pty Ltd Page 1.01

fiS

INTRODUCTION

These instructions have been prepared to assist you in the

installation, operation and maintenance of your pump. We urge

you to read and follow all of the directions in this manual.

If you have a problem that is not covered in this manual please do

not hesitate to contact :

Kelair Pumps Australia Pty Ltd

General Hours: Monday to Friday 7:30am - 5:00pm

Qld Tech Sales: (07) 3279 5700

H.O. (Sydney): (02) 9678 9466

After Hours:

Service Manager: 0411 600 601



2: Description of Equipment

CONTENTS: PUMPSET DESCRIPTION

KelairPumps

PAGE 2.00

PAGE Page 2.01




- - ns in o = 'enTaATIVI- aintenanm instructions Pp tilt

Pumpset Description

Pumpset Model No. : LP - 110015 - BM

Pump Manfacturer: ABS - Scanpump

Kelair Job No.: 110015

Pump Serial No's: 92170 -1 92170 - 2

Contract No. : CQ5121/8

Site Name : Learoyd Road, Brisbane

Pumpset Description: Horizontal base-mounted pumpset, consisting of Horizontal Split-case pump, cone ring coupled to 400kW Electric Motor. For more specific details see Section 3



KelairPumps

PAGE 3.00

3: Design Criteria & Process Description

CONTENTS : PAGE KELAIR DATA SHEET (No. 13364) Page 3.01 ABS TECHNICAL DATA SHEET Page 3.02 OVERALL DIMENSIONS Page 3.03



KELAIR PUMPS "AUSTRALIA. , . Centrtfiigal. Pump

Data Sheet No. 13364 Issue No: 3 ARW Prepared bv; Checked by: I

Client: KILPATRICK GREEN P/L (QLD) Date: 24/08/99 Service: WATER TRANSFER Quotation No: Q5121-8 Site/Plant: LEAROYD ROAD BRISBANE Contract No: CQ5121-8 Item No: 1 Job No: 110015 Quantity: 2 Serial No: - Pump Mfr: ABS - SCANPUMP Client Order No: 441/843941 Model: LP-Z22 500 500-70-6064-1MC Date R :

OPERATING CONDITIONS CONSTRUCTION' Fluid Pumped: WATER Pump Type: CENTRIFUGAL HORIZONTAL SPLIT Solid Content X by Wt: NIL Case Mounting: CENTRELINE Solid Size: NIL (ran) Nozzles Size(m) Rating Facing Location Temperature: AMBIENT (Deg) Suction 500 PN10 FF SIDE Specific Gravity at Temp.: - Discharge 500 PN10 FF SIDE Viscosity at Temp.: - (cst) Radial Bearing Type: DEEP GROOVE BALL Discharge Pressure: - (kPag) Thrust Bearing Type: DUAL ANGULAR CONTACT BALL Suction Pressure: - (kPag) Lubrication: GREASE Differential Pressure: - (kPa) Impel ler Type: DOUBLE SUCTION EYE Differential Head: 39.0 (m) Jackets: - Flow Rate: 750.0 (L/s)

BASEFRAME AND MIMING NSPH Available: - (m)

pH Value: - Base Type: FABRICATED Material: MILD STEEL Size: SEE Page 13.01

... . ..._-__ ERFE P OR MAN C

Surface Preparation: AS PER SPECIFICATION

Speed: 995 (RPM) Paint Specification: AS PER SPECIFICATION Efficiency: 89.7 (X) -

Power Design: 320.8 (kw) Guard Type/Material: ALUMINIUM/STEEL Power Max: 323 (kw)

TESTING Impeller Design: 600 (mm)

Impeller Min/Max: 540/700 (mm) Performance: Witnessed / Dert-i-fi-ed-/--14-.-A-7

NPSH Required: - (m) Hydrostatic:

N P S H:

Witnessed / Gert-lf-fecl-EN7A7,-

Witnessed -/ i--Certifi-ed / N.A. No. of Stages: 1

Min. Continuous Flow: 470 (L/s) Test Pressure : Case: 1500 (kPag) Curve No: 6064-1MC Jacket: - (kPag)

DRIVER MATERIALS

Driver Type: TO BE FREE ISSUED. ELECTRIC MOTOR Mfr: POPE Casing: CAST IRON 0120

Impel ler: BRONZE 5716 Model/Frame Size: D400L Shaft: STAINLESS STEEL 2324 Enclosure: IP66 Shaft Sleeve: BRONZE 5716 Power: 400 kw 995 RPM Casing Wear Ring: BRONZE 5716 Power Supply: 415/3/50

...

TRANSMISSION Impeller Wear Ring: BRONZE 5716 Seal Plate: - Wear Plate: - Coupling Type: RATHI NON SPACER Elastomers/Gaskets: - Coupling Si ze: RC105 Vee Belt Size: - Jackets: - Pump Shaft: 90 Pump Pulley: -

Drive Shaft: 110 Drive Pulley: - SEALING ND IMING A M Manufacturer: RATHI

Seal Type: MECHANICAL UNBALANCED ?MING Seal Mfr: FLEXIBOX

Seal Model: R2OR/L1150 Pump (each net): AS

Driver (each net):

0.00 FREE ISSUE Seal Flushing Plan: -

Extras:

Flushing Pressure: - (kPag)

REMARKS

Exchange Rate Variation: $1.00 AUS = 5.35 SEK Delivery:

Form KF004 (5/92) Delivery Basis: FOT BRISBANE OLD.




Handled by

Your ref.

A company in the Cardo Group''

Marks

P/0 : 45273 SES : 1486-10-11

Debi:

29/3/99

Customer

KELAIR PUMPS

AUSTRALIA

Oic order:NW/ref.

811657/642267 Ser.-No.

92170

Execution Pump Designation

222-500/500-70 JK VERSION Application Mtrl. code

02

Paintina

A

RATED DUTY Pump liquid

WATER Temp. C Visc. mrn2/s Conc. %

Flow rate math

2700 Head m

39 Density kg/m3

_

NPSH-pump m Speed ram

995 Absorbed power kW

327

- Test norm

ISO 2548/C

TEST: DATA Flow rate m3/h Head m Speed rpm Absorbed power kW

DESIGNATION DATA Impeller Dia. delivery /dia. max

600 Design ofessure pump

PN10 Flanges dia. mm DN1/DN2

500/500 Flange norm

ISO 2084

Bearing size Lubrication

Grease Cooling liquid Flowrate Umin Shaft seal

MECN SEAL

Type/Art No

FLEXIBOX Sealing liquid

INNER Flow rate l/min Pressure + inlet pressure

MATERIAL Casing/other pressure retaining parts

0120 Impeller

5716

S haft

2324 Shaft sleeve

5716 Base plate

DRIVER. Tvoe

Electric motor IEC Rated cower kW Speed ram

Voltage V I Frequency Hz Enclosure Type of mounting

Others

Motor mounted by customer

TRANSMISSION Type Make Size

Bore pump Bore motor Length of spacer

ERECTION Base plate

DOCUMENTATION. Operating manual Dimesion orint Test curve Drawing

pd 1525-5 6552-3 Z2E-367

OTHERS.

ABS Pumps International AB P.O. Box 2052 Telephone No.

S-431 02 MOLNDAL +46 31 83 63 00


Telefax No. +46 31 18 49 06

Registration No. SE556042500001

Page 3.02



Kelair Pumps Australia Page 3.03

Overall Dimensions

Entire Unit Dimensions Length : 3681 mm Approx. Width : 1600 mm Approx. Height: 1715 mm Approx.

Unit Weights Pump : 2200 kg Motor : 2900 kg Baseplate: 990 kg TOTAL: 6090 kg Approx.

NOTE: For more dimensional details see Page 13.01

Recommended Minimum Flow: 470 L/S



4: Installation and Precommissioning

CONTENTS: INSTALLATION INSTRUCTIONS

KelairPumps

PAGE 4.00

PAGE Pages 4.01- 13



Kelair Pumps Australia

MOUNTING

Before mounting

A horizontal pump can either be mounted separately on blocks or together with the motor on a concrete foundation. Recesses for blocks or foundation bolts should be made in the foundation before mounting.

Mounting of Pump and Motor on a Common Base Plate

1 Lift base plate with pump and motor into position.

2 Place alignment wedges between foundation and base plate, close to the foundation bolts. Knock in the wedges so that the base plate is lifted approx. 1 cm.

With the help of the wedges align the base plate accurately according to the instructions below.

4 Concrete under the base plate and tighten the foundation bolts when the concrete has hardened. Fill the space between the foundation and base plate completely.

Mounting of Pump and Motor Separately

1 Tighten the ancor blocks to pump and motor respectively. By placing shims between the blocks and pump or motor, a pump and motor with slightly different heights can be mounted and aligned without the blocks having to be altered.

2 Lift pump and motor into position with the blocks hanging in the recesses.

.3 Align the base plate according to the instructions below.

4 Concrete the blocks to the foundation and when the concrete has hardened check that they are tightened.

Page 4.01

Installation of pump and motor on a concrete foundation

The foundation should be constructed in accordance with relevant standard specifications. Recesses should be made according to applicable dimension prints. Smooth off the foundation carefully to simplify rough alignment and ensure proper packing- up.

Fit the mounting pads on to pump and motor. To permit future realignment, a shim at least 5 mm thick should be used between mounting pads and motor. Place the pump on the foundation and measure its position. Particular care must be taken to ensure that the pump shaft is horizontal. Place the motor on the foundation and line it up with the pump. Accurate alignment will simplify final adjustment after grouting. Try to attain a deviation of less than 0.05 mm both axially and radially.

Pump and motor are grouted in with an expanding type of concrete, which should be allowed to set according to the maker's instructions. Carry out final alignment of pump-motor. Tolerances will depend on the type of coupling, but a value less than 0.05 mm radially and axially should be aimed at.

NOTE: Different thermal expansions must be compensated by different heights of pump and motor.

Fit dowel pins to locate pump and motor.

Check the alignment after piping has been connected. Deviations must not exceed the values that the coupling allows. When a gear coupling or other type of coupling that permits slight disalignment is used, the alignment should be checked again after a period of operation. This check should be made with pump and motor at operating temperature.

If a gear or hydraulic coupling is included in the plant, the installation procedure is the same. First place the pump, then the gear with a shim at least 5 mm thick between mounting pad and gear, then place the motor.

When measuring up the position of the pump, particular care must be taken to ensure that the motor comes into the correct position on the foundation.




Alignment

Check the alignment on .the coupling, both regarding centering and parallelism. Check at least on the four following occassions:

a Before pump and motor are concreted to the foundation.

b When the foundation bolts have been tightened.

c When the pipes have been connected.

d When the pump has been in operation for a few hours.

The coupling bolts should be removed when checking acc. to Items a-and b.

Accurate alignment is not necessary if the pump is

fitted with flexible coupling elements and an inter- mediate shaft. A deviation of max. 3° is permitted.

Checking the Centering

Check preferably by means of a ruler or a indicator according to Fig.1.

1 Hold a ruler against the coupling halves. The pump and motor shafts are aligned when there is no visible light under the ruler.

2 Turn one of the coupling halves so that the centering is checked on at least four points round the coupling.

Max permitted run out is depending on coupling type. See separate instruction.

Checking the Parallelism

Check the parallelism with a feeler gauge or a dial indicator acc. to Fig. 2.

1 Hold the feeler gauge between the coupling halves. The distance should be 2-3 mm.

2 Turn one of the coupling halves so that the parallelism is checked all the way round.

Max permitted out of parallel is 0,05 mm




CONNECTIONS

Pipe Connections

The pipes must not cause any strain on the pump casing. They should therefore be supported as close to the casing as possible. Pumps for hot liquids should have pipes with expansion loops or compen- sators. The sealing surfaces on the connection fianges must be parallel to those of the pump.

Pressure Gauge Connections

BSP 3/8" connections are hued on suction and delivery branches.

Connections for Seal Flushing Water

Internal seal flushing water supplied from the delivery side of the pump. A pipe connection the delivery branch with the seal. See Fig.3.

The following arrangements for externed seal flushing water are available: Remove the pipe B and connect a pipe for seal flushing water at A. The channel at C is plugged. See Fig.4.

Dimension of connection acc. to Table 1.

Quality of seal flushing water: The seal flushing water must be clean. It must not contain substances which might damage the seal chemically or mechani cally.

Flow rate:

Stuffing box - 0.1-0.2 m3/h Mechanical seal - 0.1-0.3 m3/h

Pressure: 0.1 MPa (1 kp/cm2) above the pressure at the suction branch.

Fig 4




Fig. 5

Page 4.04

Connections for Waste Water

Connections for waste water are connected at D acc to Fig. 5.

The waste water can normally be connected to the drain.

Dimension of connections acc. to Table 1.

Table 1

Pump size Stuffing box

1 Mech. seal

Connection A and C

Connection D

250/200-40 x R 3:8" R 1"

300/250.55 x R 1 4" x-

350/300-35 x R 3 8.. R 1"

350/350-45 x x R 3 8" R 3:4" 350/300-60 x x R 3.8" R 3.4"

350/300-61 x R 1,4" x-

400/300-55 x x R 3;8" R 3.4

400/300.60 x R 1.4- *

400/350.70 x R 1:4" 4*

450/400-40 x R 3/8" R 3:4"

500/400-50 x R 3/8" R I- 500/400.55 x x R 318" R 314"

500/400.60 x x R 3/8" R 3/4" 500/400-70 x R 1/4"

500/500-70 x x R 3/8" R 3/4"

500/300-75 x R 3/8 R 3-4".

500/400-80 x R 3/8" R 3/4"

600/500.60 x x R 3.8" R 3:4"

600/600-65 x R 3.8" Mit 600/600.75 x x R 3 8" R 3 4-

600/400-85 x R 3 8" R 1"

600/400-90 x R 3 8" R 1-

700/700-64 x x R 3/8" R 3 4-

700/700.65 x x R 3.8" R 3-4'.

700/600-75 x x R 3/8" R 3,4"

700/500.95 x R 38" R 1"

800/800-75 x x R 1 2" R 1 1 2'

800/500-105 x R 3.8" R 3i4..

800/700-105 x x R 1:2" R 1 1:2'

800/500-120 x R 3/8" R 1"

900/600.140 x R 3/8" R 1"

1000/1000-90 x R 1/2" R 1 1,'2"

This sizes have not screwed connection D.




C

TYPE -RC

r'

DIMENSIONAL DATA

Notes :

For technical data refer page 3

Maintain gap at the time of assembly

B = 3 mm for size 020 to 105

6mm for size 120 to 215

Page 4.05

C2 B

C1

TYPE-RCT

0




SPARE PARTS

a

Page 4.06

We reserve the right to alter or change specifications without prior notice




nWilationir Operation and Main on

PLANT PREPARATION:

GENERAL PUMP DATA

Each pump is thoroughly inspected, both in the manufacturing proceSs and as a final product to assure

trouble free operation.

Prior to shipping the pump, the case and any bearing oil housingS are drained. Covers are piked on the

suction and discharge flanges to keep dirt out.

HANDLING:

Use extreme care in handling the unit, placing slings carefully so that stress will not be imposed on the

pump or base. Never place cable slings around the pump shaft.

Any eye bolts located on the driver and pump case or cover are intended for lifting only those parts and not

the complete unit.

All equipment should be thoroughly checkb'd when delivered. Shortages or damages should be retiOrted

immediately to the local agent of the transportation company.

STORAGE:

If the unit is not to be placed in service immediately, it should be stored in a dry location and protected from

dirt and moisture internally and externally.

Do not remove the suction and discharge flange covers until the unit is to be piped.

Parts subject to attack by moisture, such as bearings, shaft and other finiShed parts should be protetted and

inspected periodically and the protective coating renewed as needed.

The pump will require additional protection if it is to be stored for an extended period. Dry the inside of the

pump thoroughly. Fill the liquid end with oil, kerosene, or another suitable protective liquid. Fill oil bearing

housing(s) as high as possible with lubricating oil. Rotate the shaft occasionally to prevent pitting of the finished surfaces and to keep the rotating element free.




nstaIIation, Operation and Maintenance, instructions

INSTALLATION

Please refer to BCC Standard Specifications and Clause 6.8.3 Setup and alignment of pumps (of the Tender Documents) and if variation exists follow those instructions.

FOUNDATION:

The foundation must be rigid enough to support the pump, auxiliary equipment, driver and baseplate, and

prevent vibration and misalignment during operation. The standard pump bases are designed to be grouted

into a concrete foundation.

Pour the concrete foundation well in advance of placement of the unit to allow ample time for curing.

Position foundation bolts in that the bolts have freedom of movement in the sleeve.

Roughen the surface of the foundation to allow a good bond between the foundation and the grout. Stuff

waste into the open portion between the foundation bolts and pipe sleeves to prevent grout from filling the

cavity and destroying the pipe sleeve's function.

LEVELLING THE BASEPLATE:

The baseplate will be easier to handle if the pump and driver are removed before the levelling operations are started. Remove any protective coating on the support pads. Do not use an abrasive material to

remove any coating as it can easily be removed usually with a solvent. Blocks and shims (or wedges) will

be required for installing the baseplate on the foundation. Set the blocks at each foundation bolt as shown

in figures 2 and 3. The blocks should provide a minimum distance of 1" from the top of the foundation to the bottom of the baseplate in order to establish grout space.

Lower the baseplate onto the blocks and level in direction A-B, C-D, and G-H as shown in figure 3 with a

spirit level on the machined pads. Between each levelling operation remove shims or adjust wedges as

necessary. Lightly tighten bolts directly connected with each levelling operation as it is performed. After the

base is level, recheck the alignment in all directions and make final adjustments. Foundation bolts are not

to be tight. The baseplate is now ready for grouting.

GROUTING THE BASEPLATE:

Build a. wooden form around the baseplate to retain the grout. Select a good grade of commercial grout material and mix to the recommended consistency. Pour and work the grout until the space between the

top of the foundation and the deck of the baseplate is filled solid. If desired, holes can be drilled in the

baseplate to aid air escape. Allow ample time for the grout to set. Do not remove the blocks and shims (or

wedges) after grouting. After the grout is set, tighten the nuts on the foundation bolts.




Pum Installation Operation ani

Page 4.09

Maintenanceinstructions

GROUT HOLE

r 0

NOTE - oNe SET AX EACH OF BLOCKS AND SHIMS OR WEDGES R_EQUiREID FOR EACH FOUNDATION BOLT

FIGURE 2

/,

FOUNDATION BOLT HOLE

I

BLOCK

El GROUT 4711 HOLE

f I

E-F. A-5

ai_E;)- L

I 4--

FIGURE 3




Pump Purlrmp Installatr_on, Operation and: Maitntenance I.nstriuctio

ALIGNMENT:

Accurate aligning of the pump and driver is required. Noises, shaft ship, vibration, excessive wear or failure

of the coupling, bearings bushings, rings and possible seizure of the rotating element can result from poor

alignment.

Remove any protective coating from the coupling and shaft, and clean them thoroughly.

Except for pumps furnished with a tapered shaft extension, heat should be applied to the outside of the

coupling hub to mount or remove the coupling.

Place the pump on the pads and position it with the dowel pins. Secure the pump by bolting it down to the

pad.

Place the driver on the baseplate pads so that the distance between the pump and driver shaft ends agrees

with the figure specified on the certified outline drawing.

Temperature expansion of the driver, and pump (when the pump is in hot service), is recognised as being a

consideration in alignment but it is difficult to establish set rules regarding this expansion because of the

number of varying factors involved. Therefore, THE FIRST ALIGNMENT CAN BE CONSIDERED TO BE

ONLY PRELIMINARY. The alignment must be rechecked after the pump has run at the operating condition

a few hours, and again after several days, and corrective measures taken as needed.

CONNECTING SUCTION AND DISCHARGE PIPING:

Correct suction and discharge piping connections are essential to prevent misalignment, overheated

bearings and excessive wear on parts.

The suction line should be as short and direct as possible and be of ample size. Bends and fitting should be

kept down to an absolute minimum. If elbows or bends are required they should be the long radius type. Figure A shows the preferred suction piping set-up and an incorrect set-up for a double suction pump.

Concentric reducers should not be used on a horizontal suction line. The use of this type of reducer will create an air or gas pocket which may cause trouble in the unit. The use of an eccentric reducer (Diagram "C") is recommended.

An isolating valve and check valve should be installed in the discharge line. The isolating valve is used in

priming and shutting down the unit. The check valve is used to prevent reverse flow through the pump in

the event of a power failure.




P-um nstailation peraticon Maintenance. Instructions

SUCTION PIPEWORK INSTALLATIONI

DIAGRAM A DIAGRAM B

AIR POCKET

AIR POCKET

Ac sy INCORRECT

AIR POCKET

DIAGRAM A shows where air pocket will form when a section of the suction line is highir than the inlet port io the pump.

I NCO RREC T

LONG SWEEP ELBOW

CORRECT

DIAGRAM B.-This shows the correct and incorrect methods of using screwed reducing sockets. These musi be placed in a vertical or near vertical position. If placed horizontaBy air will fowl a pocket at the point indicated.

DIAGRAM C

AIR POCKET

INCORRECT DIAGRAM C shows foimalior. of A n at inaszicet by using suction pipe I:) the suction br:a.crl (A the pump.

-.1

at - ,L11

ECCENTRIC REDUCER

CORRFC:T

a concentric reducing piece when connecting Banged Remember alwoys that air cuts clown the opacity of the pump, and a very small quantity is s(ilcict sonic- times tri cs..e the pump to ceate d;,charcjing. It is imperative 10 1/4er p urt;011 free from att. kaki.




All piping must be supported independent of the pump and free of tendencies to impose strains on the pump. Units pumping hot fluid must have expansion joints or loops in the piping to prevent strain on the pump nozzles due to expansion.

If an expansion joint is installed in the piping between the pump and the nearest point of anchor in the piping, it should be noted that a force equal to the area of the expansion joint times the pressure in the pipe will be transmitted to the pump proper. Some slip type couplings have the same effect. This force may exceed the allowable flange loading. If an expansion joint of slip type coupling must be used, it is recommended that either an anchor be installed between it and the pump or that the joint be restrained or otherwise designed so as to prevent this force from being transmitted to the pump.

Do not weld pipe lines while they are bolted to the pump. Inspect the piping and pump suction and discharge cavities for foreign matter or scale, and clean them thoroughly before pipe connections are made.

The pump flange and pipe flange faces must be parallel, and mate perfectly without force being required to align them. When this is accomplished set the gasket and bolt them together.

A temporary strainer should be installed as close as possible to the suction flange for filtering of the pumped liquid. This strainer should be used until the line has been completely flushed.

It is recommended that a differential pressure gauge be installed for observation of a pressure drop across the strainer. A considerable drop in the differential pressure indicates that the strainer is clogging, and that the unit should be shut down immediately and the strainer cleaned. An alternate method for detecting pressure loss is to install pressure gauges on either side of the strainer.

FINAL ALIGNMENT CHECK:

After all piping connections have been completed, the alignment should be checked to be sure that the piping has not altered the pump and driver alignment.

CONNECTING PUMP AND DRIVER:

Turn the pump shaft by hand to assure smooth unrestricted rotation. Clamp the driver coupling slip shroud tight and start the driver for an instant. Check the rotation of the driver against the rotation arrow on the pump.

Connect the coupling halves and where required insert the disc, grid-member, spacer or jackshaft. Refer to the coupling manufacturers' instructions regarding lubrication required.




p Installation t nance ns tlon , Jo

MECHANICAL SEAL:

Unless otherwise specified, mechanical seals are mounted in the punip at the factory, and no adjatenents to

the seal are necessary before placing the unit in service.

FINAL CHECK LIST:

Driver rotation agrees with the rotation arrow on the pump. Do no operate pump backwards at any time.

Coupling halves and spacer or jackshaft, if used, are tightly bolted together and lubricated.

Ensure the bearings are properly packed with grease. Refer to page 8.03 for grease details.

Necessary gauges, thermometers, thermo-switches and pressure switches are properly installed.

Cooling water and sealing oil (if any) are circulating properly. All pipe connections and plugs are tight.



KelairPumps

PAGE 5.00

5: Start Up and Shut Down Procedures

CONTENTS : PAGE START-UP & SHUT-DOWN PROCEDURES Page 5.01-4 ADDITIONAL PROCEDURES & CHECKS Page 5.05

(See Also Section 4)




'TARTING AND OPERATION

Measures to be taken during the FIRST starting of a newly installed pump

Normal start: See Page 5.03

The pump must never be run without liquid!

1 Check that pump and pipes are clean.

2 Close the valve on the delivery side of the pump.

3 Open for seal flushing water (if required) Check that the pressure of the seal flushing water is correct, 0.1 MPa (1 kp /cm2) above the pressure at the delivery branch.

4 Open the valve on the suction side of the pump.

5 Fill the pump with liquid. This can be done in two different ways:

by allowing the liquid to flow into the pump from the pipe and evacuating the air through the three vent plugs on the top of the pump. See Fig. 8.

by evacuating the pump with a vacuum pump, connected to three connections acc. to Fig. 8.

a

Page 5.01




6 Check the direction of rotation.

Start and stop the motor quickly and check that the direction of rotation corresponds with the rotation arrow on the pump. Should the direction be wrong, change over two wires in the terminal box on the motor.

7 Check that the transmission guard is fitted.

8 Start the pump.

9 Open the valve on the delivery side of the pump.




.tasures to be Taken During NORMAL STARTING

The pump must never be run without liquid!

1 Close the valve on delivery side of the pump.

2 Check that the pressure of the seal flushing water (if required) is correct,0.1 MPa (1 kp/cm2) above the pressure at the suction branch.

3 Open the valve on the suction side.

4 Check that there is liquid in the pump. If not - fill the pump with liquid acc. to Item 5,

Page 5.01

5 Start the pump.

6 Open the valve on the delivery side of the pump.

Page 5.03

Fig. 12




Measures to be Taken During Operation

The volumetric flow is regulated by means of a valve on the delivery side of the pump. During operation the valve on the suction side must be fully open Check the bearing temperature regularly. It should not exceed 100°C. Pumps with temperature guard - see separate instructions.

Measures to be Taken When Stopping

Close the valve on the delivery side of the pump if there is any risk for return flow. NOTE that the seal flushing water should ALWAYS be on when the pump is under pressure, also when the pump has been stopped.




ADDITIONAL PROCEDURES & CHECKS

INSPECTION:

As soon as the pump is running check the following items: -

a. The cooling water and circulating system (if any) b. The suction and discharge gauges. They should correspond to the rated

conditions. c. Ball bearings. They should be operating-quietly. d. The pressure gauge used with the suction strainer. It should be watched

for any change in differential pressure.

ALIGNMENT CHECK:

The pump and driver alignment should be checked after the pump has been

running at the operating condition for a few hours.

Stop the pump and check the alignment as previously described. It is

recommended that the alignment be checked again after a few days of normal

operation.

FREEZING:

If the pump is exposed to freezing temperatures after it is shut down, drain all

water (or other liquid that will freeze) from the pump case, heat exchangers,

cooling jackets and piping.



IL! KelairPumps

PAGE 6.00

6: Commissioning

CONTENTS : PAGE (Refer to Section 5)



El KelairPumps

PAGE 7.00

7: Operations

CONTENTS : PAGE (Refer to Section 5)



8: Maintenance

1[1 KelairPumps

PAGE 8.00

CONTENTS : PAGE SERVICE & MAINTENANCE SHEDULE 8.01 - 3 PUMP DISSASSEMBLY & REASSEMBLY 8.04 - 8 MECHANICAL SEAL INSTRUCTIONS 8.09 - 16 CASING FACE BOLT & GASKET DETAIL 8.17 - 20




ctions-

MAINTENANCE

PUMP:

Your pump must be properly maintained if it is to deliver its full value. A conscientious

maintenance program will assure high pump performance and minimise pump shutdowns.

RECOMMENDED MAINTENANCE SCHEDULE

DAILY:

Check the bearing temperature, and watch for vibration.

WEEKLY:

Carry out daily inspection.

See Page 8.03 for details on "Weekly Inspection"

QUARTERLY:

Check the alignment of the unit.

SEMI-ANNUALLY:

Re lap or replace the seal face on mechanical seals if excessive wear and leakage are apparent.

Check the bearings for wear and replace if necessary.

ANNUALLY:

See Page 8.03 for details on "Yearly Inspection"

Check the valves, gauges, etc., for condition and accuracy.

EVERY 4 YEARS:

See Page 8.03 for details on "Inspection Every Four Years"




lERVICE AND MAINTENANCE

Lubrication of the Pump

The pump bearings are filled with grease when the pump is delivered. The bearing temperature must be

checked carefully after the starting up of the pump. If there is too much grease in the bearings the temperature may increase to slightly above normal which is 70°C. This is normal if the temperature drops to the normal value after a short while.

Clean all lubricating points before lubrication.

Reduce the lubricating intervals BY HALF when the bearing temperatures are 70-85°C.

.educe the lubricating intervals TO ONE QUARTER when the bearing temperatures exceed 85°C.

Pumps in dusty, dirty or corrosive environments should also be lubricated at shorter intervals.

Table 2

Page 8.02

Pump size

Lubricating intervals in operating hours

Lubricating point A I

at different speeds in r/min Lubricating point B

Amount of grease in g

1800 1500 1000 750 1800 1500 1000 750 A B

250 20040 9000 12000 18000 9000 12000 18000 30 15

300 250.55 6000 8000 14000 6000 8000 14000 50 30 350 300 35 9000 12000 18000 9000 12000 18000 30 15

350 35045 7000 9000 15000 7000 9000 15000 50 30

350 300.60 5000 7000 12000 5000 7000 12000 80 40 350 300.61 5000 7000 12000 5000 7000 12000 80 40

400 300.55 5000 7000 12000 5000 7000 12000 80 40 400 300.60 5000 7000 12000 5000 7000 12000 BG 40 400 350 70 3000 5000 9000 3000 5000 9000 120 60 450 400.40 7000 9000 15000 20000 7000 9000 15000 20000 50 30

500 400.50 12000 17000 12000 17000 80 40 500 400 55 7000 12000 17000 7000 12000 17000 80 40 500 400.60 4000 6000 11000 4000 6000 11000 100 50

500 400.70 3000 5000 9000 3000 5000 9000 120 60

.5,00 500.70 6000 11000 15000 6000 11000 15000 100 50

500 300 75 I 3000 5000 9000 3000 5000 9000 110 40

500 400.80 3000 5000 9000 2000 3!00 8000 110 50

600 500.60 ' 6000 11000 15000 6000 11000 15000 100 50

600 GOO 65 3500 8000 12000 3500 6000 12000 50 50

GOO 600 75 9000 14000 9000 14000 110 50

GOO 400 85 4500 9000 3500 8000 110 70

GOO 400.90 4500 9000 2500 7000 120 100

700 100.64 4500 9000 14000 4500 9000 14000 120 60

700. 700.65 4500 9000 14000 4500 9000 14000 120 60

700,600 75 9000 14000 8000 12000 110 50

700.500 95 9000 14000 6000 9000 120 110

800;800.75 8000 12000 8000 12000 150 70

800:500 105 7000 10000 5000 8000 200 80

800. 700 105 7000 10000 1000 10000 200 100

800:500 120 I 7000 10000 -1000 7000 200 130

900/600 140 4000 7000 ?000 5000 260 110

1000 1000 90 1 1100 4000 130 60




Lubrication of the motor

The motor should be lubricated according to the manufacturer's instructions.

See Section 18:Appendix 2, Page 8

Lubricants

The pump and motor bearings should be lubricated with SKF Alfa lub LGM T2 grease or with grease of corresponding grade.

This grease can be used between -30 and + 1100C.

Corresponding grades from other suppliers:

BP Energrease LS2 ESSO (Statoil) Beacon 2

MOBIL (Norsk Hydro) Mobilux Grease 2

SHELL Alvania R3 TEXACO Regal AFB2

Weekly Inspection

Check on the pressure gauge that the pump operates at the correct operating point.

Check that pump casings, seal and flanges do not leak.

Check by listening that the pump does not vibrate abnormally and that the operation is

not abnormal (for example cavitation).

Clean the pump when necessary.

Yearly Inspection

This inspection is valid for normal operation. The intervals should be reduced for cases of difficult operation.

.Carry out the weekly inspection.

Check the bearing condition with stethoscope or by vibration measurent (SPM). The bearings should be replaced if there are any knocks or scraping sounds.

Measure the temperature of the pump bearings with a surface thermometer. The temperature must not exceed 100°C. Inspect and, if necessary, replace the bearings if the temperature is too high.

Open the pump and check the inlet edges of the impeller. The pump probably cavitates if there is

noticeable erosion. This may be caused by a

blocked suction line or by the pump operating under wrong conditions.

Check the clearance between impeller and wear ring (measure the diameters). Replace the wear ring if the clearance is more than 2

mm. Also replace the impeller if the clearance is still more than 2 mm.

Check the sealing surfaces of the seal rings. Replace seal rings if the surfaces are scratched or damaged. Check at the same time condition of the 0-rings. Damaged or hard 0-rings to be exchanged.

Inspection Every Four Years

Dismantle the shaft - bearing seal unit. Always replace bearings, seal parts and other worn parts.

Carry out yearly and weekly inspections.




-Scanpump

Page 8.04

ISMANTLING AND ASSEMBLY JMW Z22

Power Transmission Page 8.05

Bearings Page 8.06

Impeller Page 8.08




DISMANTLING AND ASSLMI3LY POWER TRANSMISSION

Fig 1

3 2 4

7

ev..11.

hi NI s'a .4011 11111

vim rasd ,, 7

1 Half coupling 2 Lock ring 3 Washer

4 Rubber sleeve

5 Bolt

6 Nut 7 Stop screw

Page 8.05

Z22

Dismantling

Before starting to dismantle, make sure that the motor cannot be started. 1 Undo and remove the guard.

2 Remove nuts 6.

3 Knock out coupling bolts 5 and remove lock rings 2.

If parts of the coupling need to be changed - continue to dismantle as follows: 4 Lift off the motor or pump rotor. 5 Slacken stop screws 7 and pull off the half coup-

lings. Mark the positions of the half couplings on the shafts with a scribed line. This will simplify refitting.

6 Press rubber sleeves 4 out of the half couplings.

PD0493 EcI.2 198905

Assembly

Check the rubber sleeves for cracks or other damage If not intact, fit new ones.

1 Fit the keys in their keyways in the shafts and press on the half couplings. Make sure that the half couplings are in the same positions as they were before dismantling.

2 Tighten stop screws 7.

3 Lift the motor (or pump rotor) into place.

4 .Check the alignment

5 Fit washers 3, lock rings 2 and rubber sleeves 4

on to bolts 5 and fit the bolts into the half couplings.

6 Fit nuts 6 and tighten until the bolts come up against the stop in the hole.




DISMAN1 LING AND ASSEMBLY Of: SHAF.1-- BEARING ()NH

311 -

315

301

317

Fig 1

310

dew, si SSV 4

07/ 4.61.v..:, e J A re/. ;lir

313 307

346 346 362 362

305 304

309

306 312

Page 8.06

301 Shaft 308 304 Deflector 314 305 Deflector

306 Bearing housing 307 Bearing housing 308 Bearing cover 309 Bear ing cover 310 Bearing cover

318 311 Bearing cover 312 Ball bearing

316 313 Ball bearing 314 Shaft nut 315 Shaft nut 316 Locking washer 317 Locking washer 318 Vring 346 Shalt sleeve

362 Shalt sleeve

Dismantling

1 Disassemble the power transmission as described under DISMANTLING ANn ASSEMBLY

2 Undo any pipe connections for sealing water. 3 For a mechanical seal - remove screws 366 for

seal covers 363.

4 Remove all screws 105 in the casing joint and lift off the top part of pump casing 101. 5 Remove screws 331 securing bearing housings

306, 307 at the bottom part 102 of the pump casing.

PD01193 Ed .2 1989 05

6 Lift off the shaft-bearings unit. 7 Remove outer bearing covers 308 and 311. 8 Undo the screws for inner bearing covers 309

and 310.

9 Pull off bearing housings 306 and 307. 10 Prise up the tabs of locking washers 316 and 317

and unscrew shaft nuts 314 and 315. Remove the locking washers.

11 Pull off ball bearings 312 and 313. Use a puller that can grip across the inner bearing covers.

12 Pull deflectors 304 and 305 off the shaft.




Assembly

1 Push deflectors 304 and 305 with V rings 319

and 320 on to the shaft together with inner

bearing covers 309 and 310.

2 Press ball bearings 313 on to the shaft. Locate the bearings as shown iQ Fig.2 and use

a sleeve for mounting.

Press ball bearing 312 on to the shaft. Use a sleeve as shown in Fig.3.

Fit locking washers 316 and 317 and tighten shaft nuts 314 and 315. Lock the nuts by turning down the washer tabs.

5 Push bearing housings 306 and 307 on to the ball bearings and secure the inner bearing covers.

6 Fill the bearings 2/3rds full of grease.

7 Secure outer bearing covers 308 and 311 and push on V-ring 318.

Place the shaftbearings unit in the bottom part of the pump casing. Make sure that the wearing rings come into the correct position, see Fig.4.

3 Insert the bent part of the locking wires into the hole in 'the wearing ring groove, see Fig.4. Turn the wearing ring in the direction of pump rotation until the locking wires are completely in the bottom part of the casing.

10 Secure bearing housings 306 and 307 on to the bottom part of the pump casing.

11 Lift on top part 101 of the casing and secure it. 12 Fit the seal covers or the glands, where applicable.

13 Fit any pipe connections for sealing water. 1A Fit the power transmisson as described in

)ISMANTLING AND ASSEMBLY, PA4E 8.05

F1g. 2




DISMANTLING AND ASSEMBLY OF IMPELLER

Pump casing, top part

--------,-

Page 8.08

Z22 108 Plug

203 Wearing ring 204 Locking wire 301 Shaf t

302 Key

326 0ring 345 Inner shaft sleeve

346 Outer shaft sleeve 361 Inner shaft sleeve 362 Outer shalt sleeve 402 Piping

1) For pumps with stuffing box -' -2) For pumps with mech. seal.

Fig. 1

Pump casing, bottom part

203 301 204 345 361

Dismantling

Never place loose parts directly on the floor or on a dirty workbench, but always arrange them on a clean surface.

NOTICE that if only the impeller is to be changed, only parts on the axial bearing side need to be disassembled.

1 Disassemble the power transmission, the shaft- bearings unti and seal as described under DISMANTLING AND ASSEMBLY,

2 Remove wearing rings 203 from the impeller. 3 Remove locking wires 204 from the wearing rings 4 Pull off outer shaft sleeves 346 or 362, 0-rings

326 and inner sleeves 345 or 361 from the shaft.

5 Pull the impeller away from the shaft.

PD0493 Ed.2 1989 05

Assembly

Check 0-rings and wearing rings. Fit new ones if necessary. The shaft sleeves must not be scratched or scored.

1 Place keys 302 in their keyways on the shaft and push on the impeller.

2 Push inner shaft sleeves 345 or 361, 0-rings 326 and outer shaft sleeves 346 or 362 on to the shaft.

3 Fit the wearing rings in the impeller. 4 Fit seal, shaft-bearings unit and power transmission

as described under DISMANTLING AND ASSEM- BLY,




Data sheet part number 79890/1294/GB

FITTING & MAINTENANCE INSTRUCTIONS FOR SEAL TYPES: R**L & U**L

for SINGLE SPRING UNBALANCED SEALS TYPE Contoured shaft designs Split spring sleeve designs Setscrewed spring sleeve designs including replaceable inserted face designs

Iflexi box




This instruction covers the installation, operation and maintenance of unbalanced mechanical seals of the spring- driven type (including those with circulation and quench connections).

UNPACKING AND STORAGE OF THE SEAL The seal should be unpacked carefully and examined for signs of transit damage.

If the seal is not to be used immediately it

should be repackaged as appropriate and stored in good conditions. It should be noted that gaskets and '0' rings may

deteriorate if stored for long periods, particularly if subjected to extremes of temperature and humidity.

Documentation supplied with the seal should be kept for future reference.

DESCRIPTION

Referring to the drawing, it will be seen that seals with circulation connections and seals with circulation and quench connections differ only in the design of the seal plate (3).

Sealing action is obtained by arranging for intimate contact between a stationary and

a rotating seal ring. The faces of these seal rings are lapped to optical standards of flatness thereby effectively preventing leakage from the gland.

Each seal consists of two sub-assemblies -

the stationary assembly of parts (1) to (4), and the rotary assembly of parts (5) to (9).

Stationary Assembly: The stationary seal ring (1), resiliently supported by the stationary seal ring packing (2), is held in the seal plate (3), which is bolted to the face of the stuffing box. Under certain conditions a pin (3B) is provided to prevent rotation of the

stationary seal ring (1) in the seal plate (3). In all other cases the friction of the stationary seal ring packing (2) suffices. The seal plate gasket (4) is made in the form of an 0-ring, or of a flat washer.

Rotary Assembly:

The rotary seal ring (5) is positively, yet resiliently, driven from the spring sleeve (8) by means of the spring (7). For this

purpose the spring is coiled right-hand or left -hand according to the direction of shaft rotation and has specially designed ends




which are an interference fit on the necks of the rotary seal ring (5) and of the spring sleeve (8) respectively. The latter is fastened to the shaft by means of one or two set screws (9). In certain seal installations, the design of the spring sleeve may vary slightly from that shown in the accompanying diagram, or may even be replaced by a profile, machined directly onto the pump shaft.

Apart from driving the rotary seal ring (5) the spring (7) also furnishes the initial pressure between the two seal faces. A rotary seal ring packing (6) is located inside the rotary seal ring (5) to prevent any leakage at this point.

Materials for all parts are chosen in accordance with the working conditions under which each individual seal has to operate. The stationary seal ring (1) is usually made from specially developed grades of compounded carbon, which are self-lubricating and extremely hard wearing.

The static seals (2), (4) and (6) are made from synthetic rubbers or other resilient materials, and the remaining components from the most suitable ferrous and non- ferrous metals, including selected grades of stainless steel. The spring (7), made from heavy gauge wire, does not suffer from the disadvantages associated with

Page 8.11

small springs confined in narrow cavities.

All Flexibox Mechanical Seals are designed to cope efficiently with a certain degree of shaft misalignment, eccentricity, whip, thermal expansion and end float. The spring (7) is of large diameter and correspondingly low rate, thus allowing for considerable deviations from the specified working length without upsetting the designed pressure conditions between the seal faces. The resilient stationary and rotary seal ring packings (2) and (6) provide a further degree of self-alignment.

Flexibox Mechanical Seals with Circulation Connections are arranged for the forced flow of some of the pumped liquid around the stationary and rotary seal rings, in order to remove frictional heat at its place of generation, and to prevent the accumulation of harmful sediments and/or polymers around the seal. Reference to the diagram will show that this feature has been provided by arranging an annular chamber in the seal plate (3), surrounding the seal rings (1) and (5), through which the liquid is led from a point of higher pressure in the pump to a point of lower pressure. The Quench Connection is normally used to direct steam, water or methanol to the atmosphere side of the seal, thus preventing carbonization, crystallization, icing, etc.

FITTING, OPERATING AND MAINTENANCE Pumps vary so much in type and design that it is impracticable to provide detailed fitting instructions for each individual application. Reference to the maker's sectional drawing of the pump and to the particular Flexibox drawing illustrating the seal being fitted will make it quite clear how to proceed. The following points do, however, require special attention.

1. The shaft must run true, free from vibration and have no perceptible end play. If the shaft is fitted with a sleeve this must be truly concentric, and suitable arrangements must be made to prevent leakage between the shaft, and the sleeve.

2. The shaft or shaft sleeve must have a tolerance of +0.00/-0.05mm (0.002 inch) on the nominal dimension, and a surface




finish better than 0.8 micrometers (32 micro inches) CLA, in the region of the rotary seal ring packing (6). Shaft or shaft sleeve material must be such as to prevent any surface deterioration by corrosive attack either inside or outgide the seal.

3. Any shoulder over which the rotary seal ring packing (6) passes, during the fitting operation must be chamfered 15' x 3mm or longer. Particular care must be taken not to damage the rotary seal ring packing (6) by splines, keyways, spanner holes etc.

4. The face of the stuffing box must be machined flat and at right angles to the shaft.

5. It is very important to make sure that a seal with the correct hand of spring is fitted. Looking at the face of the rotary seal ring, clockwise shaft rotation requires a right-hand spring, and anti-clockwise rotation, a left-hand spring.

6. Only a trace of lubricant should be applied to the shaft or shaft sleeve surface when fitting the rotary assembly of the seal. No lubricant should be applied to the two seal faces, which must be protected from damage prior to and during fitting.

WARNING: Ethylene propylene is not compatible with mineral oils and silicon rubbers are not compatible with silicon oils.

7. The spring sleeve (8) must be fastened to the shaft or shaft sleeve, in accordance with the dimensional information supplied on the Flexibox drawing Illustrating the Reel heing fitted. If sot screws (9) are used, they must be tightened hard to prevent displacement of the spring sleeve (8) in operation.

8. In the majority of seal installations, circulation is provided by connecting one of the tapped holes in the seal plate (3) to

Page 8.12

the pump discharge branch, and allowing the pumped product to circulate in through the stuffing box and back into the pump. Nothing else is needed if the generated head of the pump does not exceed 1.5 bar gauge (22 p.s.i.g.). For higher heads it is necessary to install a Flexibox Flow Controller.

If installed, the flow controller should be fully open and remain so for a few hours. It

can then be adjusted to pass the minimum flow necessary to keep the seal plate (3) at substantially the same temperature as the rest of the pump.

9. When dealing with new installations, or when pumping liquids containing foreign matter, it is advisable to provide a suitable strainer on the line leading to the seal so as to protect it (and the flow controller) from damage. Care must, however, be taken to inspect and clean the strainer frequently in order to maintain circulation.

10. It is advisable to keep spares for parts (1), (2), (4), (5) and (6) in stock. When re-ordering, please quote the part numbers from the Flexibox drawing illustrating the seal in question. Components (2), (4) and (6) should never be used more than once.

11. When replacing the stationary seal ring (1) in the seal plate (3), the stationary seal ring packing (2) must first be placed around the neck of the stationary seal ring (1) and pushed home against its shoulder.

Care must be taken not to twist the stationary seal ring packing (2). In most cases, it will be found quite easy to fit the stationery noel ring (1) Into the recess of the seal plate (3), particularly It a trace of lubricant has been applied. If a press is used to perform this operation, the rotary seal ring (5) should be placed in contact with the stationary seal ring (1), and the neck of the rotary seal ring (5) protected with a block of wood or fibre before




CIRCULATION QUENCH CONNECTIONS CONNECTION

WITH CIRCULATION AND QUENCH

!PRICIR, -FRO.603:2NSIMI WITH CIRCULATION

\ ONLY

9 ) t:Si,)

applying pressure. Care must be taken to register the slot in the stationery seal ring (1) with the pin (3B) where applicable.

12. If the spring (7) has' to be removed from the rotary seal ring (5) or from the spring sleeve (8) it must be turned clockwise if it is coiled right-hand, and anti- clockwise if it is coiled left-hand. The same applies to refitting the springs.

13. Extreme cleanliness must be observed during all fitting operations.

14. Ensure that the seal and its manner Ut Utiti CO11101111 to tiny legal or licensing requirements and where appropriate meets the local Health and Safety Regulations.

15. A seal must be used only for the duty for which it was originally specified.




Although a seal may be correctly specified at time of order, the conditions of operation can sometimes be changed before the seal is put into use. Please check the duty conditions against the appropriate Flexibox General arrangement drawing and ensure that the operating condition's are within the recommendations.

IMPORTANT: If the conditions of operation are changed without approval from Flexibox then we would decline responsibility for any consequent damage and the user would assume all risks.

16. If, after a prolonged period of satisfactory operation, a seal develops a gradually increasing leak, it should be changed as soon as possible. The seal performance does not normally improve by further use.

17. Ensure that the materials of construction are appropriate to the application and particularly that the secondary packings are compatible with the pumped fluid. These packing materials will normally be Nitrile rubber or Fluoroelastomer or Ethylene Propylene dependent on your order. In certain cases, the materials of construction of the seal might be unsuitable for carrying out a performance test using water at the pumpmaker's works. Please contact FLEXIBOX in case of doubt.

18. Quench connections should be made in accordance with individual requirements.

Notes on Hazardous Products

ATTENTION: If the seal is to be fitted to equipment which handles a hazardous product then special care must be taken when fitting,

Page 8.14

operating and maintaining the seal;

Appropriate protective clothing should be worn.

If there is any danger of fire then you should be aware of the location of the fire alarms and fire extinguishers.

Mechanical seals operating normally will have a small amount of leakage across the seal faces. To cater for this leakage or for the failure of the

provision should be made to guide the leakage away to a safe location. However if such provision is made, do not modify the seal in any way without consulting Flexibox.

If replacement parts are fitted then the replaced items must be disposed of with due regard to their possible hazardous nature.

Operation

BEFORE STARTING THE EQUIPMENT ENSURE THAT ALL NECESSARY SAFETY PROCEDURES ARE BEING OBSERVED.

Ensure that the product fluid is present at the seal faces before start-up.

Mechanical seals should not run dry even for short periods, as this is liable to damage the seal faces.

Correct functioning of the circulation system is essential for efficient seal performance and the safety of the installation.

Ensure that the seal is properly maintained and that the correct flow rate is achieved.

Excessive vibration is detrimental to




seal operation and care should be taken to obtain smooth running conditions.

Periodically inspect fasteners for tightness.

Periodically inspect for signs of leakage.

If restarting after a prolonged shut down it is recommended that the equipment is flushed with clean liquid.

NOTE: A properly selected Mechanical seal will normally run for long periods without attention and it should not be disturbed unnecessarily. However, if leakage does occur it should be attended to as soon as possible before the leakage becomes a hazard.

Inspection and Maintenance

DANGER: Maintenance work must only be carried out when the equipment is stationary and the pumped fluids are at atmospheric pressure and temperature and when the pump has been made safe.

Maintenance work must only be carried out by suitably qualified personnel. Flexibox can provide training where appropriate.

Flexibox seals are designed for a long but finite life and so some wear will eventually occur. It will usually be beneficial to inspect the seal on a routine basis and rectify worn parts as necessary rather than wait for a breakdown to happen.

If excessive leakage does occur there may be underlying factors (such as a change in duty conditions, wear in the pump bearings or excessive vibration) which have caused

Page 8.15

the seal to leak and these should be looked for when the equipment is inspected.

ATTENTION: If items require re-conditioning by Flexibox they should be decontaminated and then returned to us with a document confirming the decontamination.

NOTE: WHEN CARRYING OUT MAINTENANCE WORK ONLY FLEXIBOX APPROVED SPARES SHOULD BE USED.

Genuine Flexibox spares may be obtained from Flexibox companies and Agents. To obtain the correct parts quote the Flexibox seal reference or consult the Bill of Materials on the General Arrangement drawing when one has been supplied.

It is highly recommended that the complete Mechanical seals are returned to Flexiservice for refurbishment.

WARNING: All reasonable care has been taken in the design and manufacture of this seal to ensure that it will be safe when properly used. However these instructions are general and it is assumed the user is aware of the requirements of his plant and the fluid to be sealed.

Flexibox will provide advice on the use of their seal but the following matters are the sole responsibility of the user:

Compliance with statutory plant requirements.

Compliance with other safety requirements.

Final choice of a seal for a particular duty.




Notes on these Instructions These instructions should be available to everybody who has need of them at the place where the seal is used.

In accordance with the European agree- ments certain words or symbols have particular meanings, when used within these instructions or when applied to actual seal parts. They are used as follows:

Page 8.16

`IMPORTANT' - is used for items of particular concern when using the seal.

`ATTENTION' - where there is an obligation or prohibition concerning the avoidance of risk.

`DANGER' (or '1' printed in a triangle) - where there is an obligation or prohibition concerning harm to people or damage to the equipment.

aflexibox Mechanical Seals Flexibox mechanical seals are designed to prevent leakage of virtually any kind of fluid from between a rotating shaft and its housing, even under extreme pressure, high speed or high temperature. The quality of Flexibox design, engineering and materials ensures. sealing integrity, which in turn produces real savings in terms of plant efficiency, low maintenance costs and minimum downtime. The comprehensive ranges available cover a wide variety of applications and sizes.

UNBALANCED SEALS for pressures up to 10.5 bar. Standard seals for general duties Seals to DIN 24960, ISO 3069 and BS 5257 etc Split Seals for easy refurbishing.

BALANCED SEALS for pressures up to 70 bar. Standard process pump seals

Advanced single spring design Seals to DIN 24960, ISO 3069 and BS 5257 etc Seals to API 610 and API 682 Seals to light hydrocarbons High temperature seals High viscosity, abrasive duty seals General purpose cartridge seals

SEALS FOR SPECIAL APPLICATIONS High duty seals for very high pressures (100 bar) and speeds (50,000 rpm) PTFE bellows seals for aggressive corrosives High temperature and general purpose metal bellows seals Standby seals for back-up security and zero emissions High integrity double seals

azzazons Flexible Couplings Metastream flexible power transmission couplings absorb static and dynamic misalignments which inevitably occur between nominally in-line shafts. The Metastream coupling is renowned for its ability to accept misalignment without vibration, or transmission of high loads to the associated machinery.

The all-metal construction of the coupling avoids the need for lubrication or extensive maintenance. High torsional rigidity and good inherent balance make the couplings ideal for high speed applications. All Metastream couplings incorporate spacer retention anti- fly features.

M SERIES UNIQUE SPOKE FORM MEMBRANE COUPLING TO API 610 The ultimate in safety and reliability for critical process

pump applications. Ratings from 2W to 10,000W per rev/min.

MHS high power weight ratio spacer coupling for medium to high power and speed drives.

T SERIES RING FORM MEMBRANE COUPLINGS Ratings from 2W to 50,000W per rev/min.

Economy ranges for low and medium speed applications High performance space couplings for turbines, alternators, centrifugal compressors etc. High torque ranges for marine main drives, large offshore oil pumps and boiler feed pumps, generators, etc. Standardised couplings to DIN 740, API 610, API 671 etc.

FLEXIBOX LIMITED, Nash Road, Trafford Park, Manchester, M17 1SS Tel: 0161 872 2484 Fax: 0161 872 1654



i

11.49 L

LO

Ind 0141

1xt9 ON

IP] Ilaii xi) 6/34 1.01 Jamal

.

1

009E£1,

'Cu

Waal O

L-005/005-Z

ZZ

1114 viggesuP9 ati 9144

I

pea .amai punam

01 7 UO

3 Jaj




22!1ifl1lU for dr1flin it no. AY

440,355 -190,380 445,40 -310,410 360,400 410.-372 445,425 460,470 .460.-215 460;157 -470;100 495,47 .508.0

-140,355 490,380 -245.397 -310,610 48000 -410,312 445,325 480,270 -400,215 .460,157 -470,100 495.47 1,do,ssa 187,375 245.381 Z88,382 " 338,325 365,280 mins 808,196 465,189 517,189 570,172 613,147 154,102 680,60 639.0

140,-355 187,475 246,401 298..362 338,-325 366480 378,435 468,198 4178.489 617,-189 670,-172 813.147 838r102 880,40

483,128 Dbeseernbie bac upper pact 645,-135 Disassemble bett upper part

-465,242.5 Cortical pin 667,48 Conical pin

The width of the Sealing face is approximately 32mm. Gaskets consist of a sealing band, PTFE 5x2mm; and a gasket,Klinger SIL C-4400, 0.5mm thick.



Kaiak Pumps Australia Pty Ltd

Scanpump GERGMOSAMSER Typ Eelicoil VI-gangor

STANDARD

Page 8.19

trig=12-lo

thonamisatao t Medbelap arta pp

snonteratte Ott

YtjEmnhet: Ra < 0,3 pm

d2 = kiirndiameter 12 = ganginsatsens anvandbara lamgd ti = borrdjulo fOr mellancAngtapp t2 fullskuren (anvandbar) Ongraingd t3 = skruvans inskrumingadjup med

medbringartappen kvar

Benffaming: Beteokning: Exempel: Haterial: Standard:

GKinginsatS dxL M10x1S Rostfritt still SS 2333 med Mt= 43-50 Svensk films ei

Mrsanic c. Mot %a Vo sima4 Am.'s= usonsmw igwas.




Scanpump STANDARD

Page 8.20

GXIMINSATSER

Typ Helicoil

M-Onor

ftam. 5129.001

adwpave

2

1986-12-10 3.

Standarddlmensioner:

Gang- aolaittg

1

DO M.

12 tl Ala.

Y2

min.

t3

ma.

?ate vary

Ack.

Jag= *W.

(12

ma.

0,7 4 3,36 6,80 4,0 3,0 3.7

4,15 4,29 6 5,30 8,80 6,00 5,0 6,1

4,20

0,8 S 4,20 8,20 5,00 3,8 4.3

6,20 5,17 5,93 7,5 6.70 30,70 7,50 6,3 6,9

1,0 6 5,00 10,00 6,00 4,5 4,2

6,3o 6,22 6,41 9 8,00 13,00 9,00 7,5 6,9

Ise 1,25 8 6,75 23,00 6,00 6,2 6,7

6,40 8,27 8,48 12 10,75 17,00 12.00 10,2 7,4

1,5 10 8,50 16,00 10,00 7,8 5,0

10,50 10,32 10,56 ls 13,50 21,00 15,00 12,8

,

8,1

1,75 12 10,25 19,00 32,00 9,4 5,2

12,50 12,38 12,64

13 16,25 1

25,00 18,00 15,4 8,4

K16 2,0 16 14,00 24,00 16,00 13,1 6,1

16,50 16,43 16,73 24 22,00 92,00 24,00 21,1 9,7

2,5. 20 17,50 30,00 70,00 16,3 6.3

20,75 20,54 20,00 .e 30 27,50 40,00 30,00 26,3 10.0

024 3,0 24 21,00 36,00 24,00 19,6 6,2

24,75 24,65 15,05 36 33,00 48,00 36,00 31,6 10,0

3,5 30 26,60 44,00 30,00 24,8 7,0

31,00 30,76 31,21 45 41,50 59,00 45,00 39,8 11,0

104 4,0 36 82,00 52,00 36,00 30,1

.. 7,0

37,00 36,87 37,34 54 50,00 70,00 54,00 48,1 11,1



9: Fault Protection and Rectification

CONTENTS :

TROUBLESHOOTING

KelairPumps

PAGE 9.00

PAGE Pages 9.01-2




TROUBLE SHOOTING:

The Trouble Shooting chart has been prepared to assist you in tracing

possible causes for the most common troubles experienced in the operation of centrifugal pumps.

Enquiries involving problems not covered by this chart should be directed to Kelair Pumps Australia Pty Ltd.

TROUBLE SHOOTING

TROUBLE POSSIBLE CAUSES

Pump not primed LIQUID Air or vapour pocket in suction line NOT Pump not up to rated speed DELIVERED Wrong Rotation

Impeller or passages clogged

Available NPSH not sufficient (ie suction head too low) Pump not up to rated speed

FAILURE Wrong rotation TO Impeller or passages partially clogged DELIVER Wear rings worn or impeller damaged RATED Air or gasses in liquid CAPACITY Viscosity or specific gravity not as specified AND Air or vapour pocket in suction line PRESSURE Air leak at Mechanical seal

Total head greater than head for which pump designed

PUMP Air leak in suction line LOSSES Air leak at mecanical seal PRIME Air or gasses in liquid




anon Rerationrand Vlaintenan

TROUBLE POSSIBLE CAUSES

Speed too high Specific gravity or viscosity too high

PUMP Low voltage or other electrical trouble OVERLOAD Misalignment DRIVER Total head lower than rated head

Trouble with engine, turbine, gear or other allied equipment

Available NPSH not sufficient (i.e. suction head too low) Air or gases in liquid Misalignment

PUMP Worn bearings VIBRATION Damaged rotating element

Foundation not rigid Pump operating below minimum recommended capacity Impeller clogged

Incorrect oil level Misalignment

BEARING Cooling water insufficient OVERHEAT Bearings too tight or preload OR Oil rings (if fitted) not functioning WEAR Suction pressure appreciably different than specified RAPIDLY Improper lubrication

Vibration Dirt or water in bearings



KelairPumps

10: Isolation and Restoration Procedures

CONTENTS: NOT USED

PAGE 10.00

PAGE



KelainPumps

PAGE 11.00

11: List of Sub-Contractor and Proprietary Equipment

CONTENTS: NOT USED

PAGE



KelairPumps

PAGE 12.00

12: Recommended Spare Parts and Special Tools

CONTENTS : PAGE ABS SPAREPARTS LIST Page 12.01-3 ORDERING DETAILS Page 12.04 OTHER SPARE PARTS INFORMATION Page 12.04



642267

2

00092170

811657/112180

SPA

RE

PAR

T L

IST

Pum

p de

alyn

atlo

n:

N.cod

Dat

e 99-03-23

Pek

e 1

Leve

l It

em

Pat A

mbe

r Q

uad.

D

esai

Vie

rieb

nens

trA

Mot

erla

t:Din

ensi

sa

1

208357

2

Pump casing unit

SS0120

,CK-JK

.2

19231103

2

Sealing band dim. 5X2

PTFE

.2

133680

1

Pump casing

SS0120

,CK-JK An.A,B

.2

104

19281004

1

Gasket 0,5X1500X4000

Klinger Sil C-4400

1

208324

2

Impeller unit Z22- 500/500 -70

SS5716

.2

201

133554

1

Impeller Z22-500/500-70

SS5716

.2

203

133556

2

Wear ring Z22 -500/500 -70

SS5716

.2

205

20230570

2

Shoulder M8X12

2343

1

208335

2

Shaft-bearing-seal unit

SS2324,57I6

,222-500/500-70

.2

133369

1

Seal unit

SS2324

..3

350

36220420

1

Mech.seal Flexibox

Keramik/rent KOL/Witrilgum

...4

352

21274183

1

Stationary seal ring Flexibox

Rent KOL

,56389 -304

-.4

353

21263648

1

0-ring 129,7X3,53

Nitrilg.

...4

354

21275478

1

Mech.seal ring Flexibox

Kiselkarbid I SS2343

...4

355

21263354

1

0-ring 113,7X5,33

Nitrilg.

...4

357

22812280

1

Spring Flexibox 0772 AR-154

2343

..3

351

36220421

1

Mech.seal Flexibox

Rent KOL/keramik/Nitrilgum.

...4

352

21274183

1

Stationary seal ring Flexibox

Rent KOL

,56389-304

...4

353

21263648

1

0-ring 129,7X3,53

Nitrilg.

...4

354

21275478

1

Nech.seal ring Flexibox

Kiselkarbid I SS2343

...4

355

21263354

1

0-ring 113,7X5,33

Nitrilg.

...4

356

22812710

1

Spring Flexibox 0772 AL-154

2343

..3

363

133368

2

Seal cover

SS2343

..3

364

21260915

2

0-ring 164,3X5,7

Nitrilg. SS1587

..3

365

20210503

2

Slotted head screw MCS 4X20-50

A4

..3

366

20213120

Hexagon socket head screw

StAl

,MC6S 12X70-12.9

.2

133625

1

Shaft-bearing unit

sS23245716



Our

cire

emum

bw

Wen

wrb

ec

Ntr

umun

tar

\cw

t.:v*

0100

1m

642267

2

00092170

811657/112180

SP

AR

EP

AR

T L

IST

Pum

p de

skpr

atio

n:

Z22-500/500-70 (1.cod

Dab, 99-03-23

Pape

2

Lon

,' no

m

Par

t Nur

rbw

Q

uint

D

ustr

Iptiv

n/D

irren

sion

M

a!er

iaY

DFr

ensb

n

..3

301

123210

1

Pump shaft 102X1790

2324

,

..3

302

20177878

1

Key R 25X14X180

SS2306

2343-02

..3

303

20172142

1

Key R 25X14X160

SS2306

1650-06

..3

304

122483

1

Thrower DY174,DI100,L60

0125

..3

305

122482

1

Thrower DY174,D1100,L45

0125

..3

306

133682

1

Bearing housing

SS0120

..3

307

133682

1

Bearing housing

SS0120

..3

308

122206

1

Bearing cover

0120

,Z22- 408,- 508, -5

..3

309

122205

1

Bearing cover

0120

=2-408,-508,-5

..3

310

122205

1

Bearing cover

0120

,Z22-408,-508,-5

..3

311

123211

1

Bearing cover DY255,B55

0120

,

..3

312

35022495

1

Ball bearing SKr 6319

Stil

,

..3

313

35030140

2

Ball bearing SKr 7319 BECBP

Stal

,

..3

314

20530190

1

Round nut M95X2-6 ISO 2982

Stal

f

..3

315

20530190

1

Round nut M95X2-6 ISO 2982

Stil

.

..3

316

21152190

1

Locking waysher 95-ISO 2982

Stal

.

..3

317

21152190

1

Locking waysher 95-ISO 2982

Stal

..3

318

21255030

1

V-ring V-905

Nitrilgum.

..3

319

21255048

1

V-ring V-1505

Nitrilgum.

..3

320

21255048

1

V-ring V-1505

Nitrilgum.

..3

322

20430300

1

Hexagon plug IS0-03/8

1325

..3

323

21184420

1

Seal washer 16,5X24X1,5

Gylon

,

..3

324

20213092

24


Stal

,MC6S 10X30-12.9

..3

326

21263703

4

0-ring 99,5X3

Nitrilg. SS1587

..3

328

31330630

2

Grease nipple NEC BH ISO-R1/8

Stal, F2

,SS1568

..3

329

47101008

2

Measuring nipple SPM 32000

Stal,FZ

,L=24

..3

331

20213137

12


Stal

,MC6S 16X50-12.9



Our

ord

emor

rbar

Lirs

enU

ateC

1,43

011

001'

rib:tr

.

Yoa

r art

arou

rats

c

642267

2

00092170

811657/112180

SP

AR

EP

AR

T L

IST

Pum

p is

esig

natio

n:

Z22-500/500-70 M.cod

oats

99-03-23

1312

o 3

Leve

l ham

PanNumbet

Qua

rt

Dim

apoW

Mm

imA

n M

alez

iaV

DItr

embn

..3

334

20491008

2

Protecting plug M8

Polyeten,

..3

361

133623

2

Shaft sleeve

SS5716

..3

362

133624

2

Shaft Sleeve

SS5716

..3

368

20172142

1

Key R 25X14X160

SS2306

1650-06

..3

369

21255020

1

V-ring V-80S

Nitrilgum.

..3

389

130190

1

Guard Z22 -500/500 -70

1312

1

202159

2

Tube arrangement

Sta.].

,Z222-309,-409

.2

401

31863100

4

Straight coupling GE

Stil ytbeh.

,12-L-ISO-G3/8

1

204314

2

Mounting arrangement unit

1312

,222-508,AN.A,CK

.2

20122141

2

Tapered pin GKP M12X13X65

1912-04

.2

520469-73

2

Hexagon nut M6M 12-8

Steel

.2

527238-76

12

Hexagon socket head cap screw

Steel unprot. ,MC6S 24X55-12.9

.2

501

122594

1

Pump stand Z22 -508

1312

.2

502

122594

1

Pump stand Z22-508

1312

1

207558

2

Nameplate unit Engelska

2343

.2

20372040

10

Drive screw KDS 2X5

Stil, FZB

.2

181531-72

1

Sign pump 90X35X0,5

2343

.2

133282

2

Sign ABS 195x60x0,5

SS2343




Ordering Spare Parts

Contact: Spare Parts Customer Service

Kelair Pumps Australia P/L 215 Walters Rd, Arndell Park NSW 2148

Ph: (02) 9678 9466 Fax: (02) 9678 9455

Required Ordering Information: Pumpset Part No. : LP-110015-BM Pump Model No. : LP-Z22-500/500-70-02 Pump Serial No's : 92170 -1

92170 - 2

Other Spare Parts Information

No special tools are required in the assembly & disassembly of the pumpset.

Schedule D4 of the Tender Documents is void and therefore not included in this document.



13: List of Engineering Drawings

CONTENTS: GENERAL ARRANGEMENT DRAWING Dwg No. 486/4/7-PD070/0 (GA-110015/CQ5121/8)

KelairPumps

PAGE 13.00

PAGE

Page 13.01

PUMP DRAWINGS ABS Pump Outline (Certified - PD1525) Page 13.02 Sectional Arrangement (Z2E-367) Page 13.03-4 Performance Curve (6064-1MC) Page 13.05

MOTOR DRAWINGS Motor Dimensions (42772-400L6-400D) Page 13.06 Aux Terminal Box (QI2601-355-153) Page 13.07 Aux Terminal Box (QI2601-355-110) Page 13.08 Terminal Box Assembly (QI2601-001-020) Page 13.09



PUMP DUTY : 750 L/S @ 39M HEAD

FLUID PUMPED : WATER

UNIT WEIGHTS : PUMP - 2200KG

MOTOR - 2900KG

BASEPLATE - 990K6

TOTAL WEIGHT : 6090KG APPROX.

700 900

L f 1

so

NM-

FLANGE DETAIL

SCALE : 1 : 20

1070

1150

NOTE : VOLUTE & BRG. HSG. TO BE TAPPED 3/8-24 UNF FOR 'BENTLY NEVADA' TRANSDUCERS PUMP CASING TEST PRESSURE = 1500kPa

PUMP CASING WORKING PRESSURE = 1000kPa PUMP CASING MATERIAL = CAST IRON BS1452/14

028 HOLES - 8 PLACES

( LOCATIONS FOR 1424

HOLDING DOWN BOLTS)

RAISED FACE HEIGHT = 4MM

TOTAL FLANGE THICKNESS = 45MM 026 - 20 HOLES (SUIT M24 BOUM)

FLANGES : SUCTION / DISCHARGE 500mm - DIN PN10, RAISED FACE

REV WANE ECR 0-1K APPD

A FIANCE DETAILS ADDED 934 T. Z. DJ...

FUNEE DETAILS CHANGED

WEEHT DETAILS CHANGED

PUT DETAIS CHANGED

959 T. Z. DJ.J.

962

1017

T. Z.

PAINT SPECFICATION's

PUMP 621 JADE (GREEN) MOTOR : XIS ORANGE BASEPLATE BLACK GUARDS : YELLOW 8, BLACK STRIPES

Bristhl@ne, Water.

DATE

3/1V98 21/12/98 23/12/98 29/03/99

7486/4/7-PD070/0 SHEET OF CADD FILE N°

9

All MONK IN NH

MESS OTLERWISE

STATED BO NOT SCALE

DO NOT SCALE

ORK S. G. 8

T.Z. 7

APP KL 6

ISSUED:

4 YP-110015 PAINTED STEEL RASO:UTE YP-110015 TOLERANCES:

LINEAR: tO MM

ANGULAR: 4 f 3 FC-110015 RATH RCVS COW RIG COUPLIC

2 ZM-EPEE ISSUE POPE 4001-110 400KW 1000RPM ELEC. MOTOR 42772-40016-4000 LP-M-500/500-70-02 ABS SPIH-CASE CENTRFUGAL PLOP

ITEM PART NO. DESCRIPTION OTY REF DRAWING DRAFTING TO AS 1100.101-1992

CLIENT:

KILPATRICK GREEN P/L

194 ZILLMERE ROAD

BOONDALL GILD. 4034

Ketair Pumps Australia 33 Day Street, Siverwater 2128 TEL (02) 9647 2699

N. S. W. AUSTRALIA FAX. (02) 9647 1092

TITLE:

WATER TRANSFER - LEAROYD ROAD BRISBANE

SCALE: 1 : 25

DATE 4/9/98

PART NO.

LP-110015-BM

ORG. NO: 6A-110015/C05121/8

A3



IN-LINE, HORIZONTAL SHAFT ANTI-CLOCKWISE ROTATION

Version JK Arrangement A

Z 22 PD1525

Ed. 5 Date 1996 10 16


Si

ABS Pumps International AB CERTIFIED DRAWING

Type Flange PN/ND DN1 DN2

Pump hi h3 h4

1999 -03- 2 9

Our ref sli651 I q2,1-10-1-z Your ref.: 1:V0 Lt 2;1% h9 0 Lit

Z22-500/500-70 10 / 16 500 500 880 500 700 900 500 1810 170 610 360 2200 Z22-600/600-65 10 / 16 600 600 961 620 620 880 620 1945 165 680 350 3000 Z22-600/600-75 10 / 16 600 600 950 650 900 1100 650 1920 165 785 400 3800 Z22-700/700-65 10 700 700 950 750 750 1100 750 1920 165 805 310 3400 2.22-800/700-105 10 800 700 1100 900 1000 1300 900 2220 200 1000 550 5700 Z22-900/800-90 10 900 800 1130 800 900 1300 800 2280 230 960 470 4800 Z22- 1000/1000 -90 10 1000 1000 1160 850 1200 1600 850 2340 215 1070 470 8200

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436..1E31 SECTIONAL DRAWING

Page 13.04

Z2E-367 Scanpump series Z22 Pump size 400/300-55.

500/400-60, 700/700-65,

350/350-45. 500/500-70, 800/700-105,

450/4 600/ 900/8

00-40, 600-65, 00-90,

Dote

950704

500/400-55, 600/600-75 1000/1060-90

Page

2/2 Issue

1

Item Oly. Port name Benennung 101 1 Pumpcosing, upper p art Gehouseoberteil 102 1 Pumpcosing, lower po rt Gehouseunterteil 104 1 Gasket Flochdichtung 105 74 Screw Schroube 108 7 Plug Propf en

109 7 Seol ring Scheibe 114 4 Plug Proplen 115 4 Seal ring Scheibe 120 4 Tapered pin Kegelstif t 121 4 Nut Muller

126 2 Gasket Flochdichtung 201 1 Impeller Loufrod 203 2 Wear ring Spoltring 204 2 Locking wire Sicherungsdroht 205 2 Shoulder Gewindeslilt

301 Shaft Welle 302 Key Pass( eder 303 Key Possleder 304 Thrower Spritzring 305 Thrower Spritzring

306 1 Bearing housing Logerhouse 307 1 Bearing housing Logerhbuse 308 1 Bearing cover Logerdeckel 309 1 Bearing cover Logerdeckel 310 1 Beoring cover Logerdeckel

311 1 Bearing cover Logerdeckel 312 1 Boll beoring Kugelloger 313 2 Boll bearing Kugelloger 314 1 Round nut Logermut ter 315 1 Round nut Logermut ter

316 Locking washer Sicherungsblech 317 Locking washer Sicherungsblech 318 Radial scot Rodialwellendichtung 319 Rodiol seol Rodiolwellendichtung 320 Rodiol seal Rodiolwellendichtung

322 1 Allen plug Propf en 323 1 Seal washer Scheibe 324 32 Hex, socket screw Schroube 326 4 0-ring 0-ring 328 2 Greose nipple Schmiernippel

329 2 Meosuring nipple Messnippel 331 12 Hex. socket screw Schraube 334 2 Protecting plug Propfen 340 2 Gland Stoplbuchsbrille 341 2 Lantern ring Sperring

342 7 Glond pocking Stopfbuchspockung 343 4 Stud screw Stiftschroube 344 4 Nut Mutter 345 2 Shot t sleeve WellenschonhUlse 346 2 Shalt sleeve Wellenschonhtilse

347 2 Stuffing box bushing Stoplbuchse 350 2 Mechanical seol Gleitringdichtung 361 2 Shaft sleeve' Wellenschontase 362 2 Shalt sleeve Wellenschonhillse 363 2 Seal cover Deckel filr Gleitringdichtung

364 2 0-ring 0-ring 365 2 Stop screw Sperrschroube 366 8 Hex. socket screw Schraube 368 1 Key Possleder 369 1 Rodiol seal Rodiolwellendichtung

389 1 Guard Schiilzhoube 401 4 Straight coupling Rachte Kupplung 402 1,4 Pipe Rohr 501 1 Pumpcosing foot Pumpengehbusefuss 504 8 Hex. socket screw Schraube

505 8 Washer , Scheibe

Designation Demi- corps superieur Demi-corps inf trieur Joint Vis Bouchon

Rondelle Bouchon Rondelle Goupitle conique Ecrou

Joint Roue Bogue d usure Fil de blocoge Vis de blocoge

Arbre Clovet le Clovette Deflecteur Deflecteur

Corps de polier Corps de polier Couvercle de polier Couvercle de polier Couvercle de polier

Couvercle de polier Roulement b billes Roulement a billes Ecrou de roulement Ecrou de roulement

Rondelle de serroge Rondelle de serroge Joint rodiol Joint rodiol Joint radial

Bouchon Rondelle

Vis Joint torique Groisseur

Nipple de mesuroge Vis Bouchon de protection Fouloir Bogue-lonterne

Presse-etoupe Vis Ecrou Chemise d'orbre Chemise d'orbre

Bogue de fond Gorniture meconique Chemise Warbre Chemise d'orbre Couvercle de lo garniture

Joint torique Vis de blocoge Vis Clovette Joint radial

Protection Accouplement droit Tube Pied de corps de pompe Vis

Rondelle

Benomning Pumphus, overdel Pumphus underdel Plonpockning Skruv Propp

Tittningsbricko Propp Totningsbricko Gtingod konisk pinne Mutter

Plonpockning Pumphjul Slitring Lastrod Knosler

Pumpoxel Plollkil Plottkil Avkostore Avkostore

Logerhus Logerhus Logerlock Logerlock Logerlock

Logerlock Kulloger Kulloger Rundmulter Rundmulter

Lesbricko Lesbricko V- ring V-ring V-ring

Propp Totningsbricko Sexkonthelsskruv 0-ring Smorjnippel

Molnippel Sexkonth6Isskruv Skyddspropp Gland Votskel6sring

Boxpockning Pinnskruv Mutter Axelfoder Axelfoder

Bollenring Mekonisk tlitning Axelfoder Axelfoder Ttitningslock

0-ring Stop skruv Skruv Kit V-ring

Skyddshuv Rok koppling Rot' Pumpfot Skruv

Bricko



Pun-wr- Z22-500/500-70 Curve nun

6553-3 Density

1000 kg/m3 Viscosity

Mff12/5

Teat norm

ISO 2548C Speed Irpml

1180 N.

02 Jul 1996

m .700

100

80

60

40

20

0

Shaft

kW

1200

800

184

635

Max imp. diam. in cast iron at

1180 rpm is 646'mm. Double

Volute.

88 Consult factory for all

speeds above 1200 rpm

mow , MM.

540 riallinV r

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500 1000 1500 2000 2500 3000 3500 4000 4500 5000 m3/h

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CLOSED Execution Diameter Number of vanes

7

Min channel area

70 X 80 Impeller turning Impeller

Z8H-602 Impeller Impeller Model description




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14: Training

CONTENTS: NOT USED

ID KelairPumps

PAGE 14.00

PAGE



IDI KelairPumps

PAGE 15.00

15: List of Contract Variations and Plant Modifications

CONTENTS: NOT USED

PAGE



ID KelairPumps

16: Commissioning and Test Reports

CONTENTS :

HYDROSTATIC TEST CERTIFICATE

PERFORMANCE TEST RESULTS:

PAGE Page 12.01

Summery (Pump Serial No 92170-1) Page 12.02 Test No: 4931 (Pump Serial No 92170-1) Page 12.03 Test No: 4932 (Pump Serial No 92170-1) Page 12.04 Test No: 4933 (Pump Serial No 92170-1) Page 12.05 Test No: 4934 (Pump Serial No 92170-1) Page 12.06 Summery (Pump Serial No 92170-2) Page 12.07 Test No: 4941 (Pump Serial No 92170-2) Page 12.08 Test No: 4942 (Pump Serial No 92170-2) Page 12.09 Test No: 4943 (Pump Serial No 92170-2) Page 12.10 Test No: 4944 (Pump Serial No 92170-2) Page 12.11



Kelair Pumps Australia Pty Ltd ASS A company in the Cardo Group

Page 16.01

Produktspecifikation/Object

CENTRIFUGAL PUMP

Benamning/Part name

Z22-500/500-70

Komponentbeteckning/Identification No.

92170 KontrollplantInspection plan

Sammanstallningsritning/General assembly drawing

Detaljritning/Part drawing Kontrollklass/Inspection class

Leverantar/Supplier ABS PUMP PRODUCTION AB

BOX 170 S-592 24 VADSTENA

Sesta Ilare/Customer ABS PUMPS INTERNATIONAL AB

BOX 2052 43102 MOLNDAL SVERIGE

Order (Leverantar/Supplier)

642267 Order (Sesta Ilare/Customer)

811657 Kontrolldokument / Inspection point PROVTRYCKNING / PRESSURE TEST * ) Kontrollerade / Inspected

2 PC.

Godkanda / Approved

2 PC.

Att atgarda / To adjust Omkontroll Required

erfordras erfordras ej required not required

I

Omkontroll uffores av / Reinspection by I Omkontroll rapporteras till / Reinspection to be reported to

Anteckningar / Notes

PROVNINGSINTYG / INSPECTION CERTIFICATE

* ) Test enligt / according to ISO 5199-6.3.1

Medium:Kallt vatten / Cold water Ha / Hold time : 30 min. Normtryck / Normal pressure:10 Bar Provtryckning / Test pressure : 15 Bar

Resultat / Result : Inget lackage / No leakage

Ort och datum / Place and date

VADSTENA 1999-04-09

Underskrift / Si nat

JORN AXEN _-

ID-Nummer:642267.DOC ABS Pump Production AB



Kelair Pumps Australia Pty Ltd Page 16.02 TESTING OF ABS PUMPS MODEL Z 22 - 500 / 500 - 70 WITH 400 KW POPE ELECTRIC MOTOR

. .

. .

Pump Serial No 92120-1 : - .._ .. ..

.. __. . _ ._.._ .. Test 1A Speed: 955 rpm Start Time 15.45 Date of Test: 11/08/99 .. ...

No. Flow (Us)

Result in TDH .._._ ( m)

Speed .. .._

(rpm) Pg m

Suction Head to Pump St Head

( m) m )

Vel Head Total ( m ) ( m )

Total Discharge . ._.._ . . . _..

Head

( m )

Electrical Data from Generator Power Current Voltage P.F. ________ _____ ...-.

-..( Wij ( Amp ) ( V )

995.7 995.9

_6 _ _ 0 .

169.2 - 0 54.52 0 0 i 0 _

0 54.52 i 246.5 415.1 0.955 2 247.8 51:30882136 0 0 0.081178643 0:081178643 51.39 243.8 ! 353.8 414.7 0.959 3 523.8 46.46728111 995.7

994.5 0 0 0 0.36271889 0.36271889 46.83 25.3

356.8 ! 471.9 Ti 414 0.961 4 749.9 38.22656005 0 -0.64 -0.64 0.743439947 0.103439947 38.33 519 413.3 0.96 5 941.7 27.597631 994.9

995.3 -0.7 -0.64 -1.34 1.172369001 -0.167630999 27.43 342 - 497.3 413.5 0.96 6 1029.5 20.70882659 -1.05 -0.64 -1.69 1.401173412 -0.288826588 20.42 ----324.1 470.8 414.1 0.96 7 1042.4 12.66349219 994.5 -1.1 -0.64 -1.74 1.436507809 -0.303492191 12.36 286 413.7 414.8 0.962

Test 1B Speed: 825 rpm Start Time: 10:55 Date of Test: 12/08/99

Result in TDH

( m)

Speed

(rpm)

Suction Head Total Discharge Electrical Data from Generator No. Flow Pg to Pump St Head Vel Head Total Head Power kW )

.

' Current Voltage P.F. ( Ws ) ( m ) ( m) ( m ) ( m ) ( m ) _ _____._

( m ) ___

( Amp ) ( V ) 1 0 7.36

35.16302375 31.98868861 26.95057499 19.30753593 15.20334167

826 825.5 825.3 825.5 825.6 825.3

1.1 -0.64 0.46 0 0.46 37.82 66.7 415.8 0.945 145 207.6 436

66ii----- 779.1

_

f 855.1

1.01 -0.64 0.37 0.056976253 0.25111385 4.47942012 0.802464067

0.426976253 0.411311385 0:189425012

-0.037535933 -0.123341668

35.59 143.3 208.8 415.6 0:953_ 6.656 0.957 0.956

_ .

0.956

3

4 0.8 -0.64 0.16 32.4 188.3

. ... 205.7 ...___. 198

188.6

273.8 .....:___ 298.9 288.3 274.6

415.2 0.35 -0.2 -6.45

-0.64 :=6.64

J6.64

-0.29 27.14 415.1 414.7 414.9

-oiii -1.09

19.27 15.08

Test 1C 1 Speed: 700 rpm _ .. . _. .. _ ..__ - __ ___ - Start Time` _ ___ bate of Test: -14/08/99

No. --- - -------- -

Flow ._. .. ..

Result In TDH

( m)

Speed

(rpm)

--- - - - - Pg

( . _

m )

Suction Head

.... Vel Head

( m )

Total

( m )

Total Discharge Electrical iOwei-T

_ ... .

(kW)

66.32

Data from _ du rre n f

(Amp)

Generator Voltage_

( V ) P.F.

0.93 0.944

_ to Pump

( m)

St Head

( m) _ ___ Head

( m )

27.45 27.2

25.61965172

18.88287585 14.02098114 10.4170788

701.2 701.2 701.2 76f.6- - --

0.25 0.25 0 0.25 98.86 416.4 174.7

380 0.2

-0.01 0 0.2 0.040348277 0.240348277 25.86 90.82 133.4 416.4 0 -0.01 0.190900198 0.180900198 23.43

1411 ---- 120.2 175.7 416.3

415.9 0.949 6.651

4 534.1 -0.15 0 -0.15 0.377124148 0.227124148 -128.6 188 5 6 ----- --- 661.8 - 739.5

701.3 700.9

0.2 -0.64 -0.44 0.579018862 0.139018862 14.16 124.1 182.1 415.7 _0.947 - 0.95--i- 0 -0.64 -0.64 0.722962119 0.082962119 10.5 117.1 -171 415.7 ..-

Test 1D _

Speed: __ 600 m Start Time: 915 Date of Test: 12/08/99 _ _

Result in Suction Head Total Discharge Electrical Data from Generator No. Flow TDH Speed Pg to Pump St Head Vel Head Total Head Power Current ( kW ) r ( Amp )

Voltage ( V )

P.F. (Us) ( m) (rpm) ( m) ( m) ( m ) (r11) ( m ) ( m )

20.25 _._

601.2 _ 1 0 0.08 0 0.08 0

0.029350244 0.08 20.33 43.45 67.18 416.3 0.897 149 19.06064976

17.38698349 640.7

- 601.2 0.05 0 0.05 0.079350244 19.14 60.24 90.24 416.2 _

416.5 0.926_

._

0.939 3 317.2 0.02 0 0.02 0.133016508 0.153016508 17.54 77.68 114.7 4 425.9

565.2 6-iiii

14.96019708 10.54767821 -i.66446--i4

600.8 600.7 666.6

-0.1 0 -0.1 0.239802919 0.139802919 15.1

10.77 84.29 124 416.5

416.7 0.942 644f

5 -0.2 -0.2 0A22321792 0.5301i-5507i

0.222321792 82.08 120.8 113.4

6 -0.24 0 -0.24 0.290055076 7.95 77:08 416.2 0.939



PRODUCT

TEST REPORT

Serial No.

500x.500 921201 Performance curve No.

53-6 00-00-0000 Motor module/type

000 Voltage (V)

415 Base module

000 Impeller No. Gear type Gear ratio Imp.diarn/Blade angle Water temp° C

15

TEST RESULTS Pump total head

H (m) Volume rate of flow

0 (I /s) Motor input power

P (kW) Voltage U (V)

Current I (A)

Overall efficiency

54.52 0.0 169.20 415 246.5 0.00 51.31 247.8 243.80 415 353.8 51.16 46.47 523.8 325.30 414 471.9 73.40 38.23 74919p1, - 356.80 413 519.0 78.81 27.60 941.7 ,342.00 413 497.3 74.54 20.71 1029.5 3'24:10 414 470.8 64.53 12.66 1042.4 286.00 -.418 413.7 45.28

Accepted after

IS03555B

Test facility

FAUS Australia

Test date I Time

1 99-08-11 16:57

Chief tester y

KELAIR PUMPS AUSTRALIA (955 rpm)

PLOTTED TEST RESULTS

TOTAL HEAD

(m)

60

50

40

30

20

10

Measured point : = Q/H Duty point : 40.= Q/H

X = 0/P = Q/P A= Q/ETA overall

Calculated point :A = Q/ETA overall

4

INPUT POWER

(kW)

......"---'''".-"--...-....---.."""Qqa,..._ ........ -,:. , '

-f-

4...7-::

-R.

Awaso........-. .

...I Imo..

...

...."

A

o, 0 200


400 600 800 1000

600

500

(0/0) 400

300

200

100

60

4

20

0 10 (Vs) FLOW

Page 16.03



PRODUCT

4ck 3 2- TEST REPORT Rs, Serial No.



000 Voltage (V)

415 Base module

000 Impeller No. Gear type Gear ratio Imp.diam/Blade angle Water temp o C

15

TEST RESULTS Pump total head Motor input power Voltage Current Overall efficiency

H (m) P (kW) U (V) I (A) /I(%)

37.36 35.16 31.99 26.95 19.31 15.20

0.0 207.6 436.0

779.1 '- 855.1

98.70 143.30 188.30 205.70 Ass.00 186:760,:r

416 145.0 0.00 416 208.8 49.97 415 273.8 72.66 415 298.9 77.40 415 288.3 74.55 415 274.6 67.62

!;,A,.=-'4

Accepted after

1S03555B

Test facility

FAUS Australia

Test date I Time Chief tester RAY

1 199 -08 -12 11:37


PLOTTED TEST RESULTS Measured point : -F. Q/H Duty point : Q = Q/H Calculated point : J.= Q/ETA overall X = Q/P 0 = Q/P 4

Z),= Q/ETA overall

TOTAL HEAD

(m)

60

50

40

30

20

10

INPUT POWER

(kW)

'et. ...

'', 441,..-..s,

, .,., .k ,,,s

, ''.1 ''''''''/',Zt3i*:::-

.. ...

;?114.s.,;': :ate r' :,...A osv'...,.....444,,,,,;. ..,.

wow.14.- ... ......rA.z., --

. .... -..,,,.

- ,,,,::..r. ---!.-

3I

. _ r-......_ 6,-

Volume rate of How

Q (I /s)

0 200


400 600 800 1000

600

500

(0/0) 400

300

200

100

60

4

20

0 10 (Vs) FLOW

Page 16.04



PRODUCT

TEST REPORT TT-&I- N,21/4-hS1 A

Serial No.



000 Voltage (V)

415 Base module

000 Impeller No. Gear type Gear ratio frnp.diarn/Blade angle Water tempo C

15



0 (I Is) Motor input power


Current I (A)

Overall efficiency

TI(%)

27.20 0.0 66.32 416 98.9 0.00 25.62 174.7 90.82 416 133.4 48.34 23.25 380.0 120.20 416 175.7 72.11 18.88 53-4U,,, , 128.80 416 188.0 76.79 14.02 661.8 -'..,:. '',44,4 24.10 416 182.1 73.35 10.42 739.5 '--%, 110, 416 --g......i.z.i. 171.0 64.53

Accepted after

IS03555B

Test facility

FAUS Australia


1 99-08-12 10:46


PLOTTED TEST RESULTS Measured point : = Q/H Duty point : 0.= Q/H Calculated point : A= Q/ETA overall X = Q/P D=QJP 4

A= Q/ETA overall

TOTAL HEAD

(m)

60

50

40

30

20

10

0

INPUT POWER

(kW)

''''?: 2,-- re.li, ,.,,..

_....,-.... _

f..1,,ar,

- °Y '.;r,,,,.

" .. 1:1-ii;;;::' ''''...,:::-YI,

-:5

"`" '''t; le 30' , 4°' ...--ti ,qt? ,-1. tax v

--1,,,, , ,4.2,

,..:,c,f,":11, .

:::'Ar.:',"!:J. . :; . ,,, ';.......,"-; Ar: r r.../.1.,0:`

..;q,1,,,,,,,' ,;.F.,, -

0 iX ..

,CISP47:64 ,ISSAgas."`- ''

0015.:*

.,....

r

4110""'" - r---

0 200


400 600 800 1000

600

500

(0/0) 400

300

200

100

60

4

20

0 10 (Vs) FLOW

Page 16.05



PRODUCT

TEST REPORT 16,-"1- ``)" 41 ..c-u.T.,1 R

Serial No.



000 Voltage (V)

415 Base module

000 Impeller No. Gear type Gear ratio Imp.diarn/Blade angle Water temp °C

15



0 (I /s)

20.25 0.0 19.06 149.0 17.39 317.2 14.96 10.55 565.2. 7.66 633.2

Motor input power P (kW)

Voltage U (V)

Current I (A)

Overall efficiency

11( %)

43.45 416 67.2 0.00 60.24 416 90.2 46.25 77.68 417 114.7 69.65 84.29 417 124.0 74.15

417 120.8 71.25 416 113.9 61.72

Accepted after

IS03555B

Test facility

FAUS Australia


1 99-08-12 09:44


PLOTTED TEST RESULTS Measured point : -1-= Q/H Duty point : 0= Q/H Calculated point : A = 0/ETA overall X = Q/P 0= Q/P 4

Q/ETA overall

TOTAL HEAD

(m)

60

50

40

30

20

10

INPUT POWER

(kW)

- ---.:710

" -

5'

Ta;irte ,i -

r-,..

200


400 600 800 1000

600

500

0/0 400

(

300 60

200 4

100 20

0 10 (Vs) FLOW

Page 16.06



Kelair Pumps,Australia Pty Ltd Page 16.07 TESTING OF ABS PUMPS MODEL Z 22 - 500 / 500 - 70 WITH 400 KW POPE ELECTRIC MOTOR ....

Pump Serial No: 92120-2 . . . .. _

. .

Date of Test: Test 2A - Speed: 955 rpm Start Time 13.52 17/08/99 . . ...

No Flow Result in

. .... _ .

TDH

( m)

Speed ( rpm )

_._. Pg

(m)

Suction Head ____ ... ...._ _ ....._ .. .

to Pump St Head _..:

(- m) (m) Vel Head Total

Cm ) (m)

Total Total Discharge Head

( m )

Electrical Data from Generator Power Current (kW) ' (Amp)

Voltage P.F. ( Us ) ( V )

. 993.4 993.4

1 0 54.005 1.4

1.3 -0.645 -0.645

d 755 0 0.55 0.737362278 0.5213287-6i 0.402-276974

54.76 174.6 254.6 415.2 0.954 2 249.6 50.64263772 0.655 0.082362278 51.38 46.82 38.08

247.6 327.7 354.6

359 474.4 514.4

. 415.1 414.9 414.3

0.959 0.961 0.961

3 526.4 46.2986713 993.8 0.8 -0.645 0.155 0.366328702 0.747211484 4 751.8 37.67778802 993.2 0.3 -0.645 -0.345

5 940.3 26.89611427 992.6 -0.4 -0.645 -1.045 1.168885733 0.123885733 27.02 337.4 489.3 414.4 0.961 6 1029.5 19.95382659 993 -0.41 -0.645 -1.055 1.401173412 0.346173412 20.3 322.5 467.3 414.4 0.962 7 1044.2 15.39352683 993 -0.1 -0.645 -0.745 1.441473171 0.696473171 16.09 307 445 414.4 0.961

Test 2B Speed: 1825 rpm Start Time: 15:10 Date of Test: 17/08/99

Result in Suction Head Total Discharge Electrical Data from Generator No. Flow (1/s )

TDH

( m)

Speed ( rpm )

Pg to Pump St Head Vel Head Total Head Power Current Voltage P.F. ( m ) ( m) ( m ) ( rn ) ( m ) ( m ) ( kW ) ( Amp ) ( V )

1 0 37.145 823.7 822.7

_ 823

823.2 823

822.9

1.5 -0.645 0.855 0.865 0.55 _ ....

0

0.05621678

0.479425012

0:95314037i

0.855 0.861210378

0.714425012 0.461795849 0.308140377

38 35.5

105.3 144

154

210 415.7 415.5

0.95 0.953

2

3 ---- 4

5 _

6

206.2 434.5

---- - --- 602.2 7812

. . _. . .

849.1

34.63878962 31.61541485

- 26.34557499 18.50820415 14.72185962

1.45 f.-------

0.88 0.3_

_

-0.645 4.66 ..___ 32.42 188.7

203.6 274.9 296.2

414.8 0.955 -0.645 --- -0.64

... .. _.__ -0.645

0.235 27.06 415 0.956 -61,f5----"--6656765646 -0.645

18.97 - 15.03 196.2 285.4

270.7 415.3 415.3

0.956 186.1 0.956

____ Test 2d .._. .. Speed: .. .._.

700 rpm _ .._ __ ..... .. Start Time: 15:38 .._._. ____ . ._ _ Date of Test: 17/08/99

- --- No. Flow

Tos )---

Result In TDH

- ( m) Speed

. .

( rpm )

Pg

( m )

Suction to Pump

. _ Am)

Head _.

St Head WI Head ______

(m) (m) Total (m)

Total Discharge Electrical Data from Generator Head Power Current Voltage P.F. (m) (kW) ( Amp ) ( V )

26.685 25.12414202 2i.ii* 3607 18.1810669

700 . .

0.955 1

2 0

175.6 - 1.6 -0.645 0.955 0 27.64 65.06 97.04 416.3 0.93 700

699.7 -----694.3

1.51

1.37 1.05

-0.645 0.865 0.040857983 0.905857983 26.03 92.11 135.6 415.7 0.944 3 38674 -0.645 0.725 0.191302305 0.916302305 23.53 120.4 175.6 415.8 0.952 4 538.9 -0.645 0.405 0.383933098 0.788933098 18.97 128.7 188.1 415 0.952 5 659.9 13.57930104 9.913991831

6949_ 699.9

0.6 -0.645 -0.045 0.575698957 0.530698957 0.456008169

14.11 125 182.6 415.7 0.951 6 738.5 0.38 -0.645 -0.265 0.721008169 10.37 116 169.5 416 0.95 ' . Test 20 Speed: 600 rpm Start Time: 16:00 Date of Test: 17/08/99

Result in , Suction Head Total Discharge Electrical Data from Generator No. Flow TDH Speed Pg to Pump St Head Vel Head Total Head Power Current Voltage P.F. (Ifs) (m) ( '111)

600.8

(m) (m) (m) (m) (m) (m) (kW) ( Amp ) ( V )

1 0 19.775 1.48 -0.645 0.835 0 0.835 20.61 44.39 68.57 416.1 0.898 2 149.9 18.45529412 16.89173177 14.51474643

64_6.9

600.3 1.42 -0.645 0.775 0.029705882 0.804705882 19.26 60.61 90.77 416.1 0.926 3 317.5 1.3 -0.645 0.655 0.133268b5 0.788268235 17.68 78.37 115.7 416 0.94 4 426.3 6668

6664 5.00.8

1.08 -0.645 0.435 0.240253571 0.6752537-1 6i32568441 07485892512

15.19 84.27 124 415.9 0.943 5

6 --- 568.7 833.7

9.937431559 7.374167,188

0.75 -0.645 0.105 0.427568441 10.47 81.44 120.1 415.7 0.942 0.6 -0.645 -0.045 0:530892512 7.86 76.85 113.6 415.5 0.94



PRODUCT

TEST REPORT 1q4 Q01/4.),sia

Serial No.



000 Voltage (V)

415 Base module

000 Impeller No. Gear type Gear ratio Imp.diam/Blade angle Water temp 0 C

15

TEST RESULTS Pump total head Volume rate of flow Motor input power Voltage Current Overall efficiency

H (m) Q(I /s) P (kW) U (V) I (A) II(%) 54.01 50.65 46.30 37.68 26.90 19.95 15.39

0.0 249.6 5,26.4 71q$4,, 940.3

1029.5 1044.2

174.60 247.60 327.70 354.60 .337.40

307.00

415 415 415 414 414 414

254.6 359.0 474.4 514.4 489.3 467.3 445.0

4r

0.00 50.09 72.96 78.36 73.53 62.48 51.36

Accepted after

IS03555B

Test facility FAUS

Il Australia

Test date I Time

1 99-08-17 15:01

Chief tester RAY


PLOTTED TEST RESULTS Measured point : --= Q/H Duty point : 0= Q/H X= 0/13 0=0/P

A= Cl/ETA overall

TOTAL HEAD

(m)

60

50

40

30

20

10

0 0

Calculated point : Q/ETA overall 4

INPUT POWER

(kW)

,....k

',!..p.1...

Co

.±) * ...., ° .4t.3

N., ,:i

,...

,. 40,1:

.

V4'1,1 'P:1::'.:w, '-'..i...',",l'isezi%*. 3tio"" :.

n` ;,.$:*rsfog6"'"--

t elm. A

- ...

±

1"-....

200


400 600 800 1 000

600

500

(0/0) 400

300 60

200 4

100 20

0 10 (Vs) FLOW

Page 16.08



PRODUCT

TEST REPORT To U.

Serial No.



000 Voltage (V)

415 Base module

000 Impeller No. Gear type Gear ratio Imp.diarn/Blade angle Water tempo C

15


Fl (m) Volume rate of flow

(I /s) Motor input power

P (kW)

37.15 0.0 105.30 34.64 206.2 144.00 31.62 434.5 188.70 26.35 6d2..kT, 203.60 18.51 781.2 196.20 14.72 849.1 186:10-

Voltage U (V)

Current I (A)

Overall efficiency

416 154.0 0.00 416 210.0 48.66 415 274.9 71.41 415 296.2 76.44 415 285.4 72.29 415 270.7 65.89

Accepted after

IS03555B

Test facility

FAUS Australia

Test date Time Chief tester RAY 1 199 -08 -17 15:31


PLOTTED TEST RESULTS Measured point : -4-= Q/H Duty point : 0= Q/H Calculated point : A= Q/ETA overall X = 0/P 0 = 0/F' 4

A= Q/ETA overall

TOTAL HEAD

(m)

60

50

40

30

20

10

INPUT POWER

(kW)

TV,. ;';',U,

14.. . 'V i

. 1 aniiiriat...

11111111111111111.. ,

A

-....0411

Ith.

o 0 200


400 600 800 1000

600

500

(0/0) 400

300

200

100

60

40

20

0 10 (Vs) FLOW

Page 16.09



PRODUCT

TEST REPORT 111' ^---)=2 4-143 cvsty Serial No.



000 Voltage (V)

415 Base module

000 Impeller No. Gear type Gear ratio Imp.diam/Blade angle Water temp ° C

15

TEST RESULTS Pump total head Volume rate of flow Motor input power Voltage Current Overall efficiency

H (m) Q (I Is) P (kW) U (V) I (A) li( %)

26.69 25.12 22.61 18.18 13.58

9.91

0.0 175.8

659.9 738.5

65.06 92.11

120.40 128.70 :1_25.00

416 97.0 0.00 416 135.6 47.04 416 175.6 70.09 415 188.1 74.68 416 182.6 70.32 416 169.5 61.91

-

Accepted after

IS03555B

Test facility

FAUS Australia

Test date I Time

1 99-08-17 15:55

Chief tester RAY


PLOTTED TEST RESULTS Measured point :

TOTAL HEAD

(m)

60

50

40

30

20

10

4- =QM Dutypoint: <>=0/H 0= OM X = D/P

Calculated point : A = Q/ETA overall 4

A= 0/ETA overall

INPUT POWER

(kW)

I. If

x..%%t. U

'''''5;:g .

' 1 IAA 70

1 -'. ...,

. .

Istoloa° .f. ,. --

-

67Z..'''........."......."4( .

r- o 0 200


400 600 800 1000

600

500

(°/0) 400

300

200

100

60

40

20

0 10 (Vs) FLOW

Page 16.10



PRODUCT

TEST REPORT SI 4

Serial No.



000 Voltage (V)

415 Base module

000 Impeller No. Gear type Gear ratio Imp.diarn/Blade angle Water temp°C

15



Q (I /s) Motor input power


Current I (A)

Overall efficiency 11 (%)

19.78 0.0 44.39 416 68.6 0.00 18.46 149.9 60.61 416 90.8 44.78 16.89 317.5 78.37 416 115.7 67.13 14.51 4263: 84.27 416 124.0 72.03 9.94 568.7 .81.44 416 120.1 68.07 7.37 633.7 416 113.6 59.65

Accepted after

IS03555B

Test facility FAUS

Australia


1 99-08-17 16:18


PLOTTED TEST RESULTS Measured point : += Q/H Duty point : Q= Q/H Calculated point : A= Q/ETA overall X = a/P 0=0/P 4

A= Q/ETA overall

TOTAL HEAD

(m)

60

50

40

30

20

10

INPUT POWER

(kW)

'';:;!, ".!.., .""''''-'"

.:'..,,,

ip,

- ,..

'k'Z'st.1....

..1..,,,

.._... .

,.,', i - - -

-.0- , ?0,1.-.19 : +1 Ivi4

.A.

... r--,.. 0 200


400 600 800 1000

600

500

(0/0)

400

300

200

100

60

40

20

0 i 0 (Vs)

FLOW Page 16.11



KelairPumps

PAGE 17.00

17: Appendix 1

CONTENTS : PAGE SCHEDULE D5 - VIBRATION LIMITS FOR PUMPS Page 67 FAN MONITOR Pages : 19 - 24

91 -94



BRISBANE CITY COUNCIL

CONTRACT NO. R.51197198 ATTACHMENTS - Schedules

250

200

1150

SCHEDULE D5 - VIBRATION LIMITS FOR PUMPS

200 300' 500 700 1000. 20b0 VIBRATION FREQUENCY

CYCLES PER MINUTE

Notes: 1. Vibration amplitude is the maximum allowable in any plane. 2. Horizontal Pumps e. measure, ibration on bearing housings. 3. Vertical Pumps - measure vibration at top motor bearing.

10000.

Name of Tenderer:

Signature of Tenderer: Date:

Name of Witness: Signature of Witness: LEAROYD RD P/S M&E CONTRACT °ATE: 11 ttovembet 1997

ATTACHMENTS, Page 67 CPA9SAMWMCOMTRACT107-013136-m,wpd



Fan Monitor 1900/55

The 1900/55 Fan Monitor is a 4 channel vibration monitor that is

designed for use on cooling tower fan assemblies. The 1900/55 Fan Monitor measures the signal from the Velomitor® cr Transducer. Together they provide a comprehensive fan monitoring solution.

Why did we develop a monitor for cooling tower fans?

Vibration switches do not provide the accuracy or reliability our customers need, and walk around data collection programs do not sample fan vibration data often enough to provide adequate fan protection. The 1900/55 Fan Monitor solves both of these problems.

Why is vibration monitoring on cooling towers important?

Safety and convenience - The 1900/55 Fan Monitor provides remote access to information on fan vibration levels and provides remote access to transducer vibration signals. The fan deck area on a cooling tower can be a

safety hazard, especially during poor weather conditions. The Fan Monitor can help to reduce the amount of time Operators and Vibration Technicians spend at the fan, which increases safety and productivity.

Machinery protection - Cooling tower availability is a crucial element of plant productivity. The 1900/55 Fan Monitor provides reliable vibration protection that will help to prevent costly catastrophic fan failures.

Where to use the 1900/55 Fan Monitor

The 1900/55 Fan Monitor can be used in most cooling tower fan vibration monitoring applications where the fan gear box employs rolling element bearings. The 1900/55 Fan Monitor uses a low frequency velocity transducer, the Velomitor® CT Transducer, that mounts on the speed reducer (gear box). The 1900/55 Fan Monitor system monitors

r

1900/55 Fan Monitor

the vibration generated by the fan assembly and gear box. The 1900/55 Fan Monitor is ideal for other low speed fans, such as air cooled heat exchanger fans.

Features/benefits The 1900/55 Fan Monitor is capable

of monitoring four separate fans. The four channel design keeps installation cost low by locating all monitoring functions in a common enclosure.

The frequency response of the 1900/55 Fan Monitor system is 90 cpm (cycles per minute) to 60,000 cpm (1.5 Hz to 1000 Hz), which is ideal for most cooling fan applications. _User interface -The Fan Monitor provides you with a variety of convenient user interface choices:

Large easy to read alpha-numeric LCD display - The LCD display provides a quick overview of vibration levels, transducer OK status and alarm status and set points. The display can automatically scroll through each active channel for hands-free operation. You can enter a unique name for each channel through the configuration menu. The monitor can be configured and labeled in four different languages, English, French, German and Spanish.

Relays - The six internal relays provide the interface to your control system or plant computer. There is

one alert level relay that is common to all channels, and four individual danger relays. Alarm delays are programmable from 5 to 15 seconds. There is also a common OK relay to inform you of transducer and monitor problems.

Buffered outputs - Buffered outputs provide a convenient way to access the transducer signal. The buffered transducer signal is available at the front of the monitor for temporary use, or from a terminal strip at the rear of the monitor that can be used for permanent remote access.

4 to 20 mA Communication Card option - The optional Communication Card allows you to connect the 1900/55 Fan Monitor to a trending device or to your plant computer/ control system. 4 to 20 mA output terminals are provided for each channel.

Remote reset - Remote reset terminals allow you place the monitor reset function at a convenient location.

Remote relay inhibit - Special terminals are provided that allow you to inhibit the alarm relays. This feature is useful if you have fans that experience temporary high vibration during start up or speed changes.

BENTLY NEVADA 1617 WATERS NIINDKR, NEVADA 89423 (702) 782-3611 FAX: (702) 782-9253

19



Fan Monitor

You can wire the inhibit terminals into your control system to reduce the chance of false alarms.

Fault checking - Being able to verify the proper operation of the system is important, especially if there is a machine problem. The 1900/55 provides internal system checks during power up and normal operation. The fault checking feature can also be initiated by the user. Fault checking verifies proper monitor voltages, proper transducer connection and operation.

ACAUT1ON

If housing measurements are being _

made for overall protection of the machine, thought should be given to the usefulness of the measurement for each application. Most common machine malfunctions (imbalance, misalignment, etc.) originate at the rotor and cause an increase (or at least a change) in rotor vibration. In order for any housing measurement alone to be effective for overall machine protection, a significant amount of rotor vibration must be faithfully transmitted to the bearing housing or machine casing, or more specifically, to the mounting location of the transducer.

In addition, care should be exercised in the physical installation of the transducer. Improper installation can result in a decrease of the transducer amplitude and frequency response and/or the generation of signals which do not represent actual machine vibration.

Specifications

INPUTS

Power Supply Specifications 120 Vac Power Source:

Voltage: 90 to 125 Vac. Current: <0.11A.

20

240 Vac Power Source: Voltage: 180 to 2.50 Vac. Current: <0.05A. Frequency: 47 to 63 Hz.

Signal: Accepts signals from the Bendy Nevada Velomitor® CT Transducer or similar type Velomitors.

Transducer Scale Factor: 3.94 mV/ (um/sec) pk, (100mVginisec) pk ±5% at 100 Hz.

SIGNAL CONDITIONING

Monitor Full-scale: English units: 2 in/sec pk,

15 in/sec rms. Metric Units: 50 mm/see pk,

35 mm/sec rms. System Frequency Response (when

using a Velomitor CT Transducer.

±1.0 dB 3.0 11Z to 900 Hz; ±3.0 dB 1.5 Hz to 1.0 kHz.

System Accuracy: Liquid crystal display: ±10% plus

5 counts at 100 Hz. Buffered Output: ±10% at 100 Hz.

OUTPUTS

Buffered Output Specifications (with Velomitor CT): Scale Factor: 500 mV (in/sec) pk.

Frequency response: ±1.0 dB 3.0 Hz to 900Hz; ±3.0dB 1.5Hz to1.0 kHz.

System phase response: 0° at 100Hz. Output Impedance: 3000 typical.

Note: The buffered transducer output is available at two locations on the monitor. The first location is the BNC connector on the monitor front panel. The transducer output from the front panel BNC connector will correspond to the current channel that is shown on the display. The second location is on the "buffered output" terminal strip at the rear of the monitor. The terminal strip provides four simultaneous outputs and is not dependent on the monitor display condition. The scale factor at each buffered output location is 500 mV (in/see) pk.

Reset Specifications A short between "REMOTE

RESET" A and B will clear a NOT OK latched alert or danger relay (alert or danger relays that are no longer above the set points).

Pushing the "RESET" button will clear a NOT OK, latched alert or danger relay, an alert or danger condition that is no longer present.

Bypass Specifications A short between remote bypass

units A and B will inhibit all relays. Relays are inhibited during power

up and for 18 ms after power up.

Communication Card: 4 to 20 mA output is proportional to

monitor full-scale range. Compliance voltage 18 to 36 Vdc. Total loop resistance to 600 0. A NOT OK condition will produce a

2 mA output. A channel over-range condition will produce an output greater than 21 mA, but no greater than 26 mA.

RELAYS

Type: 1 Form C SPDT. Contact Ratings:

Maximum switched power: 224 W or 1600 VA.

Maximum switched current: 8 A. Maximum switched voltage: 28 dc

or 300 Vac. Dielectric Strength (at sea level):

4000 Vrms contact to coil. Life Expectancy:

Mechanical: 10 million operations. Electrical: 1 million operations at

-rated load. Insulation Resistance: 1000 M

minimum, @ 20° C, 500 Vdc.

DISPLAYS

Liquid crystal display: 2 line by 16 characters.

LED Indicators: OK: Green LED on indicates an OK

condition.



Fan Monitor

Alert: Yellow LED on indicates vibration level is higher than alert set point.

Danger: Red LED on indicates vibration level is higher than danger set point.

Bypass: Red LED on indicates a

channel is bypassed.

CONTROLS

Program mode switch: Allows access to the main configuration menu during initial monitor set up.

ENVIRONMENTAL LIMITS

Operating Temperature: -20°C to +70° C (-4°F to +158°F).

Storage Temperature: -30°C to

00°C ( -22 °F to +194°F). Maximum Relative Humidity: 95%

po ncondensing. cord osu re: Type 4 enclosure,

fiberglass. ItiptImpedance at transducer

lit at: 1 M Q in parallel with pF typical. The noise floor will not exceed

0.70mmisec pk (0.03 in/sec pk). alannEMI: Passes all tests

=wired to achieve CE mark.

PHYSICAL

Dimensions: Height: 337 mm (13.25 inches). Width: 295 mm (11.62 inches). Depth: 130 mm (5.13 inches).

ACCESSORIES

190155-01 Operation Manual

190101-01 Type 4 housing. The housing is used when the monitor is mounted locally on the fan deck, or when mounted in other outdoor locations.

190501-AA-BB-CC Velomitor CF Transducer, see data sheet L.5053 for transducer ordering information.

106769-01 Terminal Housing for terminating transducer signal cable from the Velomitor CT outside the fan stack. This junction box is provided with terminal strips.

Ordering Information A BCD

1900/55 - OD -00 -DO -00

Option Descriptions A OD Power Supply Option

O 1 120 Vac Power Supply O 2 240 Vac Power Supply

B DO Communication Option O 0 No communication O 1 4 to 20 mA output

COO O 1

O 2

O 3 O 4

Language Option English French German Spanish

D 00 Hazardous area approvals 0 0 No approvals 0 1 CSA/NRTLJC

21



Fan Monitor

FRONT VIEW

FAN MONITOR

MENU STOP/ IBLIE

PROGRAM MODE

BUFFERED OUTPUT

NORMAL 0 500 mV/Ips

119.7 mV /mm /sect

CHANNEL SETTINGS {WOWS

POINT ID MEET DAM=

22

10.22 1259.81

1t37 1288.91

11.82 1296.11

Figure 1: 1900/55 Fan Monitor front view dimensional drawing

12.00 13.25 (304.81 1338.81



Fan Monitor

REAR VIEW

eeseesseseeeseeeee 4J

!cfsPReh.

?0142E802222keR!R

FalgaVISP4er-c hdphegpqa m mm mm mm m

gli-UMV-Mq

- U F 2 6

00a: moo/ssl 1 SERIAL NUMBER

0

222222222222AA 7.60D.wv.wy>mroA

6 6 6 61,1

1

REMOTE BUFFERED OUTPUTS

tt'Se4-$PRPT

222EFIEEM? 4.8T+Iv+IT+IT

6 6 6 G

111111111111111111 00000000000

12.24 1310.91

10.24 1280.11

Figure 2: 1900/55 Fan Monitor rear view dimensional drawing

23



Fan Monitor

TOP VIEW

Valid conduit entry locations, both aides and ends, when used withNi- 1900/55 Fan monitor

RIGHT BIDE VIEW

1

71114111 11 I- 1 L. --1

1.51 .37

14-7 167016 . 3

END VIEW

0111.21 4.66 I

0.09172.91 mom

16.51 1393.91

Figure 3: Top, side and end dimensional drawing of the Fan Monitor Enclosure p/n 190101-01

BENTLY NEVADA

WORLDWIDE SALES AND SERVICE United States of America: ALABAMA. Birmingham o ALASKA. Anchorage o ARIZONA, Phoenix o CALIFORNIA. Sacramento, & Los Angeles COLORADO. Denver o FLORIDA, SI. Petersburg & Tampa a GEORGIA. Atlanta a ILLINOIS, Chicago o INDIANA. Evansville KENTUCKY, Edgewood (Cincinnati) o LOUISIANA, Baton Rouge o MARYLAND. Baltimore o MASSACHUSETTS, Boston MINNESOTA, Minneapolis a NEVADA. Minden a NEW JERSEY. Newark a NEW YORK. Buffalo & Albany a NORTH CAROLINA, Charlotte

OKLAHOMA, Tulsa o OHIO. Toledo o OREGON, Portland a PENNSYLVANIA, Philadelphia & Pittsburgh o TEXAS. Dallas & Houston Worldwide: ARGENTINA 0 AUSTRALIA o BRAZIL 0 CANADA a CHILE a CHINA a COLOMBIA o EGYPT o FRANCE a GERMANY

HONG KONG o INDIA a INDONESIA o ISRAEL o ITALY o JAPAN o KOREA a KUWAIT a MALAYSIA a MEXICO a THE NETHERLANDS NEW ZEALAND a NORWAY a PEOPLE'S REPUBLIC OF CHINA o PHILIPPINES a POLAND o PORTUGAL 0 QATAR a ROMANIA a RUSSIA

SAUDI ARABIA 0 SINGAPORE 0 SLOVAKIA 0 SOUTH AFRICA o SPAIN a SWEDEN a TAIWAN o THAILAND a TURKEY UNITED ARAB EMIRATES a UNITED KINGDOM o VENEZUELA

Corporate Office: 1617 Water Street Minden, Nevada, U.S.A. Telephone: 702-782-3611 Fax: 702-782-9253 © 1996 Bently Nevada Corporation

24 Data Subject to Change L1955 -01(4/97)



190501 Velomitor® CT Velocity Transducer

Vibration measurement on low speed machines

The Velomitor CT Transducer is

ideally suited to measure casing vibration on rolling element bearing machines, such as cooling tower and air cooled heat exchanger fan assemblies that operate at or above 90 rpm. Cooling towers and air cooled heat exchanger fans typically operate at speeds of 100 to 300 rpm. The Velomitor CT transducer can measure vibration amplitudes at these frequencies as well as the vibration frequencies generated by the fan motor and speed reducer.

The Velomitor CT transducer's frequency response and rugged construction are important for fan protection and diagnostics.

Rotating machinery should be equipped with continuous monitoring to provide machinery protection, predictive maintenance and machinery diagnostic capabilities. The result is increased machine availablilty and plant safety. Before monitors can be specified, transducers are selected based on the type of bearings used in the machine.

Fans usually come equipped with rolling element bearings that have minimal clearances and good energy transmission characteristics. Case mounted transducers, such as the Velomitor CT, are mounted at each bearing location to measure bearing housing vibration. This measurement is a good indication of the machine's overall condition.

The Velomitor CT transducer employs a piezoelectric sensing element and on-board, low noise electronics enclosed in a rugged, stainless steel case. The integral connecting cable and epoxy-filled case allows the Velomitor CT transducer to operate in

harsh environments without any additional protection.

The Velomitor CT offers a variety of mounting options, and is supplied with a threaded stainless steel cap that can interface to flexible, liquid-tight conduit.

BENTLY

190501 Velomitor® CT

Key advantages of the Velomitor CT Transducer:

Excellent frequency response of 1.5 hz to 1000 hz for measuring low frequency vibrations. Stainless steel case and cap provide a robust system that can interface with flexible, liquid-tight conduit, and mounts on the machine without the need of a housing. The Velomitor CT Transducer's 10 metre integral cable design provides a simple, reliable interface to the monitor or junction box. The Velomitor CT Transducer's robust design is suitable for use in harsh environments, such as on cooling tower fans and air cooled heat exchanger fans.

Specifications Parameters are specified at 25°C (77°F) unless otherwise indicated.

Note: Operation outside the specified limits will result in false readings or loss of machine monitoring.

ELECTRICAL

Scale factor: 3.94 mV/(mm/s) pk (100 mV/(in/s) pk) ± 5% at 100 Hz

Frequency response: ±1.0 dB 3.0 Hz to 900 Hz ±-3.0 dB 1.5 Hz to 1.0 kHz

Velocity range: 63.5 mm/s pk (2.5 in/s pk) (see Figures 3 and 4)

Transverse response: less than 5% of the axial scale factor

Amplitude linearity: ± 2% to 63.5 mm/s pk (2.5 in/s pk)

Mounted resonant frequency (stud mounted, except quick disconnect): 4 kHz, minimum

Power requirement: dc voltage: 22 to 30 Vdc Bias current: 2.5 to 5 mA

Output bias voltage: 10.1 Vdc (nominal) Pin A referenced to Pin B

Dynamic output Impedance: 50 0 typical

Broadband noise floor 0.229 mm/s pk (0.009 in/s pk)

Grounding: Internal electronics are isolated from case

Maximum cable length: 305 metres (1000 feet) with no degradation of signal

NEVADA 1617 WATER STREET MINDEN, NEVADA 60423 (702) 782-3611 FAR: (702) 782-9253 91



190501 Velomitor® CT Velocity Transducer

ENVIRONMENTAL LIMITS

Temperature range: Operating: -40°C to +85°C

(-40°F to +185°F) Storage: -40° to +100°C

(-40° to +212°F) Shock limit: 2500 g pk, minimum Humidity limit: 100% condensing,

non-submerged

MECHANICAL

Dimensions: See Figure 1

Mounting surface: 33 mm diameter (13 inch diameter)

Mounting torque: 4.5 ± 0.6 Nrn (40 I- 5 inlbs)

Case material: 300 Series stainless steel

Connector: None Polarity: Pin A goes positive with

respect to Pin B when velocity is from base to top of the transducer

Weight (no cable): 365.7 g (12.9 oz), typical

Mounting angle: Any orientation

ELECTROSTATIC MAGNETIC

Radiated electromagnetic: IEC

Ordering Information A B C

190501 -00-00-00 Option Descriptions A DO Mounting Hardware Option

0 0 No Stud 0 1 Stud 3/8-24 to 3/8-24 0 2 Stud 3/8-24 to 1/2-20 0 3 Adhesive Stud 3/8-24 0 4 Stud M6x1 with 3/8-24

Adapter 0 5 Adhesive Stud M6x1 with

3/8-24 Adapter 0 6 Stud 3/8-24 to 1/4-28 0 7 Plate Stud 3/8-24 to 3/8-24 0 8 Plate Stud 3/8-24 to 1/2-20 0 9 Plate Stud 3/8-24 to 1/4

NPT 1 0 Plate Stud M6x1 to M6x1

with 3/8-24 Adapter 1 1 Plate Stud 3/8-24 to 1/4-28 1 2 Plate Stud 3/8-24 to M8x1 1 3 Quick Disconnect Stud

B Integral Cable Option 1 0 10 Metres

C OD Agency Approvals 0 0 No Approvals 0 1 CSA/NRTUC Approvals 0 2 LCIE/CENELEC

ACCESSORIES

801-3, Level 3 (10 V/m) at 1 metre, installed in flexible metal conduit.

:mmunity: Frequencies from 20 Mhz to 1000 Mhz. Max Velocity Error: 3.8 mm/s (0.15 in/s) pk

Electrostatic discharge (ESD): IEC 801-2 (1991-01, second edition), Level 4 (8 kV) contact discharge. No nonrecoverable errors.

32

125389-01 Operation manual

Adhesive Mount Base Kits These kits are designed for machines with thin casings which do not permit drilling and tapping a mounting hole. 04284020 Contains material

(adhesive and bases) for 4 each :3/8 -24 UNF adhesive-mount base. One kit per 4 Velomitor Cr transducers.

04284021 Contains materials (adhesive and bases) for 4 each M6x1 adhesive- mount base. One kit per 4 Velomitor Cr transducers. (Requires part number 80755-01 3/8-24 to M6x1 adapter).

Spare Mounting Adapters All mounting adapters are made from 300 series stainless steel. Standard Studs 04365657 3/8-24 to 3/8-24 Stud 87910-01 3/8-24 to 1/2-20 Stud 87931-01 M6x1 to M6x1 Metric

Stud (requires metric adapter)

87055-01 3/8-24 to M6x1 Metric Adapter

89139-01 3/8-24 to 1/4-28 Stud

Hex Plate Studs 107756-01 3/8-24 to 3/8-24 Plate

Stud 107755-01 3/8-24 to 1/2-20 Plate

Stud 107754-01 3/8-24 to 1/4 NPT Plate

Stud 107757-01 M6x1 to M6x1 Plate Stud

(requires metric adapter) 125094-01 3/8-24 to M8x1 Metric

Plate Stud 128038-01 3/8-24 to 1/4-28 Plate

Stud

Fittings Conduit fittings let you connect flexible, metal, liquid-tight conduit or armor to the Velomitor Cr transducer. 03839201 1/2 inch NPT straight,

male conduit fitting for connecting flexible, liquid-tight conduit to the transducer or a weatherproof enclosure.

03850000 1/2 inch NPT straight, male compression type fitting connecting teflon- coated 3/8 inch stainless steel armor to the transducer or aweatherproof enclosure. Fitting will fit teflon-coated armor with a maximum outer diameter of 13.8 mm (0.543 inch) (including teflon thickness).



1 Velomitor® Cl' Velocity Transducer

-Coated Stainless Steel

us part includes the teflon- mor but not the cable. Two NPT compression fittings 'levada part number 0) are required to attach the the transducer and terminate nclosure.

A

DO )escription Armor Length Option in Feet ler in increments of 10 feet .0 metres) in Length: 10 feet

(3.0 metres) m Length: 90 feet

(27.4 metres)

Metal Conduit ro 1/2 inch NPT compression 3ently Nevada part number 1) are included with the order. A

1 )ascription flexible Conduit Length )ption in Feet ler in increments of 1 foot 13 metres) n Length: 01 foot

(0.3 metres) m Length: 99. feet

(30.2 metres) S Bulk Cable (specify length

in feet). Two conductor twisted shielded cable used between Velomitor CT transducer and monitor or junction box.

t 1/2 inch DPI straight, male conduit fitting-for connecting flexible conduit to the transducer or a weatherproof enclosure.

1 Terminal housing. Provides a convenient interface between the transducer signal cable and monitor signal cable.

1/2' NPT .x 12.2 DP

11/2' NPT x 0.48 DPI

38.1 Dla. 11.501

78.2 13.001

1

4

38.8 11.451

$

Veloadlor CT

3/8-24 UHF z 8.9 DP

13/8-24 IMF x 0.35 DPI

11.25t8 1

3 Hex Flat

Adhesive Studs

3/8-24 04284020

____EI____. 118/(1

04284021

31.5 11.24101a.

Figure 1: Velomitor® CT Outline Drawing

Dula( Disconnect Studs

Union Mtg. Base Nut 43055-01

1-3/8 Hex Plate Studs

IACIX1 to M8X1 107757-01

3/8-24 to 3/8-24 107758-01

Quick Disconnect Stud Base

128889-01

Quick Disconnect Xducr Piece 128890-01

Standard Studs

U 3/8-24 to 3/8-24

04385057 M8X1 to 118X1

87931-01

3/8 -24 to 1/4-21 3/8-24 to V2-20 89139-01 87910-01

3/8-24 UNF to 1/4 NPT 3/814 UNF to V2-20 UNF 107755-01

. 4FD 3/8.24 UNF to 118X1 3/0-24 UNF to 1/4-28 IMF

125094-01 128038-01

107764 -01

Figure 2: Mounting Studs

3/8.24 to M8X1 Adapter

87055-01

1000

HzI

10000

93 )53 -03 (8/96)



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KelairPumps

PAGE 18.00

18: Appendix 2

CONTENTS : PAGE MOTOR INSTALLATION & MAINTENANCE MANUAL

(For contents see the forth page of this section)



PEM-MAN

JANUARY 99

POPE ELECTRIC MOTORS

INSTALLATION AND MAINTENANCE MANUAL

TEFC

LOW VOLTAGE

SQUIRREL CAGE INDUCTION MOTORS

Customer : Emsby Serial No. : 42772

415 Volts 34 50 Hertz

Sydney Melbourne Adelaide Perth Brisbane Mackay

E-mail: infotk000e.com.au - Internet: http://www.pope.com.au/pope



Pope Electric Motors

PREFACE

Health & Safety at Work

Information in this manual is given for guidance purposes only. Pope Electric Motors cannot accept responsibility for the way in which it is interpreted, or any consequence as a result.

Abuse of electrical equipment can be hazardous. Every effort should be made to eliminate these hazards and the following notes should assist in minimising these risks.

All motors are carefully inspected and tested before dispatch, to ensure they comply with the relevant specifications in relation to electrical and mechanical parts and they operate safely.

This manual gives guidance for installation and maintenance procedures for the TEFC range of Pope

Cage induction motors. It should be carefully read prior to installation and commissioning the

motor.

Further information can be obtained from the following standards:

AS1359 Rotating Electrical Machines. General requirements.

AS1359.101 Rating and Performance

AS4024 Safeguarding of Machinery

AS3000 Electrical Installation - Building, Structures and Premises (known as SAA Wiring Rules)



l'ope Electric Motors

CONTENTS

1. GENERAL

1.1 Inspection And Storage

1.2 Installation

1.3 Bearing Sizes And Lubrication Intervals

1.4 Recommended Greases

1.5 Bearing Maintenance

1.6 Cable Terminations

1.7 Anti - Condensation Heaters

1.8 Thermal Protection Devices

1.9 Overcurrent Protection

2. MAINTENANCE

2.1 Routine Maintenance

2.2 Workshop Repairs

3. APPENDICES

APPENDIX 1 - Tightening Torques For Shaft Locking Clamp Bolts

APPENDIX 2 - Standard Drive End Shaft Dimensions

APPENDIX 3 - Bearing Sizes And Lubrication Interval

2

3

4

8

9

10

11

12

13

14

15

16

17




GENERAL



Pope Electric Motors 3

1.1 INSPECTION AND STORAGE

Squirrel cage electric motors used in industry today are robust, reliable machines requiring little maintenance. There are however a few conditions that should be checked to ensure this reliability.

Inspection

On delivery check the following:

I) Are the rating plate details and enclosure as ordered?

2) Can the motor shaft be rotated?

3) Was the motor damaged during transit?

4) Are the condensation drain holes in the correct position for the motor mounting application?

5) If the winding is meggered to earth, ensure that the thermal protectors are not inadvertently damaged (see Thermal Protectors Section 1.7)

6) If a shaft locking clamp is fitted check that it was secured properly for transit. Motors with roller bearings should have a locking clamp fitted during transit even when mounted on the driven equipment

Storage

When the motor is not for immediate use store as follows:

1) Ina clean dry place

2) Cover with waterproof cover if outdoors

3) If fitted with anti-condensation heaters, the heaters should be energised if the environment is

likely to be damp

4) Free from vibration from any external source. If a shaft locking clamp has been supplied ensure that it is secure. External vibration can cause false brinelling of bearings resulting in additional noise when running and premature failure of the bearing

42772 Rev A INSTALLATION & MAINTENANCE MANUAL




1.2 INSTALLATION

Motor reliability is dependant on proper installation therefore the following precautions should be

observed:

1.2.1. If a motor is installed while construction work is in progress, ensure that it is covered to prevent

contamination from oil, water or dust.

1.2.2. Motors that use ROLLER bearings are fitted with a shaft locking clamp to stop axial movement of the rotor assembly. This axial movement gives rise to a phenomenon termed "false brinelling" which eventually leads to premature bearing failure. The clamp should therefore remain fitted for as long as possible. Motors likely to remain stationary for lengthy periods should have

locking clamps refitted. (Refer to Appendix 1 for tightening torques)

Note - All locking clamp bolts should be of high tensile steel and the nuts stainless steel.

1.2.3. As rotor and shaft assemblies are finely balanced during manufacture, it is essential that pulleys

and couplings also be balanced. This could prevent premature failure of the motor and the driven

equipment due to vibration. The Drive end shaft extension is balanced with a halfkey therefore

pulleys or couplings should be balanced without a keyway.

1.2.4. When slide rails are used in conjunction with pulley drives etc. the adjusting screw ends should

be positioned, one between the motor and load at drive shaft end and the other diagonally

opposite. This helps speedy and accurate belt aligning, tensioning and replacement.

1.2.5. Do not use undue force in fitting pulleys and couplings. These should be machined to H7 limits.

It is recommended that both shaft and bore be cleaned and lubricated. If still too tight, heat up

the pulley or coupling in air or oil to approximately 95°C. Similarly, shock methods must not be

used in removing pulleys and couplings. Use correct wheel or pulley removers to prevent shaft

and bearing damage.

1.2.6. Pope Electric Motors' shafts are machined to Australian Standard 1359-10/1985 dimensions.

(Refer to Appendix 2 for standard dimensions)





1.2.7. Belt Drives

When fitting belt drives, the belt manufacturers recommendations for installation and tensioning must be strictly adhered to.

1. Shafts are not parallel to one another.

3. Shafts are parallel and in alignment, but pulleys are not aligned

End View of the above

2. Shafts are not in correct alignment, although they appear parallel when seen from above

4. Correct installation - both shafts and pulleys are parallel and in alignment

Dotted lines emphasise the faults by indicating the correct position





1.2.8. Direct Coupling

Care must be taken in checking alignment of driving and driven shafts.

Correct

Straight Edge

1.4-

Misalignment through axis

Angular Misalignment

Dimension A should be the same when measured at any location with a thickness gauge. After fitting and connecting check for vibration and out of balance.

1.2.9 Connection Diagrams

Typical connection diagrams for standard motors.

All motors are provided with suitable earthing studs.

INTERNAL

DIAGRAM 1

Star Wound Connections DIAGRAM 2 Delta Wound Connections





EXTERNAL

r

R Y B

DIAGRAM 3 Direct On-Line Connections for both Delta and Star wound motors

Ui V2 I

0 U1

O V2

L1

O V1

O W2

W1 U2

L2

O U2

L3

R Y B STAR DELTA

DIAGRAM 4 Star Delta StartingConnections for Delta wound motors

DIRECTION OF ROTATION IS CLOCKWISE AT DRIVE END WHEN LINES RED (R), YELLOW (Y) AND BLUE (B) ARE CONNECTED AS ABOVE.

Note:

1. The shorting links shown above are supplied on all Pope motors with 6 stud terminal boards.

2. Connections shown in diagram 3 are also used for autotransformer starting

3. Reversal of direction of rotation of any 3-phase motor can be effected by interchanging any two

line leads





1.3 BEARING SIZES AND LUBRICATION INTERVALS

(Refer to Appendix 3 - bearing sizes and lubrication intervals for details)

Re-lubrication intervals are based on a maximum bearing outer ring temperature of 70° C.

The re-lubrication interval should be reduced by half for every 15° C that the bearing outer ring temperature exceeds 70° C.

The re-lubrication interval should be reduced by half if the motor is mounted vertically.

Where grease may be contaminated or the grease serves as a seal against moisture, then the re- lubrication interval should be further reduced.

For example bearing manufacturers quote a situation in which the bearing housing has water running over it for which they recommend weekly re-greasing.





1.4 GREASES RECOMMENDED FOR USE IN POPE MOTORS

a) General Purpose Grease - as used for the motors covered by this manual

This is a Lithium hydroxy-stearate grease.

NLGI consistency No. 3.

The operating temperature range is -35°C to +120° C.

This grease has a high oxidation resistance and will retain consistency after periods of extreme service.

Rust inhibitor is contained in the grease.

Recommended Manufacturer - Shell Alvania No. 3 (or equivalent)

b) Low Temperature Grease

This is an inorganic hecite clay grease with mineral oil

NLGI consistency No.2 to No.3

Operating temperature range is -40°C to +120°C

This grease has a high oxidation resistance and will retain consistency after periods of extreme service.


Recommended Manufacturer - Aeroshell No.6 (or equivalent)

c) High Temperature Grease

This is a Lithium complex soap base with mineral oils.

NLGI consistency No.3

Operating temperature range is -25°C to +150°C

This grease is non-melting with a high oxidation resistance and will retain consistency after periods of extreme service.


Recommended Manufacturer - S.K.F. LIGHT 3 (or equivalent)

NOTE - When regreasing motors ensure that the correct type of grease is used. If in doubt about existing grease type, clean out old grease thoroughly from the bearings and bearing housings, prior to regreasing.

NEVER MIX GREASE TYPES





1.5 BEARING MAINTENANCE

1.5.1 Replenishment

Fresh grease should be added to renew the original charge at pre-determined intervals suitable for the conditions under which the motor is operating (Section 1.3).

Where grease valves are fitted, replenishment should be carried out while the motor is running. The rotating slinger expels grease through the exhaust port in the bearing cap ensuring the correct level of grease is maintained in the bearing housing.

1.5.2 Packing

The amount of grease packed into a bearing assembly or housing, can be critical especially when operating at high speeds. Too much grease can cause churning and over-heating, which may result in the breakdown of the grease and leakage from the housing, while too little grease can result in dry running and cage wear.

The bearing itself should always be packed as full as possible, working the grease thoroughly into the bearing parts in order to ensure proper lubrication immediately upon starting.

The amount of grease to be put into the cover is the balance of the total needed for satisfactory lubrication, and is determined by the free space needed in the covers to accommodate the excess grease which works out from the filled bearing during the initial stages of running.

The most convenient way of packing covers is to fill them completely in the first place and then to remove a radial segment of appropriate size. The empty space in the cover should not be

placed opposite a filling plug, or at the bottom of a horizontally mounted bearing. With bearings mounted on a horizontal shaft a cover pack of about two-thirds is usual.

In vertically mounted a different system of packing is needed to allow for the tendency of the grease in the top cover to slump through the bearing and thus cause the bottom cover to become overfilled. In these cases, the top cover should only be half-filled and the bottom cover three- quarters filled.

1.5.3 Caution

If a motor is dismantled, cover the bearings with plastic sheet or clean, lint-free rag to prevent

the ingress of foreign matter. Never use cotton waste.

1.5.4 Removing and-Fitting Bearings.

The inner races of rolling element bearings are an interference fit on the shaft. Proper drawing and fitting gear must be used if bearing damage is to be prevented. If a bearing is removed it

should be renewed. Replacement bearings must be the correct size and internal clearance grade

as given in section 1.3.




Pope Electric Motors I I

1.6 CABLE TERMINATIONS

When connecting the supply cable to the motor terminal studs, the position of cable lugs, connectors and washers should be arranged such that the terminal stud is not used as a conductor. Tight terminals must be maintained. It is advisable to tighten nuts or bolts to the recommended torques. (see table below). If connecting drawing diagram from POPE is provided, the position of cable lugs, connectors and washer should be as shown on drawing.

THE CORRECT CREEPAGES AND CLEARANCES BETWEEN LIVE PARTS SHOULD BE MAINTAINED.

Terminal Stud Tightening Torques.

(Thread sizes used on Pope Electric Motors)

Stud size mm

Tightening Torques in Newton Metres + or - 10%

Brass Steel

4 1.2 1.7

5 2.0 2.8

6 5.1 7.3

8 10.5 15.0

10 17.7 26.0 14 41.0 92.0 16 83.4 130.0





1.7 ANTI - CONDENSATION HEATERS

Anti-condensation heaters are located inside some machines. They are usually energised when the motor is not in use, thus preventing condensation forming inside the windings. Dampness in the windings is a common form of winding failure.

TESTING

Megger test to earth and to motor windings 1000 Vdc for 120/240 volt heaters

CONNECTIONS

Details of heater connection are located in an auxiliary box located on the top of the motor frame or on the side of the main terminal box. Heater connection details can also be found in POPE GA drawing if provided.

CAUTION

THE HEATER ISOLATION WILL BE SEPARATE FROM THE MOTOR ISOLATION





1.8 THERMAL PROTECTION DEVICES

Alarm and Trip RTDs where fitted to low voltage induction motor as Stator Winding Thermal Protection Devices. The RTDs are embedded in the head windings, each RTD leads are terminated in an aux box.

The recommended temperature settings for safe operation of the motor are

ALARM SETTING

TRIP SETTING

145 °C

155 °C

Trip thermistors where fitted to the motor as Stator Winding Thermal Protection Devices. The Therm istors are embedded in the head windings and the leads are terminated in an aux box.

THERMISTOR TRIP SETTING 145 °C

Should it be necessary to test the insulation of the protection devices to earth and/or phases the test voltage must not be applied across the device.

The correct procedure is to short all the leads together and apply the test voltage (100 VOLTS) between the shorted leads and earth.

Bearing RTD where fitted to Low Voltage motor as bearing temperature monitoring device. These RTD are embedded in the bearing housing and the connection wires are protected inside a stainless steel wire tube and terminated inside an auxiliary box. The recommended bearing temperature limit.

ALARM SETTING

TRIP SETTING

100 °C

110 °C

"Meggering" across the device is likely to cause irreparable damage, and must be avoided.

Continuity testing should be carried out using a low voltage tester such as a multimeter or battery and ammeter.

Do not apply more than 2.5 volts across these devices.





1.9 OVERCURRENT PROTECTION

Over current protection should be used and it shall be set in accordance with the following safe stall times -

Full voltage stall from hot not to exceed 15 seconds

Full voltage stall from cold not to exceed 20 seconds. STALLING THE MOTOR FOR LONGER THAN THIS CAN CAUSE INTERNAL DAMAGE





3. APPENDICES




APPENDIX 1- TIGHTENING TORQUES FOR SHAFT LOCKING CLAMP BOLTS

Frame Size TEFC

Shaft bolt

Shaft Clamping Bolt Torque (Nm)

Locking bolt

Shaft Tension Bolt Torque (Nm)

180 M10 38-40 M10 7-8

200 M10 38-40 M10 9-10 225 M10 38-40 M10 12-13

250 M10 38-40 M10 18-20

280 M16 81-90 M16 23-25 315 M16 81-90 M16 30-33

355 2xM12 111-120 M16 33-37 400 2xM12 111-120 M16 33-37 450 2xM12 111-120 M16 33-37 500 2xM12 111-120 M16 70-80

FOR FRAMES LARGER THAN ABOVE, REFER TO ENCLOSED DRAWING

Rev C INSTALLATION & MAINTENANCE MANUAL




APPENDIX 2 - STANDARD DRIVE END SHAFT DIMENSIONS

Key Thickness

Diameter

Key Seat Depth

I ' -Key Length

Extension Length -1

Shaft Extension Diameter Tolerance Length

Key Length

Key Seat Depth

Key Selection Width x Thick

16 40 22 13.0 5 x 5

19 +0.009 40 25 15.5 6 x 6

24 -0.004 50 32 20.0 8 x 7

28 60 20 24.0 8 x 7

38 +0.018 80 56 33.0 10 x 8

42 110 80 37.0 12 x 8

48 +0.002 110 80 42.5 14 x 9

55 110 80 49.0 16 x 10

60 +0.0030 140 110 53.0 18 x 11

65 140 110 58.0 18 x 11

70 +0.011 140 110 62.54 20 x 12

75 140 110 67.5 20 x 12

80 170 140 71.0 22 x14

85 +0.035 170 140 76.0 22 x 14

110 +0.013 210 160 100.0 28 x 16

FOR SHAFTS LARGER THAN ABOVE, REFER TO ENCLOSED DRAWING





APPENDIX 3 - BEARING SIZES AND LUBRICATION INTERVAL

Non-grease valve motors

Frame Size TEFC

Poles Bearings Regreasing interval (Hrs)

Regreasing volume (grams)

D.E. Size (mm) N.D.E. Size (mm) 80 2,4,6 6204- 20 x 47 x 14 6204- 20 x 47 x 14 sealed for not required

& 8 2RS1 2RS1 life 90 2,4,6 6205- 24 x 52 x 15 6205- 24 x 52 x 15 sealed for not required

& 8 2RS1 2RS I life 100 2,4,6 6206- 30 x 62 x 16 6206- 30 x 62 x 16 sealed for not required



& 8 2RS1 2RS I life

Grease valve motors

Frame Size TEFC

Poles Bearings Regreasing interval (Hrs)

Regreasing volume (grams)

D.E. Size (mm) N.D.E. Size (mm)

160 2

6309 45 x 100 x 25 6309 45 x 100 x 25 4700

250 4 7300 6 9300 8 11700

180 2

6310 50 x 110 x 27 6310 50 x 110 x27 4100

280 4 7000 6 9000 8 11100

200 2

6312 60 x 130 x31 6312 60 x 130 x31 3500

350 4 6700 6 8700 8 10600

225 2

6313 65 x 140 x 33 6313 65 x 140 x 33

3100 400 4 6300

6 8600

8 10300





250 2 6313 65 x 140 x 33 6313 65 x 140 x 33 3100 400 4

75 x 150 x 37 6313 65 x 140 x 33

6000 6 6315 8300 550 (DE)

400 (NDE) 8 10000

280 2 6314 70 x 150 x 35 6314 70 x 150 x35 2700 450 4

6317 85x 180x 41 6314 70 x 150x 35

5700 800 (DE)

450 (NDE) 6 8000

8 9500 315 2 6316 80 x 170 x 39 6316 80 x 170 x 39 2000 700

4

NU319 95 x 200 x 45 6319 95 x 200 x 45

5500 1000 6 7700

8 9000 355,400,450 2 6318 90 x 190 x 43 6318 90 x 190 x 43 1400 900

4

NU326 130 x 280 x 58 6326 130 x 280 x

58

3200 1500 6 6000

8 7600

500 4

NU328 140 x 300 x 62 6328 140 x 300 x

62

3000 1800 6 5500

8 7500

* Regreasing intervals on 315 frame and larger, are based on a cylindrical roller bearing. Refer to suppliers' catalogue for intervals when deep groove ball bearings are used at both ends

* Where different size bearings are fitted at each end, intervals are given for the larger bearing

Bearing manufacturers recommend re-lubrication intervals based on a maximum bearing outer ring temperature of 70 degrees C.

The re-lubrication interval should be reduced by half for every 15 degrees C that the bearing outer ring temperature exceeds 70 degrees C.

Where grease may be contaminated or the grease serves as a seal against moisture then the relubrication interval should be further reduced.

For example bearing manufacturers quote a situation in which the bearing housing has water running over it for which they recommend weekly re-greasing.




I Di KelairPumps

PAGE 19.00

19: Appendix 3

CONTENTS: ' PAGE VARIABLE SPEED DRIVE Pages 1-1 to 15-2



Omniverter Drive Multipurpose Inverter

75 kW to 1.0 MW

11110111101100

11111111101110

11111111101110

1110111011101

111111110111011

11111110111011

11111111101110 11111110111011

11111111101110 11111110111011

IIn11u101110 11011110111101

USER MANUAL 48070031.DOC

VECTEK VECTRON INDUSTRIES LTD

21 Carnegie Road, Onekawa Napier, New Zealand Phone ++64 6 843 1400 Fax ++64 6 843 0398 www.vectek.co.nz



Omniverter drive parameters relate to drive software version 6.0 or later.

Revision History

H Released 27 August 1998 1) Recommended spares list updated and given its own appendix (was section 6.2, now appendix 4). 2) Corrected parameter description for 'LOW parameters in analogue I/O modules 100,110, 120 & 130. Used to

read 'ie. 4mA or -10V% now 'ie. 4rnA or OV'. 3) Enhanced module and parameter descriptions for module group 400:MOTOR in section 4. 4) Enhanced module and parameter descriptions for module group 500:VECTOR CONTROL in section 4. 5) Default values changed for 520:GAINS to match drive software version 5.6 onwards. 6) Range increased for 510:IBOOST to match drive software version 5.6 onwards (increased to +/-250%). 7) Enhanced descriptions in sections 3.4 and 3.5. 8) Improved Figure 3-1. 9) Additional rating information for Table 1-1 and Section 1.4.2.

I Released 30 October 1998 1) Corrected parameter description for parameter 7B0:ENABLE in section 4. 2) Added descriptions in sections 4 & 10 for parameters 020:KB S/R and 020:EXTS/R new to version 6.0 software. 3) Added tables in sections 4 & 10 for module 1CO:SERIAL COMMS new to version 6.0 software. 4) Added tables in sections 4 & 10 for module 7CO:PRESET SELECT new to version 6.0 software. 5) Added tables in sections 4 & 10 for module 7D0:PID CONTROLLER new to version 6.0 software. 6) Added tables in sections 4 & 10 for module 7E0:SKIP BANDS new to version 6.0 software. 7) Added tables in sections 4 & 10 for modules 7F0:COMPARATOR1, 7G0:COMPARATOR2,

7H0:COMPARATOR3 new to version 6.0 software. 8) Updated section 5 with new source and destination ports, including serial communications parameter codes for

source ports. 9) Added new appendix: section 11 Appendix 7 - Serial Communications. 10) Updated Figures 2-4 and 2-6 with new parameters. 11) Updated Figure 2-5 with earth screens on digital inputs and pot. supply. 12) Updated Figure 2-5 with earth screens on digital inputs and pot. supply. 13) Added new appendix: section 13 Appendix 9 - Bearing Filters - Protecting Motor Bearings. 14) Added new appendix: section 14 Appendix 10 - Mains Harmonic Reduction. 15) Updated Figure 3-1 with ME (motor earth terminals). 16) Deleted OD4 0150 from Table 1-1 and replaced with OD4 170.



Table of Contents

1. Specification 1-1

1.1 Scope 1-1

1.2 System Description 1-3

1.3 General Requirements 1-4

1.4 Technical Data 1-5

2. Application of the Omniverter Drive 2-1

2.1 Important Omniverter Drive Concepts 2-1 2.2 Menu Structure and Operation 2-4 2.3 Omniverter Configuration Overview 2-4 2.4 Configuration Modules 2-6 2.5 Default Configuration 2-8 2.6 Motor Derating 2-10

3. Installation and Commissioning 3-1

3.1 Mechanical Installation 3-1 3.2 Electrical Installation 3-2 3.3 Commissioning 3-4 3.4 Overload Warnings 3-7 3.5 Latched Fault Indications 3-8

4. Details of Configuration Modules 4-1

5. Appendix 1 - Index of Configuration Module Ports 5-1

5.1 Destination Port Index 5-1 5.2 Source Port Index 5-2

6. Appendix 2 - Forms 6-1

6.1 Interface Configuration Record 6-1

6.2 Commissioning Schedule 6-2

7. Appendix 3 - Omniverter Dimensional Drawings 7-1

8. Appendix 4 - Omniverter Recommended Spares 8-1

9. Appendix 5 - Omniverter Fan On/Off Control 9-1

10. Appendix 6 - Field Bus I/O Map 10-1

10.1 From Omniverter to Field Bus 10-1

10.2 From Field Bus to Omniverter 10-2 10.3 Status Code 10-2 10.4 Type Code 10-3 10.5 Module State 10-3

11. Appendix 7 - Serial Communications 11-1

11.1 Connecting the Host to the Omniverter 11-1

11.2 Protocol Details 11-1

11.3 Sending an enquiry 11-2

11.4 Sending a command 11-3 11.5 Table of Parameter Identifiers 11-4

12. Appendix 8 - Configuration Modules Quick Reference 12-1

12.1 Configuration Modules 12-1

13. Appendix 9 - Bearing Filters - Protecting Motor Bearings 13-1

13.1 Review of problem 13-1

13.2 Vectron Bearing Filters 13-1

13.3 Bearing Filter Installation 13-2



1.1.2 Models Available

The Omniverter Drive range includes models of the following series. Custom models outside this scope are available to order.

Omniverter Output Current Output Current Overload Typical Motor Typical Motor Drive © 50°C, 2kHz © 40°C, 2kHz Current

Rating Rating Model

@ 40°C, 4kHz © 30°C, 4kHz (150% 0/L) (125% OIL)

(150% 0/L)* (125% OIL)*

OD4 0170 170A 204A 255A 90kW 110kW

OD4 0250 250A 300A 375A 132kW 160kW

OD4 0300 300A 360A 450A 160kW 200kW

OD4 0450 450A 540A 675A 250kW 315kW

OD4 0600 600A 720A 900A 355kW 425kW

OD4 0750 750A 900A 1125A 450kW 500kW

OD4 0900 900A 1080A 1350A 500kW 630kW

OD4 1050 1050A 1260A 1575A 630kW 760kW

OD4 1200 1200A 1440A 1800A 730kW 870kW

OD4 1350 1350A 1620A 2025A 820kW 1.0MW

* 2kHz switching frequency @ 610: SWFREQ=LOW; 4kHz switching frequency @ 610: SWFREQ=high

Table 1-1 Available Model Range

............. > . . .



Omniverter Drive

1.2 System Description

The Omniverter Drive range benefits from the use of the latest electronic technologies in association with today's most advanced motor control theory.

1.2.1 Components

Semiconductor fuse protection

AC line reactors for reduced harmonic distortion and immunity to mains disturbances

Rectifier incorporating solid state charging control for improved reliability

Inverter Grade Electrolytic Capacitors

Homogenous IGBTs for improved paralleling

Output dv/dt limiting filters to protect motor windings and reduce RFI

32 bit RISC Microprocessor necessary for true sensorless vector algorithms

1.2.2 Construction

IP20 environmental protection with IP54 option

Modular structure minimising spares holding requirements

Modular structure permitting subsequent up-scaling or down-scaling

Surface or through panel mount to simplify provision for cooling airflow

Panel width of <250mm per 150A (180A 40 deg C) to minimise switchboard and installation costs

1.2.3 Digital Control and Diagnostics

The Omniverter Drive range incorporates digital control. A remote mountable keyboard and display incorporates a four line, eighty character back lit display with status information presented in plain language. Two LEDs provide immediate indication of Omniverter Drive status.

1.2.4 Configurable Interfacing and Control

The Omniverter Drive provides facility for highly configurable interfacing. Analogue inputs and analogue outputs can be programmed individually for voltage or current (4-20mA) control. Fully isolated digital inputs may be configured for active high or active low operation from +24 or +12V.

Two high speed digital outputs and three change over power relays each may be programmed to signal one of many conditions.

Special function modules permit user configuration of all control inputs and outputs. Custom modules can be developed on request.

1.2.5 True Sensor less Vector Control

A very advanced form of sensorless vector (also known as sensorless field oriented) control, trade- named Vectorque, is incorporated.

Unlike normal voltage/frequency controllers, Vectorque directly controls the current and torque of an induction motor. This facility eliminates the characteristic low speed instability often exhibited by traditional control methods and provides many other advantages - speed is controlled more precisely and transient overloads are absorbed without causing trips. ...



The Vectorque true sensorless vector implementation in the Omniverter Drive incorporates parameter insensitive algorithms which avoid such problems altogether. Vectorque algorithrris have only become practical through the use of a very powerful 32 bit RISC microprocessor.

1.2.6 Modular Mechanical Design

The Omniverter Drive is unique in adopting a modular approach to mechanical construction. This permits ready change of size (add or remove modules) at a later date while minimising spares holding requirements since the same components are used in all models.

1.2.7 Radio Frequency Suppression

The Omniverter drives include radio interference suppression to the requirements of CISPR11 (AS /NZS 2064:1997) level A, suitable for industrial environments (formal tests to be completed).

1.2.8 Special Options

The following special options are available together with full custom solutions:

Dynamic Brake option - facility is included for internal fitting and control of dynamic brake switching transistors. External power resistors are supplied to order.

Regenerative / Unity Power Factor / Software Option - Ofnhiverter Drive may be supplied together with a full four quadrant regenerative inverter / rectifier for applications requiring much braking or very low harmonic distortion of the supply.

Harmonic Reduction Options - Several options exist for the reduction of harmonic distortion of the supply in high power applications - contact your supplier. Refer to Appendix 10 - Mains Har &tonic Reduction for details of 12 pulse options for the Omniverter driVes.

Bearing Protection - AC drives increase risk to motor bearings. Various solutions exist inclikling special bearing filters. Refer to Appendix 9 - Bearing Filtet$ - Protecting Motor Bearings.

1.3 General Requirements

1.3.1 Standards

Vectron Industries operates a quality system in accordance with the general requirements of ISO 9001, and plans to apply for accreditation in 1998.

Omniverter Drive is designed to meet the CE Mark requireMetits of European Safety and EMC Directives.

1.3.2 Components and Materials

All materials and parts comprising the Omniverter Drive are new and in current produCtion, and to ensure maximum reliability, are used well within the parameters recommended by the supplier.



1.4 Technical Data

1.4.1 Input

Nominal Input Voltage -Phases Voltage Tolerance Frequency Input Current Displacement Factor (COS.) Distortion Factor Interruption Ride Through Power connection

1.4.2 Output

Output Voltage Output Voltage Slew rate - dv/dt Output Frequency

Current Ratings:

380 - 440 Vac 3 -20/+5% 50/60Hz (DC option) S Output Current n.95 s 0.88 > 2 seconds

OD4 600, single cable OD4 750, dual cables

Bottom entry

0 - Vin 500V /µs

0-100Hz - sensorless vector 0-200Hz - V/Hz

Omniverter Drive

Model 50°C,150% 0/L, 2kHz* @40°C, 125% OIL, 2kHz* 40°C,150% 0/L, 4kHz* 30°C,125% 0/L, 4kHz*

(A) (A) OD4 0170 170 204 OD4 0250 250 300 OD4 0300 300 360 OD4 0450 450 540 OD4 0600 600 720 OD4 0750 750 900 OD4 0900 900 1080 OD4 1050 1050 1260 OD4 1200 1200 1440 OD4 1350 1350 1620

* 2kHz switching frequency © 610 : SWFREQ=LOW; 4kHz switching frequency @ 610: SWFREQ=high

Continuous Current Current Overload

Efficiency at rated load

Control Method

Power connection

0 - 100% rated 50°C/2kHz; 40°C/4kHz ratings - 150%, 30s 40°C/2kHz; 30°C/4kHz ratings - 125%, 30s

> 97% © 2kHz switching; > 96.5% @ 4kHz switching

True Sensor less Vector

OD4 600, single cable OD4 750, dual cables

Bottom exit

'



I.1.5 Keyboard and Display

The keyboard and display module is an intelligent controller connecting to the Omniverter Drive hrough a standard 9 way D connecting cable. The module may be remotely mounted up to 3m with he standard cable, but greater distances are possible - consult the factory.

The four line LCD display is largely prograMmable. The top line is fixed and shows status ',formation about the Drive, including Local/Remote indication at the end of the line ie. "L" or "R". The second, third and fourth lines can be programmed to show any of several preset meters (eg. >PEED, CURRENT, POWER) or either of two user defined meters (see 030:LCD DISPLAY in Iection 4 of the manual for details). The fourth line doubles as the menu display line. Simply press le down arrow key to access the menu system if line four currently displays a meter.

%crow keys, +, - and enter or cancel keys permit navigation and adjiistment of the menu system described below). Stop and start push buttons permit local control of the Drive. They are always ctive, though subject to the status of external interface controls.

;top (0) also provides a reset for any fault conditions which may be latched and displayed on the top ne of the display.

Line 2 Selectable Meter



000: Menu Config

100 : Interface

200 : Controller

300: Fault Info

400: Motor

500: Vector Control

600 : Inverter

700 : Special Function

Status Description (Keyboard)/R=Remote control

,

........,, ....,.. 2, .9.---

RUN R CURRENT = 342.0A SPEED = 100.0%

CONFIG

Go ( 0 )'.

CPTT"b

Ch anp Value EM Caned e @ 0 00 \ l Omni005e

Status LEDs

Start (Local)

Stop/Reset

igure 2-1 Keyboard and Display

tvo LEDs provide immediate status indication and the function of each is explained in the following ble.

IN LED DESCRIPTION OK LED DESCRIPTION

P Not running, no run command active. OFF Omniverter control electronics not powered.

I Running, run command active. ON No faults have been detected.

ASH Temporarily stopped due to low mains voltage, run

command active. Will restart if mains voltage returns

while the Omniverter control electronics is still powered

from residual DC bus voltage.

FLASH A fault exists which has tripped the drive. The description

field on the top line of the display will state which fault has

occurred.

able 2-1 Functions of the status LEDs on the keyboard.



Omniverter Drive

2.1.6 Menu Screens and Control Configuration

The menu screens of the Omniverter appear in line 4 of the display and are arranged using the block outline presented in Figure 2-2. Each of these blocks contains a group of modules and each module in turn contains parameters and configuration connections.

In summary, modules are grouped as:

000:Menu Config contains edit locks, keyboard refs. and meter selections.

100:Interface contains set up of all low voltage inputs and outputs

200:Controller contains all set up of the basic motor controller

300:Fault Info contains fault history and auto reset controls

400:Motor contains set up of motor nameplate information etc

500:Vector Control contains vector control parameters

600:Inverter contains inverter user options and factory calibrations

700:Special Functions contains a range of user selectable functions

r Input line rectifier

Mains I

L

100:Interface

600:Inverter

700:Special Function

200:Drive Controller

1 Output dV/dti

filter

400:Motor

_J

300:Fauh Info

000:Menu Config

500:Vector Control

Figure 2-2 Omniverter Drive Block Diagram



2.2 Menu Structure and Operation The basis of the menu system is the use of a three deep "outline" structure to provide simple and familiar navigation (like computer file handling) through the many programmable aspects of the Omniverter Drive. A three letter code before each item in the list defines which module each item belongs to. A brief experiment with the keyboard is all that is required for most users to quickly grasp the principles of operation. The following explanations are provided for reference if needed. A complete listing of all display lines can be found in section 4.

At the first level (Module Group level), the menus are arranged in a vertical list of eight module groups (Figure 2-3). The vertical arrow keys (ft and 11) are used to scroll up and down thitugh such a list. Items from first level menus are shown with a digit followed by two zeros (eg "400:MOTOR").

Level: Module Groups Modules

000:MENU CONFIG

100: INTERFACE

200: CONTROLLER

300:FAULT INFO

400:MOTOR

SOO:VECTOR CONTROL

600: INVERTER

700:SPECIAL FUNCTION

410:MOTOR NAMEPLATE

Parameters/ Connections

410:VOLTS = 400V

410:AMPS = 120A

Figure 2-3 Menu navigation example - setting motor nameplate current

The second level (Module level) is entered by the use of the right arrow key A list of modules is presented and navigation through this list may be made again by the use of the vertical arrows. Items in second level menus are located by the second digit (eg "410:MOTOR NAMEPLATE"). To return to higher level menus, push the left arrow key (=). The third and final level (Data lei/el) is selected by using the right arrow key again, as the example in Figure 2-3.illustrates. Changes to parameters or module connections are performed at this level (levels one and two provide headings only). Third level displays also start with a three digit address in order to identify which module they belong to and are followed by the label of the parameter or module connection.

2.3 Omniverter Configuration Overview The Omniverter Drive treats the variety of different functions within the drive as separate "configuration modules". For example, accessing the analogue output 1 module from the interface group in the menu permits the programming of current or voltage output, the definition of output scaling, as well as the specification of the controlling source (eg. speed, torque etc). Each module is presented in the same format and each consists of the following elements (listed in the menu in this order):

.". . .... ....



Parameters

Destination Ports

Source Ports

1<_.1

Omniverter Drive

These are the settings or adjustments for the particular controls of the module eg. programming voltage/current mode for the analogue output 1 module as a voltage output.

130:TYPE =VOLTAGE

Destination ports are software connectors which consume signals (such as the speed reference input). They may be fed from source ports which produce signals (such as analogue input 1). An example of a connection between source and destination ports would be analogue input 1 connecting to the speed reference (see Figure 2-4). This connection carries the signal from the analogue input to the speed reference (the direction of the arrow on the drive LCD display always shows direction of data flow).

220:SPDREFE-110ANAIP1

Source ports are software connectors which produce signals (such as the run indicator). They may feed into destination ports which consume signals (such as relay output 1). An example of a connection between source and destination ports would be the run indicator connecting to relay output_1 (see Figure 2-4). This connection carries the signal from the run indicator to relay output 1 (the direction of the arrow on the drive LCD display always shows direction of data flow).

210:SPEED 4160RELOP1

Modules which are required for a particular application may be connected together to achieve the required control over the Drive. The example in Figure 2-4 illustrates how Interface modules and controller modules are connected together for simple speed control in the factory default configuration. The analogue input 1 module is configured as a voltage input scaled for -10 to+10V control and it's source port is connected to the speed reference input ie. "220: SPDREFE-110ANAIP1".

150:Digital Inputs

DIGIP14210START DIGIP24210ENABLE DIGIP34210RESET DIGIP49NC DIGIP53NC DIGIP6 -'NC

110:Analogue Input1.

TYPE =VOLTAGE LOW = 0% HIGH = 100% AMAIP14220SPDREF

210:Sequemng STRMDE=NORMAL STPMDE=NORMAL START (-150DIGIP1 ENA8LE4-150DIGIP2 RESET 4-150DIGIP3 START 4NC RUN 4160RELOP1

220:CondMoning

TRQLIM= 100% LWRSPD= -110% UPSPD = 110% ACCZL1= 60.Os DECEL1= 60.03 ACCE12= 60.0s DECEL2= 60.Os SPDREF4-110ANAIP1 TRQREF4-NC TRQMDE4-NC SPDINV+NC TRQYWV4-NC RAMP2 ENC AT SPD4NC CURLIM4NC TROLIM4NC

160:Digital Outputs DIOOP14 -NC DIGOP24-NC RELOP14-210RUN RELOP24-420MTR OL RELOP3+230/FAULT

1130:Fieldbus Digital Outputs FEDOP1+210RUN FBDOP24-14C FBDOP34-14C FBDOP44-NC FEDOP5+NC 1714D0P64-NC

Figure 2-4 Example configuration for simple speed control (part of the default setup)

Where additional functions are needed, these are incorporated as special functions (eg motorised potentiometer), usually to be inserted between the interface and the controller. Special functions may be cascaded and (with care) quite sophisticated configurations created by the commissioning engineer. The great flexibility imparted by this system also permits the ready development of "special functions" which may be customised to particular requirements.



2.4 Configuration Modules This section goes through the steps involved in adjusting parameters and in creating connections between modules.

2.4.1 Parameters ("=" on LCD display) Parameters display an equal sign "=" between the parameter label and its value and this is followed by the parameter's unit of measure (eg. "220:ACCEL1= 60s1.*

Adjusting a parameter value Adjustment of the value of a parameter is achieved by pressing the "+" or "-" keys. While adjusting the value of a parameter, the equal sign becomes an underscore "_" to indicate that the parameter is being adjusted.

Accepting or cancelling an adjustment When the desired value or option is displayed, pressing the "Enter" key will accept the adjustment which has been made. At this point the underscore will revert to an equal sign and the change will now be reflected in the drive's operation. Alterhatively, to abandon an adjustment press the "Cancel" key.

Fine-tuning with Omniverter running Another feature of the Omniverter keyboard module is that fine-turiing of parameters can be made while the Drive is running by holding down the "Enter" key while pressing the "+" or "-" keys. This allows changes made to the parameter to be instantly reflected in the operation of the Omniverter Drive.

Resetting module parameters A module's parameters can be reset to factory defaults by pressing "Enter" at the "RESET PRMTRS?" option located at the bottom of the module's menu list. The user lock must be unlocked." Connections between modules are not affected by a module reset.

Screen Display

RUN CURRENT = SPEED = 220:ACCEL1=

342.OA 100.0% 60.0$

RUN CURRENT = 342.OA SPEED = 100.0% 220:ACCELl_ 30.Os

RUN CURRENT = 342.0A SPEED = 100.0% 220:ACCEL1= 30.Os

RUN CURRENT = 342.0A SPEED = 100.0% 220:RESET PRMTRS?

* Module ports have a meter below each which displays the value of the signal at that port and this uses the equal sigm meters are not parameters so cannot be adjusted.

** See 010:USER in section 4 for details on the user lock.

"Metering" a port The location in the menu immediately below each port is it's "meter" which displays the signal value at that port. This will be a percentage for analogue ports and TRUE orFALSE for digital ports: It is read-only so cannot be adjusted.

2.4.2 Destination Ports ( "+.-" on LCD display) Destination ports are identified by a left arrow "4-" after the title field. The data field shows which source port it is connected to and the arrow shows the direction of signal flow. In the example illustrated in Figure 2-4, the speed reference is being fed a signal from analogue input 1.

NOTE: It is not possible to have more than one connection to an individual destination port because there would be a conflict. This simply means that a destination port can only 'listen' to one signal at a time.

Unconnected ports If no connection exists then "NC° will appear in the data field. A "no connection" has a FALSE value for digital inputs and 0.0 for analogue inputs.

2-6 .............. . . .....

These

RUN CURRENT = 342.0A SPEED = 100.0% 220:SPDREF= 100.0%

Screen Display

RUN CURRENT = 342.0A SPEED = 100.0% 220:SPDREF4-110ANAIP1

OFF CURRENT = 0.0A SPEED = 0.0% 220:SPDREF4 -NC



2.4.3 Source Ports ( "-+" on LCD display) Source ports are identified by a right arrow "-+" after the title field. The

data field shows which destination port(s) it is connected to and the arrow

shows the direction of signal flow. In the example illustrated in Figure 2-4,

the run indicator is being fed to relay output 1 and fieldbus digital output 1.

NOTE: It is possible to have more than one connection to an individual

source port because these ports produce signals. This simply means that

the source port is 'talking' to more than one destination port at a time.

Viewing multiple connections If more than one connection to a source port has been made then each

can be viewed in turn in the data field by pressing the right arrow key " =" eg. if relay output 1 and fieldbus digital output 1 are both connected to the

210: RUN indicator (as in Figure 2-4) then 160 : RELOP1 will be the first

to be displayed and 150: FBDOP1 will appear next.

Omniverter Drive

Screen Display

RUN CURRENT SPEED 210: RUN

R = 342.OA = 100.0% 4160RELOP1

RUN CURRENT SPEED 210: RUN

R = 342.OA = 100.0% 41BOFBDOP1

2.4.4 Making Port Connections The procedure for creating the kind of drive configuration illustrated in Figure 2-4 is quite straight

forward but a little different to the traditional approach taken by some drive manufacturers. Rather

than presenting the user with a long selection list of possible connections, the connection method employed in the Omniverter simply requires the user to select the start and end points of the

connection by navigating through the menu system (explanation follows).

Unlocking the connection configuration Before making a connection the configuration modules must be unlocked. This requires stopping the drive (if it is running) and navigating to parameter 010 : CONFIG. Press the "-" key, then "Enter" to unlock the

configuration. The status line will now indicate that the Omniverter is in

configuration mode, allowing changes to the connections between modules to be made. Note that the drive will not accept a start command while in the configuration mode.

Making Connections 1) To initiate a connection change, go to the source or destination port

that you wish to start the connection from and press the "+" or "-" key.

The arrow after the port's title will then change to an underscore character "_" to confirm that the connection can be changed.

NOTE: Any existing connection will be replaced by the new connection being made.

2) Navigate through the menu to the desired end point of the connection (for a handy list of all available ports see the table in section 5.2). Any port may be connected to any other port providing they are both of a

compatible type ie. digital to digital, analogue to analogue, source to

destination, destination to source. Sections 5 and 12 list the signal

type for each port.

3) Press "Enter" to make the new connection (or "Cancel" to leave the

configuration unchanged). The position in the menu will now jump back to the start point and will display the connection.

4) Lock the configuration when all connections have been, made. This will allow the drive to be restarted.

Screen Display

OFF CONFIG CURRENT = 0.0A SPEED = 0.0% 010:CONFIG=UNLOCK

OFF CONFIG CURRENT = 0.OA SPEED = 0.0% 220:SPDREF110ANAIP1

OFF CONFIG R CURRENT = 0.0A SPEED = 0.0% 180:FBAIP14NC

OFF CONFIG R CURRENT = 0.0A SPEED = 0.0% 220:SPDREF4-180FSAIP1

OFF READY CURRENT = 0.0A SPEED = 0.0% 010:CONFIG=LOCK

if starting a connection from a destination port (4-) and no new connection is desired then pressing 'Enter immediately after

initiating a connection change will break the existing connection, causing "NC' (No Connection) to appear in the data field. A

"no connection" will Input a FALSE value for digital ports and 0.0% for analogue ports.



2.5 Default Configuration

2.5.1 Description

The factory default configuration of the Omniverter Drive is summarised in the following two fiatires. The default control configuration provides analogue voltage (-10 to +10V) speed control with three- wire start/stop/reset and analogue output (-10 to +10V) of speed and motor current.

2 Wire Control

Loop out It unused

3 Wm Control

0 - 10 Vdts required

N.A.

NA

NA

To Mores

Field Connections Schematic Title

1

0 - 10 Volts 6rro 110 : An e Input Mut 1 2 2

= 0 - 100% Speed

0 Volts 3 3

4 4 L-. NA 721

120 : Analogue Input 2 5 5

--a 0 votts 6 6

( 7 0- 10 Volts = 0 - 100% Speed

7

-7_

1 130: Analogue Output 1

o Volts

- 8 8

at t<r, 9 0- 10 Volts = 0 - 100%

9

-3_

140: Analogue Output 2

0 Volts

- 10 Motor Current 10

11 Start 11 ----c=11 . 150:DIgnal Input 1

= 12 Enable (Stop) 12 $ a <. 150:Dignal Input 2

13 Reset 13 $ a (,... 150:Dlgrtal Input 3

(=7' 14 TorqueJSpeed 14 a It . 150:Digital Input 4

15 Speed Invert 15 --='-al C 150:Digital Input 5 .r 15 Torque Invert 15 c=) a a ,..., 150:DIghd Input 6

17 17 T 24 Von / 100mA

18 18 Common

19 19 0 Volts

20 20 +24 Volt / 100mA

21 21 0 Volts

22 22 PTC VP -40-4=s- 23 23 0 Volts

24 24 /s----.2t- 150: Degttal Output 1 -__i 25 25 0 Volts

26 26 --(9??I- 160: Digital Output 2

27 27 _ 0 Volts

28 28 7 OW Pd. Supply

29 29 f-'9.--1. tsv - Pot. Supply

30 30 0 Volts

31 31 Encoder Supply p 1111111. nv , WO. Encoder A+ 32 32 is 33 Encoder A-

34 34 Encoder B 38 35 Encoder B- 36 36 0 Volts

N.O. off . mined

O n = RUN

N.O.

160 : Relay Output 1 COM COM

N.C. N.C.

On MOTOR

OVERLOAD

N.O.

160: Relay Output 2 C" COM

N.C. N C. N.O.--'). Cff *FAULT on . ok

N.O.

160 : Relay Output 3 COM COM

N.C. N.C.

OMN1011a

Figure 2-5 Default Interface Configuration for 36 Terminal Control Board (Control PCB# 2001- 012 Rev B)

2-



Omniverter Drive

010:Locks

CONFIG=LOCK USER =UNLOCK FCTRY = 0.00

150:DigitaHnpats

DIGIP19 DIGIP24 DIGIP33 DIGIP43 DIGIP54 DIGIP64

11 Vmalogue Input 1

TYPE =VOLTAGE LOW = 0% HIGH = 100%

ANAJP14

120:Analogue Input 2

TYPE =VOLTAGE LOW = 0% HIGH = 100%

ANAJP24

020:Keyboard

LOCREM=REMOTE LOCMDE=SPEED KBFREQ= 0.0% KBTORQ= 0.0% K8 S/R=LOC 6 REM EXTS/R=REM ONLY

210:Sequendng

STRMDE = NORMAL STPMDE=NORMAL START 4-150DIGIP1 ENABLE+150DIGIP2 RESET 4-150DIGIP3

START 4 RUN 4

220:Conditioning

320:Auto Reset

NUMBER= 0

DELAY = 30s PERIOD= 3600s

410:Motor Nameplate

VOLTS = 400V AMPS = OA POWER = OkW RPM = Orpm FREQ = 50Hz

420:Motor Thermal

F COOL=OFF STRTIM= 10.0s TRIP =ON

MTR OL4 MTRTMP4

TROLIM= 150% LWRSPD= -110% UPSPD = 110% ACCEL1= 60.Os DECEL1= 60.Os ACCEL2= 60.Os DECEL2= 60.Os SPDREF4-110ANAIP1 TRQREF4-120ANAIP2 TRQMDE+ SPDINV+ TROINV4 RAMP2

AT SPD9 CURLIM3 TRQLIM4

230:Monitoring

FREQ 4 SPEED 4 VOLTS 4 TORQUES MTRCUR4 POWER 4 /FAULT-* INV OL4

240:Operating Modes

CNTRL =VECTORQUE LOAD CONST TRQ LVTRIP=OFF

30:LCD Display

LINE 2=CURRENT LINE 3=SPEED LINE 4=REg SPEED USER A+NC USER Be-NC

510:Vector Settings

HOIST =OFF IBOOST= 0% J COMP= 0.0s FWK PT= 120%

520:Vector Gains

WLPEP = 16000 WLPKI = 20 WL14.00 = 0

PHLPKP= 10000 PHLPKI= 400 FRLPKP= 3000 FRLPKI= 800 ILPKP = 2000 ILPKI = 400

130:Analogue Output 1

TYPE =VOLTAGE LOW = 0% HIGH = 100% ANA0P1+230SPEED

140:Analogue Output 2

430:Motor Model

RS = 1.0% RR = 1.0% IMAG = 50.0% LKG = 16.7%

610:Waveform

SWFREQ=LOW

TYPE =VOLTAGE LOW = 04 HIGH = 100% ANAOP24-230MTRCUR

160:Digital Outputs

DIGOP1ENC DIGOPEENC RELOP1+210RUN RELOP24-420MTR OL RELOP34-230/FAULT

630:Dynamic Brake

DBOUTY= 104 TIME = lOs ENABLE=OFF

Figure 2-6 Default Control Configuration

Refer to Section 4 for a detailed explanation of each module and its parameters.



2.6 Motor Derating

Figure 2-7 shows recommended derating of motors (without special cooling provision) connected to the Omniverter. At low speeds torque derating is required due to reduced efficiency of motor 'cooling fans. At rated speed, derating of 5% 'is required to allow for slightly reduced output voltage with respect to input voltage (eg. with 400V input, at full load and speed, the Omniverter will produce 380V ie. 5% low). If it is necessary to overcome this derating, 380V motors can be applied (dtalAring 5% more current) or the supply voltage can be set 5% high. Above rated speed insufficient fluxing voltage is available, and available torque per ampere drops inversely.

Continuous running derating factor for induction motors supplied from a Vectron Omniverter AC Drive

uu

90

80

N......._

70

60

SO

40

"INIbm-a-

30

20

10

0 a 4:, c* /- 04 00000000000000000C el .1. 20 CD P. CO CO 0 /' (Nt el cr WI CO is CO CO C

Speed (%)

Figure 2-7 Omniverter Typical Motor Derating Curve

...... ....



Omniverter Drive

3. Installation and Commissioning

3.1 Mechanical Installation

3.1.1 Mounting

The Omniverter Drive is supplied with brackets for surface mounting. The same mounting brackets can be repositioned centrally to permit through wall mounting. Through wall mounting permits the main air stream to be placed external to an electrical switchboard, eliminating the need for additional switchboard cooling. Refer to Figure 1-2 Dimensional Details, for dimensions.

3.1.2 Cooling

Cooling airflows in the Omniverter Drives must not be impeded. If mounting internally in a

switchboard, sufficient airflow must be provided (See Section 1.4.8 for power loss and airflow information).

Two methods are available to the installer to simplify this problem.

Through wall mounting-- if through wall mounted care must be taken to allow for remaining losses of about 30% in the switchboard itself. Additional air flow exhausting from the top of the switchboard is usually required.

Make provision for air inlet into the switchboard and duct exhaust air outside the switchboard directly from the Omniverter Drive outlet. The Omniverter Drive fan has sufficient power to draw and exhaust its cooling air requirements as long as ducting is not restrictive. This can eliminate the need for additional air supply.

In all cases check that airflow is unimpeded and cooling is adequate during commissioning.



3.2 Electrical Installation

3.2.1 EMC (Electromagnetic Compatibility)

Electromagnetic compatibility refers to the safe and reliable operation of both the Omnivertee Drive and other equipment sharing the same electromagnetic operating environment.

To assure EMC and radio interference levels are achieved, it is irilportant that installation is carried out exactly according to the instructions of this manual.

3.2.2 Control (Signal) Cabling

Normal control cabling practice applies. Controls should be screened and earthed at the OmniVerter Drive end only. Control cable should be run at least 1m away from power cables (especially power output cables from AC Drives) and, where necessary, should cross power cables only at right angles.

3.2.3 Earthing

The Omniverter must be solidly bonded to power supply earth before energising the drive. Potentially high leakage currents necessitate a permanent connection between drive chassis and mains earth.

Mains power earth must be connected to the PE terminal.

Motor earth must be made directly from motor chassis to drive motor earth terminal (ME) - preferibly via the motor cable screen bonded at both ends. Where maximum radio suppression is required, screened three core cables must be used and the cable screen must be well bonded to the motor frame and connected directly to the Omniverter ME terminal - it must not be connected elsewhere en-route.

3.2.4 Power Cabling

Power Cabling requirements are summarised in Figure 3-1 Power Connection Details.

Omniverter Drive models up to OD4 600 are designed for connection with single input and output cables. Models OD4 750 and above have dual termination points designed for connection to paralleled cable runs.

Cable entry is made through a gland plate at the bottom of the Omniverter Drive.

The Omniverter Drive has very effective RFI filtering built in as standard.

In sensitive applications, and where output cables run with other output cables or near mains supply cables, a screened three-core motor cable is recommended. Such a cable must be solidly and directly bonded to both the motor and Omniverter Drive chassis to be effective.

3.2.5 Motor Bearing Protection

AC Drives can place motor bearings at increased risk due to flow of induced currents. Refer to Appendix 9 - Bearing Filters - Protecting Motor Bearings.

Risks can be minimised by ensuring the motor and load earths are made as recommended in this section.

Refer to 13.3 Bearing Filter Installation if installing bearing protection filters

3-2



Omniverter Drive

*1 *2

O 4 , =.-. PE

OMNI003c

Notes:

Oka

OMNIVERTER

*3

Motor

mE f

- Supply: All local Electrical Safety Regulations must be obeyed. Extemal isolation and supply protection as required Power Factor correction is not required. The Omniverter provides cos. > 0.95.

2 - Supply Cabling: No special requirements are placed on input cables Omniverter chassis must be solidly bonded to electrical earth (using one PE terminal only)

before energising the drive (high levels of earth leakage currents can flow from ac drives) Input is not phase sensitive

3 - Control Cabling: All control cabling should be screened, the screen connected at drive end only Control cables should run separately to power cables (preferably by 1m) Control cables should cross power cables only where absolutely necessary and at right angles

4 - Output Cabling: Output isolation (if required) should only be operated off load (ie with Omniverter stopped). Symmetrical three-cored screened cables are preferred. The cable screen should be solidly

bonded to both motor frame and inverter motor earth (ME) terminal only not anywhere else). If motor and load frames are electrically isolated, but electrically connected via shafts, install an isolated coupling in the shafts or bond motor and load using a wide flat (25mm) conductor such as braid or copper foil using the shortest possible connecting route (don't rely on common earth connections back to switch boards).

Some regulations may require an earth to be run in addition to using the cable screen. If required this earth should run externally to the screened cable. Power factor correction capacitors must not be connected to Omniverter output. If facility for electrical bypass of the motor to mains is required, the Omniverter output must be isolated from the motor first (the Omniverter output must never be connected to mains supply).

Figure 3-1 Power Connection Details



3.3 Commissioning For convenience section 6.2 presents a suggested commissioning schedule.

3.3.1 Safety Warning

Omniverter Drive is a high power electronic device. It is usually connected to high energy mains supplies.

Installation of Omniverter Drive must only be carried out under supervision of staff who are suitably qualified and experienced in the installation of such equipment.

Service must only be carried out by staff who are suitably qualified and experienced in the service of such equipment.

All usual safety precautions concerning power electronic equipment must be observed.

Safety glasses must be worn if operating the drive with the covers removed.

Capacitors in the Omniverter store charge. Allow at least fifteen minutes for charge to dissipate before servicing.

3.3.2 Installation Inspection

Mechanical

Check that the mechanical mounting of the drive is adequate.

Thermal

Check that airflow paths are free and are able to carry the required air flow (approx. 6m3/min per module, flowing into the bottom rear of the drive and exhausting at the top rear of the drive). Check that thermal design caters for potential heat loss (approx. 70% of motor load at the rear cooling path, 30% (max) at front cooling path - see Figure 1-2).

Electrical

Check the electrical installation of cables, crimps and lugs making sure that sizing is appropriate. Check at the drive input, output and motor terminals.

Check that the earthing has been carried out correctly accolting to the instructions in Figure 3-1.

Ensure that no loose material, swarf or moisture has entered the drive.

3.3.3 Energising the Drive

Warning: Omniverter Drive is powered from high energy electrical supplies. Suitably qualified staff must inspect and approve the installation prior to powering the Drive. Safety is the responsibility of the commissioning engineer. Safety should never be compromised.

Ensure mechanical safety by

- making sure all staff are clear of connected machinery

- if necessary, decoupling the motor shaft

- if possible, isolating the motor while programming the Drive

- open the PTC circuit - this will always prevent the Omniverter Drive starting, regardless of set up.

Turn the power on. The fans should start and the display should illuminate. If the PTC circuit has been opened the display will indicate a motor PTC fault.

...



Omniverter Drive

3.3.4 Using the Omniverter in its "Standard Configuration"

When received ex factory, the Omniverter Drive has been fully reset to default condition (see Section 2.5). Often the drive can be used in this configuration, or with only a few simple adjustments. For more information about any parameter or setting refer to the relevant screen detail in Section 4.

The standard configuration sets the drive up with a very standard set of inputs and outputs (refer to Figure 2-5).

The standard configuration is set up for voltage inputs and outputs (+/- 10V = -100 to +100% which means 0 to +10V = 0 to 100%). If current (4-20mA) input or output is required, the analogue channels can be reprogrammed using the appropriate interface programming screens (100: INTERFACE).

Standard parameters are preset: -

acceleration 220 : ACCEL1= 60.0 seconds

deceleration 220: DECEL1= 60.0 seconds

upper speed limit 220:UPSPD = 110% of rated motor speed

lower speed limit 220: LWRSPD= -110% of rated motor speed

If negative speed (ie. reverse) is not desired, it is a good idea to set 220: LWRSPD to 0%.

Normal start (ramp from zero speed) and stop (ramp to zero speed) are set.

For those familiar with earlier generation drives and used to having to set up "boost" controls, note that normal Vectorque control does not need (or therefore provide) any form of boost adjustment.

Motor nameplate (410:MOTOR NAMEPLATE) details must be entered correctly to ensure motor protection and provide correct operation. Following entry of the motor parameters, the option is

given to "410: CALCULATE MODEL?". It is important to accept this option (press the Enter key) at this point to have the motor model parameters automatically calculated from the nameplate data entered.

For standard motors and applications, these are usually the only parameters which must be set prior to operation of the drive.

Warning: Vectorque must not be used with motors rated at less than 1/3 of the drive current rating (for test purposes with small motors V/Hz mode can be used - set 240: CNTRL =V/Hz). Attempts to

trial very small motors in Vectorque mode will result in excessive motor current and damage to the motor.

3.3.5 Master Reset

If necessary the Omniverter can be fully reset to the ex-factory state using the master reset screen 040: RESET (but note motor parameters (410: MOTOR NAMEPLATE) are not reset).

3.3.6 Local or Remote Control

Operation may be achieved from the local keyboard controls if required. Change screen 020: LOCREM= to LOCAL to obtain local control. In local control, the speed reference is taken from

the keyboard setting (020: KBFREQ= ) Stop and start are controlled purely from the keyboard controls - all external inputs are disabled (but motor PTC remains active - this can be useful if wanting a completely assured lock out mechanism while setting up).

Change screen 020: LOCREM= to REMOTE to return to remote control.

3.3.7 Advanced Set Up

For more detailed setups, the user is referred to section 2 detailing the concepts and methods employed in the Omniverter, and section 4, detailing the function, default setting, range and setup of each individual screen.



3.3.8 Start Up

Plan an approach which will allow Drive system to be exercised safely, always ensuring the Omniverter Drive can be stopped immediately if necessary.

Remove Motor Isolation.

Reset any fault indications (push 0 button to reset faults).

Start the Omniverter Drive in an appropriate mode of operation which permits observation of operation. Check direction of motor shaft rotation and that motor currents are correct.

With care, check operation at higher speeds or torque. Check acalerations and decelerations are appropriate.

Always check that motor currents and speeds are as expected.

If any faults are reported, refer to 3.5 Latched Fault Indications to determine cause and suggested solution.

If starting problems are encountered, 430: MOTOR module parameters may need to be trimmed. If motor rocks back and forth at start up or spins in the wrong direction sometimes 430: IMAG may be set too low - refer to Table 4-2.

If start sometimes results in a current limit or trip, 430 : RS in may be set too high - refer to Table 4-2.

If insufficient starting torque is generated, 4 30 : IMAG may be set too low - refer to Table 4-2.

With high starting torque loads indicatidns of motor overload and torque limit are not unusual - these are warnings that the motor will overheat if operation at the level of load is prolonged and that the inverter has trimmed acceleration or frequency to reduce torque respectively. The warnings are provided for information only - no change to set up is necessarily required.

If extended periods of operation at low speed (<20% speed) are envisaged, 430 : IMAG should be optimised. To do this, run the motor at no (or light) load above 20% speed and take note of the no load current (in Amps) on the LCD display. Set 430: IMAG to the no load current as a percentage of the motor nameplate current. If this method is impractical refer to 4 30 : IMAG in Section 4.

.. ... . . .

. . . . .



tl

umniverter unve

3.4 Overload Warnings Overload warnings appear in the type field of the LCD display (centre, top line). They appear as long as the overload condition exists and are usually a warning that a trip (a latched fault) is imminent.

Overload display and description

Possible Cause Possible Solution

MOTOR OL Motor thermal model indicates that motor will have reached maximum temperature

TRQ LIMIT Torque limit

CRNT LIM Current limit

INV OL Inverter overload

Motor current exceeds thermal capacity according to motor thermal model. Not immediately dangerous but will trip motor protection if overload persists.

Torque is being limited by the drive because the torque limit set too low, or load torque is too high.

If 430: RS is too high, TRQ LIMIT may occur under no load at startup.

Gross over current of output.

Inverter current exceeds inverter continuous rating. Not immediately dangerous, but will trip inverter protection if overload exceeds 50% duty for more than 30 seconds.

Check motor and load conditions. Check motor model settings.

Check load. Reduce acceleration rate. Check torque limit setting 220 : TRQLIM.

Lower 430: RS (refer Table 4-2).

Check for cable short circuit or motor faults. Check control and setup of motor (esp. high 430: RS) refer Table 4-2.

Check motor and load condition. Review set up of Drive.

Table 3-1 Limit indications on LCD display



3.5 Latched Fault Indications Fault indications are presented alphabetically together with description, cause and solution where appropriate. A log of the ten most recent faults is listed in module 310: FAULT LOG under the 300: FAULT INFO module grouping.

Faults may be locally reset by pressing the stop 13' button or may be remotely reset by closing the reset input.

Fault display and description Possible Cause Possible Solution

BRAKE OL Brake thermal model indicates that brake resistor will have reached maximum temperature

BRK DESAT Brake transistor overload

DCV HIGH DC bus volts excessive

GROUND Earth fault on output

DC RIPPLE Excess DC bus voltage ripple

CRNT TRIP Over current trip

INTERNAL internal fault detected

INV OL Inverter has been overlokled

INV THERM Internal trip on excessive heatsink temperature

LOW MAINS Mains supply low

LVDC LOW Fault in low internal low voltage supplies

Operation of brake resistor beyond specification. Income& set up of brake model.

Gross overload of brake circuit (eg short circuit in brake cabling), internal fault

Excessive regeneration through overhauling load or too fast deceleration. Overshoot in speed loop. Earth fault on output.

Earth fault

Loss of an input or output phase.

Gross over current of output

Internal circuit fault

Inverter thermal model has tripped the protection due to timed excessive current

Excessively hot ambient temperature.

Cooling air blockage or fan failure.

Electrical supply low fault

Electronic failure

Check load braking conditions. Check brake model settings.

Check brake resistor cabling. If fault persists call service agent.

Check load. Check deceleration rate (220: DECEL) and extend if necessary. Reduce 430: RR or 520 : WLPKI (refer Table 4-2 & Table 4-3). Check for earth faults in output circuit.

Check output circuit for failure to earth.

Check input circuit for blown fuses or open circuit faults. Check output circuit for open circuit faults.

Check for cable short circuit or motor faults. Check control and setup of motor (esp. high 430: RS) refer Table 4-2.

Call service agent if fault persists

Check motor and load condition. Review set up of Drive.

Check environment is not excessively hot.

Check and clean air path and fan. Replace fan if necessary.

Check mains supply; disable low voltage trip option (240: LVTRI P).

If fault persists call service agent



Omniverter Drive

Fault display and description Possible Cause Possible Solution

MOTOR OL Motor thermal model has calculated that motor will have reached maximum winding temperature

MOTOR PTC Motor PTC circuit has tripped

NOVRAM Fault in non volatile memory storage

OVER SPD Drive has exceeded 110% of maximum speed setting

U+ DESAT (also U-, V+, V, W+, W-) Output transistor overload

Operation at excessive current for given speed and cooling conditions. Incorrect set up of motor model.

Excessive motor winding temperatures. Break in PTC circuit.

Electronic failure

Incorrect set up. Over driving load.

Gross overload of output (eg short circuit in motor cabling), internal fault

Check motor and load conditions. Check motor model settings.

Check motor and load conditions. Check PTC circuit.

If fault persists call service agent

Check load and set up. Increase 4 30 : IMAG.

Check output cabling. If fault persists (especially with motor disconnected) call service agent.

Table 3-2 Latched fault indications on LCD display

.. ....... .... . ...



omniverter unve

4. Details of Configuration Modules

This section lists all of the Omniverter drive information in the order in which it is listed in the drive menu. Omniverter drive parameters relate to drive software version 6.0 or later.

A number of icons have been used to help illustrate the tree structure layout of the menu.

L7 Open folder This item is a menu heading. The items which follow are contained within this sub-menu.

O Closed folder This item is a menu heading. There are items contained within this sub-menu not listed immediately below.

Equal sign This item is a module parameter.

Destination Port This item is a module destination port.

4 Source Port This item is a module source port.

Tick This item is subject to User/Config/Master reset.

X Cross This item is NOT subject to User/Config/Master reset.

N/A Not Applicable User/Config/Master reset is not applicable to this item.

L7000:MENU CONFIG [0010:LOCKS 0020:LOCAL CONTROL 00301CD DISPLAY 0040:MASTER RESET

010: LOCKS

- 010 : CONFIG=

- 010 :USER =

010:FCTRY =

DESCRIPTION: Modules which define the operation and appearance of the menu and

the LCD display are located in this module group.

DESCRIPTION: Locking the drive parameters and connections is controlled from the

lock controls in this module. The connection configuration, all drive parameters and

factory calibration constants are locked by the CONFIG, USER and FCTRY locks res tive .

Description Default Range/Type User Lock

Config Lock

Master Reset

For safety reasons connections between modules can only

be made with the Drive disabled. After stopping the Drive

and unlocking the configuration (010:CONFIG=UNLOCK), all

start signals to the Controller are disabled so changes to

configuration connections can be performed without the

possibility of accidentally starting the Drive. Connection

changes are stored in non-volatile RAM as they are made.

Once the necessary changes have been made, the

configuration should be locked to enable operation of the

Drive.

LOCK unlock, lock N/A NIA N/A

All drive parameters and connections can be locked by the

user to prevent unintentional changes to the drive

configuration.

UNLOCK unlock, lock N/A N/A N/A

Factory calibration constants are unlocked by entering the

correct password code (not user accessble).

0 . 00 0.00 to 655.35 N/A N/A N/A

' ''



020:LOCAL CONTROL

- 020 : LOCREM=

-020:LOCMDE=

-020:KBFREQ=

020:KBTORQ=

020:KB S/R=

020:EXTS/R=

DESCRIPTION: Local control makes it possible for the Omniverter Drive to be conveniently controlled the from the drives LCD display. Located in the Local Control module are speed and torque reference values, as well as a parameter to switch between speed and torque modes of operation.


Config Lock

Master Reset

When local mode is selected the locaVremote indicator on

the LCD display (ie. the right-most character on the top line)

will change from 'Fr to V. In local mode the speed and torque reference inputs to the

Controller Conditioning module are ignored ie.220:SP0REF,

220:TRQREF. The 210:START input is always ignored. See

020:EXTS/R to determine when the 210:ENABLE and

210:RESET inputs are ignored.

In remote mode the start key on the keyboard is disabled.

See 020:KB S/R to determine when the keyboard stop key is

ignored.

REMOTE remote, local X

Switches between speed or torque control when in local

control.

S PEED speed, torque X

Keyboard speed reference - used when in local control speed

mode.

0. 0% -400.0 to +400.0% X

Keyboard torque reference - used when in local control

torque mode.

0. 0 % -400.0 to +400.0% X

Keyboard stop/reset enabled in LOCAL only or in LOCAL and

REMOTE modes.

LOC & REM LOC ONLY,

LOC & REM ,

X

External stop/reset (module 210) enabled in REMOTE only

or in LOCAL and REMOTE modes.

REM ONLY REM ONLY,

LOC & REM

X

030:LCD DISPLAY

030:LINE2 =

030:LINE3 =

030: LINE4 =

030:USER A 4-

030:USER BE-

DESCRIPTION: The Omniverter Drive's 4-line, 20-character LCD display permits easy- to-read displaying of speed, current, output voltage etc. Although the top line is dedicated to displaying the status of the drive, the information displayed on lines two, three and four is user selectable.

Description Default RangeJType User Lock

Config Lock

Master Reset

Selects which meter is to be displayed on line 2 of the LCD

display.

CURRENT X

Selects which meter is to be displayed on line3of the LCD

display.

SPEED X

Selects which meter is to be displayed on line4of the LCD

display. Line 4 is also used for menu navigation so is

located in the menu above 000:MENU CONFIG.

REF SPEED ' X ..(

Destination port: Displays the value of any analogue or digital

source port when 'USER A' is the selected meter in

030:LINE2, 030:LINE3 or 030:LINE4.

NC analogue/digital X

Destination port: Displays the value of any analogue or digital

source port when 'USER B' is the selected meter in

030:LINE2, 030:LINE3 or 030:LINE4.

NC analogueldgital X

' frequency (inverter, Hz), current (output, A), speed (% synchronous), ref speed (% synchronous), torque (% motor rated), ref torque (%

motor rated), bus volts (VDC), output volts (inverter, Vrms), power (electrical output, kW) , motor Imp (% motor rated temperature), kWh (kW hours), inv

on (inverter on-time, hours), motor run (motor run-time, hours), user A, user B

040:MASTER RESET

E7

L 040: RESET (ENTER) ?

DESCRIPTION: The master reset module bonta ns the master reset command which will re-Initialise drive parameters and connections to factory defaults.

Description Default Range/Type Use Lock

Contig Lock

Master Reset

The master reset command will re-initialise

drive parameters and connections to factory

defaults. Parameters NOT affected by the

master reset are the inverter calibration

constants (620:CALIBRATION), the motor

nameplate data (410:MOTOR NAMEPLATE)

and the local control data (020:LOCAL

CONTROL).

N/A N/A N/A



0:7I0O:INTERFACE - 0110:ANALOGUE INPUT 1

- 0120:ANALOGUE INPUT 2

h- 0130:ANALOGUE OUTPUT 1

- 0140:ANALOGUE OUTPUT 2

- 1:3150:DIGITAL INPUTS - 0160:DIGITAL OUTPUTS - 0170:FIELD BUS SETUP - 0180:FBUS ANLG INPUT

0190:FBUS DGTL INPUT 01A0:FBUS ANLG OUTPUT 1231 BO:FBUS DGTL OUTPUT

110:ANALOGUE INPUT 1

et' -110:TYPE = -110:LOW =

-110:HIGH =

110 : ANAI P1 -)

umniverter unve

DESCRIPTION: Modules which define the control interface for the drive are located in this module group. They define the scaling and interconnection of digital and analogue inputs and outputs (for 4-20mA, +/-10V, switched input, relay output, open collector output and field bus i/o).

DESCRIPTION: Parameters which control the operation of analogue input 1 only are contained in this module. Selection between 4-20mA and +/-10V can be made and the input can be scaled to cover any sub-range within the total analogue range for the Omniverter of +/-400%.


Config Lock

Master Reset

Selects betiveeii 4-20mA (current) or =+/-10V (voltage). . VOLTAGE voltage, current X

Sets the analogue percentage which should correspond to

the lowest electrical level ie. 4mA or OV.

0 % -400 to +400% X ..i


the highest electrical level ie. 20mA or +10V.

10 0 % -400 to +400% ..t X

Source port: Analogue Input 1 220SPDREF analogue


-120:TYPE = 120:LOW =

- 120:HIGH =

120:ANAIP2-

DESCRIPTION: Parameters which control the operation of analogue input 2 only are contained in this module. Selection between 4-20mA and +/-10V can be made and the input can be scaled to cover any sub-range within the total analogue range for the Omniverter of +1-400%.


Config Lock

Master Reset

Selects between 4-20mA (current) or =+/-10V (voltage). VOLTAGE voltage, current X



0 % ' -400 to +400% X



10 0 % -400 to +400% X

Source port: Analogue Input 2 22 OTRQREF analogue

130:ANALOGUE OUTPUT 1

e:7

-130:TYPE = -130:LOW =

-130:HIGH =

-130:ANA0P1c-

DESCRIPTION: Parameters which control the operation of analogue output 1. only are contained in this module. Selection between 4-20mA and +/-10V can be made and the output can be scaled to cover any sub-range within the total analogue range of 4-20mA or +/-10V.


Config Lock

Master Reset



the lowest electrical levet ie. 4mA or OV.

0 % -400 to +400% ../ X



100% -400 to +400% X

Destination port: Analogue Output 1 230SPEED analogue



140:ANALOGUE OUTPUT 2

e 140:TYPE =

-140:LOW =

- 140:HIGH =

- 140:ANA0P24-

150:DIGITAL INPUTS

DESCRIPTION: Parameters which control the operation of analogue output 2 only are contained in this module. Selection between 4-20mA and +/-10V can be made and the output can be scaled to cover any sub-range within the total analogue range of 4-20mA or +/-10V.


Config Lock

Master Reset




0% -400 to +400% X ,,(


the highest electrical level ie. 20iPA or +10V.

100% -400 to +400% X

Destination port: Analogue Output 2 230MTRCUR analogue

- -150:DIGIP24 - 150: DIGIP3 -,

- 150: DIGIP4

150:DIGIP53 - 150: DIGIP6-,

DESCRIPTION: Source ports for the control board mulitfunction digital inputs.

Description Default Rangefrype User Lock

Config Lock

Master Reset

Source port: Digital input 1. 210START digital ..1

Source port: Digital input 2. 210ENABLE digital -.1

Source port: Digital input 3. 210RESET digital

Source port: Digital input 4. 22 OTRQMDE digital

Source port: Digital input 5. 220SPDINV digital

Source port: Digital input 6. 220TRQINV digital

160:DIGITAL OUTPUTS E:7

- 160: DIGOP14-

- 160:DIGOP24-

- 160: RELOP14-

- 160 : RELOP2 e- 160: RELOP3 4-

DESCRIPTION: Destination ports for digital outputs.


Config Lock

Master Reset

Destination port: Open collector digital output 1 NC digital

Destination port: Open collector digital output 2 NC digital

Destination port: Relay output 1 210 RUN digital

Destination port: Relay output2 42 OMTR OL digital

Destination port: Relay output 3 230/ FAULT digital

170:FIELD BUS SETUP

- 170 : ENABLE=

- 170: FBTRIP=

170:FBLOSS4

DESCRIPTION: This module determines the operation of the field bus connection (if present). Its primary purpose is to detect the loss of the field bus and to take the appropriate action as required by the application.

Description Default Range Type User Lock

Config Lock

Master Reset

Module enable/disable switch. Disable this module if no field

bus connection is required.

FALSE false, true

Selects whether the Omniverter should trip if a loss of the

field bus is detected.

FALSE false, true

'

Source port: Field Bus Loss Error. NC digital

180:FBUS ANLG INPUT

e7 - 1130: FBAI P1 -)

- 180: FBAIP29 -180:FBAIP3-,

- 180 : FBAI P4 -)

180 : FBAI P5

180: FBAIP6-)

DESCRIPTION: Source ports for the field bus analogue Inputs are grouped together in

this module.


Config Lock

Master Reset

Source port: Field Bus Analogue Input 1. NC analogue ../ ../

Source port: Field Bus Analogue Input 2. NC analogue ..1

Source port: Field Bus Analogue Input 3. NC analogue




190:FBUS DGTL INPUT

- 190: FBDIP1

- 190: FBDIP2

- 190: FBDIP3-)

- 190 : FBDI P4 -)

- 190: FBDIP5-,

- 190: FBDIP6-,

DESCRIPTION: Source ports for the field bus digital inputs are grouped together in this module.


Config Lock

Master Reset

Source port: Field Bus Digital Input 1. NC digital








1AO:FBUS ANLG OUTPUT

0=7

1AO:FBAOP1(-

1AO:FBA0P2+ -1AO:FBA0P3+ 1AO:FaA0P44-

1AO:FBA0P5+ 1AO:FBA0P6+

Omniverter unve

DESCRIPTION: Destination ports for the field bus analogue outputs are grouped together in this module.


Config Lock

Master Reset

Destination port: Field Bus Analogue Output 1. NC analogue ../

Destination port: Field Bus Analogue Output 2. NC analogue ,./

Destination port: Field Bus Analogue Output 3. NC analogue

Destination port: Field Bus Analogue Output 4. NC analogue ../ ,/ Destination port: Field Bus Analogue Output 5. NC analogue

Destination port: Field Bus Analogue Output 6. NC analogue

1BO:FBUS DGTL OUTPUT

- 1B0 : FBDOP 1 4-

1B0 : FBDOP2 (-

- 180 FBDOP3

- 1B0: FBDOP4

- 1B0 : FBDOP5 E-

- 1B0 FBDOP6 4-

DESCRIPTION: Destination ports for the field bus analogue outputs are grouped

together in this module.


Config Lock

Master Reset

Destination port: Field Bus Digital Output 1. NC digital



Destination port: Field Bus Digital Output 4. NC digital ../


Destination port: Field Bus Digital Output 6. NC digital ,./

1CO:SERIAL COMMS

- lc° : STATUS=

1C0 :ADDRSS=

- 1C0 : SCAI P1 4 1C0 SCAIP2 -)

- 1C0 : SCAIP3 1CO:SCDIP1

-1CO:SCDIn-, 1CO:SCDIP39

DESCRIPTION: From within this serial communications module the address of an

Omniverter drive can be specified and the status of the serial communications interface can be viewed. Source ports for the serial communications analogue and digital inputs are grouped together in this module. NOTE: In applications where an Omniverter drive is to be actively controlled via the serial

communications interface it is strongly recommended that only the analogue and digital

source ports provided in this module be used. The value of these ports can be regularly updated without changes being stored in non-volatile memory every time a value

changes. This is important because the lifetime of the non-volatile memory in the Omniverter is limited to 106 data changes.

Description Default Range/Type Use( Lock

Config Lock

Master Reset

Status of the serial communications interface. Refer to

Table 11-4 for explanations of the different status messages

displayed.

READ ONLY N/A N/A N/A

Drive address used on the serial communications line. The

first digit designates the drive group (1-9) and the second

digit designates the drive within that group (1-9).

11 11 to 99

Source port: Serial communications Analogue Input 1. NC analogue



Source port: Serial communications Digital Input 1. NC digital

Source-port: Serial communications Digital Input 2. NC . digital

Source port: Serial communications Digital Input 3. NC digital



e7200:CONTROLLER 1 J210:SEQUENCING f3220:CONDITIONING C3230:MONITORING 0240:OPERATING MODES

210:SEQUENCING

eD

- 210 : STRMDE=

- 210 : STPMDE=

-210: START *.

210 : ENABLE*.

- 210:RESET

- 210 : START

210:RUN 4

DESCRIPTION: The Controller performs the core motor control functions of the Omniverter Drive and is divided into three modules according to function. These modules can be seen in Figure 2-6 which also shows the default settings of Contioller parameters in these modules as well as default connections to and from the Controller modules.

DESCRIPTION: The start, stop and reset destination ports of this module control the Drive (when in Remote control, not Local (020:LOCREM)). Vectorque sensortess vector control has made spin start and spin stop modes possible without the need for speed feedback signals from a shaft speed encoder. An explanation of these start and stop modes while operating under either speed or torque control follows in Table 4-1. Description Default RangeJType User

Lock Config Lock

Master Reset

Start Mode determines whether the frequency is ramped up

at the preset acceleration rate 1) from zero or 2) from the

motor's present speed'

NORMAL normal, spin X

Stop Mode determines whether 1)the frequency is ramped

down at the preset deceleration rate or 2) coasts to rest with

drive running for quick restart or 3) coasts to rest with drive

stopped.'

NORMAL normal, spin, coast X

Destination port: Drive Start input (positive edge triggered). 15 ODI GI P1 digital ../ Destination port: Drive Enable input (must be TRUE for drive

to run). A FALSE input will clear the start latch.

150DI GI P2 digital

Destination port: Drive Fault Reset input (positive edge

triggered).

150DI GI P3 digital

Source port: Drive Start Acknowledge output (TRUE while

drive running, FALSE while drive stopping or stopped).

NC digital

Source port: Drive Run Acknowledge output (TRUE while

drive running and while stopping, FALSE when stopped).

160RELOP1 digital

Spin start and stop modes are only available under the Vectorque sensorless-vector mode of operation ie. not V/Hz. See

table below for details of start/stop operation under speed or torque modes.

210:Start Mode

NORMAL

SPIN

Speed Control

Zero shaft speed is assumed. There is a 0.5 second delay as the inverter applies fixed current to the motor to bring the motor flux level up. Frequency is then ramped from zero up to the reference level at the preset acceleration rate. Consequently if the shaft is spinning at startup the Drive will effectively be applying a braking torque. This will cause the motor speed to reduce until it reaches the inverter frequency from which point it will accelerate.

The spin-start mode accelerates the motor from its present speed. The Drive applies current at zero torque to identify the shaft speed. After approximately one second the frequency is ramped from the present shaft speed to the reference level according to the preset acceleration ramp rates.**

Torque Control

Sufficient current is applied to produce the level of torque set by the reference input 220:TRQREF. Rotor speed is assumed to be zero.

The spin-start mode accelerates the motor from its present speed. The Drive applies current at zero torque to identify the shaft speed. After approximately one second the reference torque level is applied. **

*In low inertia systems the shaft may rotate very slightly at zero speed in spin start. If this is a problem, use NORMAL start mode.

°Spin start is not applicable to V/1-1z mode. The drive controller

will revert to NORMAL start.



umniverter urive

220: Stop Mode Speed Control Torque Control

NORMAL

SPIN

COAST

The frequency is ramped down to zero at the preset deceleration

rate.

A small drag torque is applied allowing the load to decelerate the

motor.° The Drive knows the shaft speed as it decelerates,

permitting an instantaneous transition into acceleration from the

present speed if required. The shaft will coast to rest below 10%

speed. ° The inverter applies no power to the motor, allowing the motor to

coast to rest as if no inverter were connected.

°If the drag torque which is applied causes too much power to

regenerate back into the inverter ie. the Omniverter trips on high

DC bus voltage 'DCV HIGH", select the COAST stop mode.

Table 4-1 Setup Guide for Start/Stop Modes

220:CONDITIONING

- 220 : TRQLIM=

- 220 : LWRSPD=

- 220:UPSPD = - 220 :ACCEL1=

- 220 : DECEL1=

- 220 :ACCEL2=

- 220 : DECEL2=

- 220 : SPDREF4-

- 220 : TRQFLEF+

- 220 : TRQMDE4-

- 220 : SPDINV4-

- 22 0 : TRQINV4-

- 220:RAMP2 4-

- 220:AT SPD9

- 220 : CURLIM4 220 : TRQLIM4

A small drag torque is applied allowing the load to decelerate the motor.° The Drive knows the shaft speed as it decelerates, permitting an instantaneous transition into acceleration from the present speed if required. The shaft will coast to rest below 10%

speed.

A small drag torque is applied allowing the load to decelerate the motor.° The Drive knows the shaft speed as it decelerates, permitting an instantaneous transition into acceleration from the present speed if required. The shaft will coast to rest below 10%

speed.° The inverter applies no power to the motor, allowing the motor to

coast to rest as if no inverter were connected.

°Spin start is not applicable to V/Hz mode. The drive controller

will revert to NORMAL start.

DESCRIPTION: Speed and torque control signals are input to the Conditioning module and are processed together with the start/stop sequencing logic to control the operation of the Drive. A number of limits (acceleration, deceleration, upper and lower speed limits, maximum torque limits) set boundaries to the area of operation of the Controller.


Config Lock

Master Reset

Sets the limit for maximum positive and negative torque

magnitude.

15 0 % 0 to 300% X

Sets the lower limit for speed. -110 % -200% to 220:UPSPD X

Sets the upper limit for speed. 110% 220:LWRSPD to +200% X

Sets the ramp-rate group 1 accelerating limit for the

Controller. Set as required by process. Avoid unnecessarily

high acceleration.*

6 0. Os 0.1 to 3000 seconds X

Sets the ramp-rate group 1 decelerating limit for the


high deceleration.

60 . Os 0.1 to 3000 seconds X

Sets the ramp-rate group 2 accelerating limit for the


high acceleration.*


Sets the ramp-rate group 2 decelerating limit for the


high deceleration.


Destination port: Speed reference. 11 OANAI P1 analogue

Destination port: Torque reference. 12 OANAI P2 analogue

Destination port: Torque/speed mode selector (FALSE for

speed mode; TRUE for torque mode).

15 ODIGI P4 digital

Destination port: TRUE inverts the sign of the remote control

speed reference.

NC digital

Destination port: TRUE inverts the sign of the remote control

torque reference.

NC digital

Destination port: TRUE selects ramp-rate group 2

acceleration/deceleration limits for the drive controller.

FALSE selects ramprate group 1 acceleration/deceleration

limits for the drive controller.

NC digital

Source port: At speed setpoint indicator. NC digital

Source port: Current limit indicator. NC digital

Source port: Torque limit indicator. NC digital

Value is the time for a 100% change in speed.



230: MONITORING

eD

- 230: FREQ 4

- 230: SPEED

- 230: VOLTS 4

- 230: TORQUE4

230: MTRCUR4

230:POWER 4

230:/FAULT-,

230:INV OL4

DESCRIPTION: The Controller Monitoring module outputs a number of useful control variables: inverter frequency, shaft speed, applied voltage, motor torque, current, electrical power and a fault indicator. These may be used for control purposes, linked to appropriate interfaces or shown on the LCD display.


Config Lock

Master Reset

Source port: Inverter frequency. NC analogue

Source port: Motor speed. 13 OANA0P1 analogue i Source port: Inverter output voltage. NC analogue

Source port: Torque. NC analogue

Source port: Current as a percentage of rated motor current. NC analogue

Source port: Electrical output power. NC analogue

Source port: Failsafe fault indicator (r indicates inverted

logic) ie. TRUE = No Fault. Changes to FALSE for any drive

trip condition.

160 RELO P3 digital

Source port: Inverter overload indicator. NC digital

240:OPERATING MODES

e:7

- 240:CNTRL =

- 240:LOAD =

240: LVTRIP=

DESCRIPTION: The Controller Operating Modes module permits selection of a number of different operating modes for the drive.


Config Lock

Master Reset

Selects 1)V/1-1z or 2)Vectorque encoderless vector control

mode. Limited torque features are available under V/Hz

control. Spin start and stop modes are only available under

the Vectorque sensorless vector mode of operation.

VECTORQUE VA-1z, Vectorque

Selecting variable torque (VAR TRQ") enables a special

pump curve which provides reduced flux and noise at

fractional speeds - suits centrifugal loads. Set to constant

torque ('CONST TRQ") for all other loads.

CONS T TRQ const trq, var trq

Forces Drive to trip upon low mains voltage detection.

Disable this option to allow ride-through during mains

disturbances (drive output is disabled during low mains; spin

start should be selected to restart on to spinning motor.

In V/Hz mode the motor will run down to zero speed on

current limit).

OFF off, on

,, ,, , .... ..........................



E77300:FAULT INFO C3310:FAULT LOG

L 0320:AUTO RESET

310:FAULT LOG

- 310: FAULT1= - 310: FAULT2= 1- 310 : FAULT3= - 310: FAULT4= -310: FAULTS= - 310: FAULT6= - 310: FAULT7= - 310: FAULT8=

-310: FAULT9=

umnivener urive

DESCRIPTION: This group has two modules - one which logs faults and another which provides control over auto-resetting behaviour whenever a fault occurs.

DESCRIPTION: By logging the nine most recent faults, this module enables the user to investigate the fault history of the drive. The fault log is stored in non-volatile RAM. Clearing the fault log can be performed by scrolling down to the parameter reset command at the bottom of the list and then oressina enter.


Config Lock

Master Reset

Fault log entry number 1. (most recent) N/A - Fault log entry number 2. ' N/A

Fault log entry number 3. N/A





Fault log entry number 8. N/A ../ Fault log entry number 9. (least recent) N/A

See section 3.5 for the list of all possible fault indications.

320:AUTO RESET

E7

- 320:NUMBER=

- 320: DELAY =

320:PERIOD=

DESCRIPTION: Controls auto-reset option following a fault. Faults which will be auto- reset are: overcurrent trip (CRNT TRIP), high dc bus voltage (DCV HIGH), low mains voltage (LOW MAINS) and inverter overload (INV OL).


Config Lock

Master Reset

Sets the permissible number of auto-resets before the

Omniverter will remain tripped - manual reset is then required

to continue operation.

0 0 to 5 X

Sets the delay between when the fault occurs and when the

next attempt to automatically reset will be made.

3 0 s 0 to 100 seconds X 1

The fault-free period after which the fault counter is reset. 3 6 0 0 S 0 to 3600 seconds X



e:7400:MOTOR [CD410:MOTOR NAMEPLATE

C3420:MOTOR THERMAL C:1430:MOTOR MODEL

410:MOTOR NAMEPLATE

-4 10:VOLTS =

-410:AMPS =

- 4 10 : POWER = -410:RPM =

4 1 0 : FREQ =

4 1 0 : CALCULA

DESCRIPTION: Modules which relate to motor characteristics are listed in this grouping. It is essential that the nameplate values be entered and that the motor model be calculated. Motor thermal and motor model parameters do not usually need adjusting unless a special motor or forced cooling is used.

DESCRIPTION: The rated motor parameters as stated on the motor nameplate should be entered here. Unless a special motor or cooling method is used, these are the only motor parameters which must be entered at commissioning, but the calculate model motion must be accepted..


Config Lock

Master Reset

Rated motor voltage. 4 0 OV 50 to 1000V X Rated motor current. OA 0 to 2000A X Rated motor power. 0 kW 0 to 1000kW X Rated motor speed. 0 rpm 0 to 65535rpm X Rated motor supply frequency. 50Hz 0 to 100Hz X r E MODEL? Automatic calculation of motor model parameters (estimates motor parameters from nameplate data and

enters them into module 430 automatically). Always accept this option unless precise motor model data is

available to be entered into module 430 directly. Press the Enter key to activate this function.

If precise motor model data exists then enter this data directly into module 430.

420:MOTOR THERMAL

- 4 2 0 : F COOL= - 420 : STRTIM= 420:TRIP =

- 420:MTR OL4

-4 2 0 : MTRTMP -)

DESCRIPTION: Parameters in this module do no usually require adjustment by the user. Incorporated in the Omniverter Drive is thermal modelling of the motor, protecting it from overheating. Parameters 'n this module affect the model operation. Source port indicators provide information on the motor temperature and overload status.


Config Lock

Master Reset

If the motor is being force cooled, select ON. 0 FF off, on X Maximum allowable DOL start duration of the motor. 10 . Os 0 to 60seconds X Allows the motor thermal model to trip the Omniverter. ON off, on X Source port: Motor thermal overload warning indicator. This

indicates that the thermal model has detected that the motor

is being overloaded and that the Omniverter will soon trip.

This indicator clears once the Omniverter has tripped.

1 6 0 RELOP 2 digital

Source port: Estimated motor temperature rise. 100%

implies rated or design level temperature rise.

NC analogue ../

430:MOTOR MODEL

-4 3 0 : RS

-430:RR =

-430:IMAG =

-430:LKG =

430:CALCULA

DESCRIPTION: Parameters in this module do no usually require adjustment by the user. These parameters are motor parameters used in the Omniverter Drive control algorithms. The values which can be automatically calculated by "410:CALCULATE MODEL'?" should provide satisfactory performance for most applications. The motor model parameters define the critical motor electrical parameters required for Vectorque. Parameters are expressed in normalised notation and will not vary widely for most standard motors. Refer to Table 4-2 for a guide to setting up motor model parameters.


Config Lock

Master Reset

Stator resistance (approx. equals one to two times rotor

resistance). This parameter is important in high torque, low

speed operation eg. hoists.*

1 . 0$ 0 to 10.0% ./. X

Rotor resistance (approx. equal to percentage slip)' 1.0% 0 to 10.0% . X ..4

Magnetising current.' 5 0. 0 % 0 to 50.0% X Leakage inductance.' 1 6 . 7 % 0 to 150.0%

rE MODEL? Automatic calculation of motor model parameters from the motor nameplate values entered in module 410.

Press the Enter key to activate this function.

See Table 4-2 for a guide to setting up motor model parameters manually.



umnivener unve

NOTE: "410 : CALCULATE MODEL?" uses the following formulae to automatically calculate motor model values. This function should be used to generate values unless more precise data about the motor parameters is available directly.

Parameter Setting Effect on performance

RS: Stator resistance

RS is typically 0.4% to 2.3% (smaller in large motors)

RS approximately equals 75% of the percentage motor slip at full

load.

RS = 100 x Rpn x POWER / VOLTS2

where Rpn = Equivalent cold motor phase to neutral resistance in

ohms. Note that Rpn = Line to line resistance / 2.

The stator resistance has an important effect on peak torque

especially at very low speed. If it is too small peak starting

torque will be reduced. If it is too high then the drive will source

high current limited by the current limit, but be unable to run up to

speed and may surge at low speed.

Provides automatic boost in ViHz mode.

RR: Rotor resistance

RR is typically 0.5% to 3% (smaller in large motors)

RR approximately equals the percentage motor slip at full load.

With encoderless operation this motor is not critical unless high

accuracy is needed in the speed control.

RR = 100 x1 ( 1 - (poles x RPM)/(120 x FREQ) r number of motor oe where poles is the poles. p

The rotor resistance primarily corrects for slip in the induction

motor. If it is set too low then the shaft speed will be lower than

the set-point under load. If it is set too high then the opposite will

occur. Excessively high rotor resistance settings may cause

surging at low speeds with light loads. Doesn't affect torque

significantly and can be set to zero if speed regulation is not

important.

Provides slip compensation in V/Hz mode.

IMAG:

Magnetising Current.

IMAG typically equals (approximately) the percentage no load

current of the motor.

Typical values are 30% to 70% depending on motor design

(higher for high pole number machines)

No-load current can be read directly from the LCD display if the

motor is run above 20% speed with less than 10% load.

IMAG only has effect below 20% speed and is important to

achieve correct operation at low speeds.

IMAG = 100 x Int x 1.732 x VOLTS / POWER

where Inl = rms no-load current in amps

It can also be approximated from the nameplate data using:

IMAG =100 x [ (1/PF2 - 1 )01) - LKG

where: PF = full load power factor of the motor

and LKG == the % leakage as given below.

The magnetising current parameter defines the magnetic field

current in the motor at low speeds. If it is set too low the motor

will not generate correct torque.at low speed. It is acceptable

and beneficial to set this level significantly higher than the normal

no-load current to ensure sufficient flux is available if high

starting torque is required. If set much too high the motor will

operate at higher current than necessary and may surge at low

speed with light load. If it is set too low the motor may not

support the load at low speed and will not start reliably.

Sets magnetising current in V/Hz mode.

LKG:

Leakage inductance.

This parameter is typically 10% to 20% in most standard motors

and generally does not need adjustment from the default.

LKG = 628 x FREQ x L x POWER / VOLTS2*

where L = total leakage inductance in henrys.

It can be approxiinated from:

LKG= 100 x AMPS / DOL_AMPS

where DOL_AMPS is the rms starting current for the motor.

Under normal operating conditions the leakage inductance

parameter has little observable influence so can be left at the

default setting.

The leakage inductance parameter has a small effect on the

dynamic performance of the vector control and the peak torque

capability of the system.

Extreme settings may destabilise the control. .

nnttrnna)-.-s tint Tr *1100 corn D/ ....... I.,, ..........1...1.. ....c...... .1 4s,,, ...Met.

Table 4-2 Setup Guide for Motor Model Parameters



L7500:VECTOR CONTROL M510:SETTINGS C=1520:GAINS

510:SETTINGS

V7

- 510:HOIST =

- 510 : IBOOST=

-510:J COMP=

- 510 : FWK PT=

520:GAINS

- 520 :WLPKP = - 520 :WLPKI = - 520 :WLPKD = - 520 : PHLPKP= - 520 : PHLPKI= - 520 : FRLPKP=

520 : FRLPKI= 520: ILPKP = 520 : ILPKI

4-1

DESCRIPTION: Modules which relate to the vector controller are listed in this grouping but do not normally require user adjustment.

DESCRIPTION: Vectorque allows some special adjustments to enhance perforfnance. In particular the operation at low speeds with constant torque loads can be enhanced using the Hoist mode. This mode improves the smoothness of shaft rotation and

rmits full load to be supported with slow speed reversals.

Description Defautt Range/Type User Lock

Config Lock

Master Reset

Required to support hoist-type loads around zero speed.

The current boost parameter (510:IBOOST) must be set to a

high enough level to support the load.

OFF off, on X

Sets current (% of motor rated) through zero speed region.

Leave at zero unless requiring high holding torque (not

starting torque) near zero speed eg. hoist applications. If

used, set to percentage torque needed at zero speed.

0$ -250 to +250% -4/ X

Motor inertia compensation, only used in high performance

applications.

0 . 0 s 0 to 100 seconds X

Field weakening point. The motor excitation (magnetic field)

is adjusted to keep the terminal voltage below this level in

steady state operation. This point represents the transition

to constant power. If insufficient dc bus voltage is available,

field weakening will occur earlier ie. will override this setting.

12 0 % 80 to 150% X

DESCRIPTION: Not usually adjusted - consult the factory before adjusting any of these. The Vector control system comprises several control loops to ensure high performance control. The default values have been selected to meet most normal conditions and standard motors. In general these do not need adjustment. However two loops may be adjusted to modify performance or improve control or to suit non-standard motors. These are the current control loop and the speed control loop. Vectorque has an inner control loop to control the current (torque) and an outer control loop to control the speed. Refer to Table 4-3 for a guide to adjusting key vector control gains.


coring Lock

Master Reset

Speed loop proportional gain. 160 0 0 0 to 65535 X Speed loop integral gain. 2 0 20 to 65535 X Speed loop derivative gain. 0 0 to 65535 X Flux loop proportional gain! 10 0 0 0 0 to 65535 X Flux loop integral gain! 4 00 20 to 65535 X Frame loop proportional gain! 3 00 0 0 to 65535 X Frame loop integral gain! 8 00 20 to 65535 X Current loop proportional gain. 2 0 0 0 0 to 65535 X Current loop integral gain. 4 00 20 to 65535

*Factory set - do not adjust.



umnivener unve Parameter Setting Effect on performance

WLPKP: Speed loop proportional gain.

Not usually adjusted consult the factory.

Adjust to improve disturbance response or if speed control

is unstable or poorly damped.

Reduce for low inertia load.

Increase for high inertia poorly damped load.

If too high the motor will run roughly and unstably.

If too low the motor will have a slow response and may have excessive overshoot on high inertia loads. This may cause bus overvoltage trip as the control recovers from overshoot.

WLPKI: Speed loop Integral gain.


Adjust to improve dstuibance response or if speed control

is unstable or poorly damped.

Decrease for high inertia poorly damped load. Do not set

to less than 20.

Increase to improve disturbance rejection with low inertia

loads.

If too high the motor speed will have excessive overshoot and may become oscillatory. This may cause bus

overvoltage trip as the control recovers from overshoot.

If too low the motor will have a slow response and poor disturbance rejection on low inertia loads.

ILPKP: Current loop

proportional galn. Not usually adjusted consult the factory.

Adjust to improve the current and torque step response or

if current control is unstable.

Generally this is only adjusted when non-standard motors

or motors with low leakage inductance are used.

If too high the current will be unstable as evidenced by noisy operation and possibly current trips.

If too low the current response and torque response will be slow and the speed loop will need low gains.

ILPKI: Current loop integral galn.


Adjust to improve the current and torque step response or

if current control is unstable.

Generally this parameter is not adjusted.

If too high the current will exhibit step response overshoot and poor damping.

If set too low the step response will be slow.

Table 4-3 Setup Guide for Vector Control Gains



E=7600:INVERTER 4610: WAVEFORM 0620:CALIBRATION 0630:DYNAMIC BRAKE

610:WAVEFORM

L 610: SWFREQ=

DESCRIPTION: This module group contains modules which affect the Omniverter hardware.

DESCRIPTION: Inverter waveform module.


Config Lock

Master Reset

Selects PWM switching frequency. NOTE: After changing

this parameter the Omniverter must be powered off then on

again - the switching frequency is changed by this parameter

at power-up only.

LOW low, high X

620:CALIBRATION

[620:CTSCLE= 620:RATING= 620:TSTMDE= 620:VER =

DESCRIPTION: This is the inverter calibration module which contains factory set parameters for the inverter hardware. Adjustment is factory locked by the 010:FCTRY parameter and user adjustment is not permitted.


Config Lock

Master Reset

Calibrates CTs to Omniverter rating. N/A 0 to 65535 X X X Calibrates inverter to correct current rating. N/A 2000A X X X Test mode for factory use. N/A false, true X X X Software version number. N/A READ ONLY X X X

630:DYNAMIC BRAKE

[630:DBDUTY= 630:TIME =

630:ENABLE=

4-1

DESCRIPTION: Details of the brake resistor used for dynamic braking must be entered here for the Omniverter to provide thermal model ing protection for the resisto Description Default Range/Type User

Lock Config Lock

Master Reset

Rated duty cycle of the dynamic brake resistor. 10 $ 10 to 100% X ../ Time constant of the dynamic brake resistor. 1 Os 1 to 500 seconds X Enables operation of the dynamic brake. OFF off, on X



CE7700:SPECIAL FUNCTION - 0710:ANALOGUE PRESETS - 0720:DIGITAL PRESETS - 0730:2 TO 1 ASWITCH1 - 0740:2 TO 1 ASWITCH2 - 0750:2 TO 1 DSWITCH1 - 0760:2 TO 1 DSWITCH2 - 0770:2 TO 1 DSWITCH3 - 0780:DIGITAL FUNCT1 - 0790:DIGITAL FUNCT2

07A0:DIGITAL FUNCT3 - 0760:MOTORISED POT

7:10:ANALOGUE PRESETS

^ 710 :VALUE1=

- 710 :VALUE2=

- 710 :VALUE3=

-710:VALUE13 - 710 :VALUE24

710:VALUE3-)

umniverter unve

DESCRIPTION: This module group contains modules which can be used to provide additional control over the Omniverter drive. Additional modules will be added on an ongoing basis.

DESCRIPTION: Analogue sou ce ports with use specified fixed values. Preset sources are useful when fixed reference levels are required.


Config Lock

Master Reset

Analogue Preset 1 Value 0 . 0% -400.0 to +400.0% X

Analogue Preset 2 Value 0. 0% -400.0 to +400.0% X

Analogue Preset 3 Value - - 0 . 0 % -400.0 to +400.0% X

Source port Analogue Preset 1 NC analogue

Source port: Analogue Preset 2 NC analogue

Source port: Analogue Preset 3 NC analogue

720:DIGITAL PRESETS

er/

- 720 :VALUE1= 720:VALUE2=

- 720: VALUE3= - 720:VALUE14 - 720 :VALUE24 720 :VALUE3

DESCRIPTION: Digital source ports with user specified fixed values. Preset sources are useful when fixed reference levels are required.


Config Lock

Master Reset

Digital Preset 1 Value FALSE false, true X



Source port: Digital Preset 1 NC digital

Source port: Digital Preset 2 ' NC digital

Source port: Digital Preset 3 NC digital

730:2 TO 1 ASWITCH1

er/

[

730:INO +

730:IN1 +

. 730:SELECT+ 730:OUTPUT4

DESCRIPTION: This module is an analogue switch controlled by a digital connection (ie.

an analogue multiplexer). It can be used to switch the source for the speed reference,

for example, from one analogue source (such as the field bus) to another (such as 4-

2OrnA analogue in ut ).


Config Lock

Master Reset

Destination port: connects to Output if Select = FALSE. NC analogue

Destination port: connects to Output if Select = TRUE. ' NC analogue

Destination port: selects between INO and IN1. NC digital

Source port: outputs either INO or IN1. NC analogue

740:2 TO 1 ASWITCH2

750:2 TO 1 DSWITCH1

e,

[750:INO 4-

750:IN1 4-

750:SELECT+ 750:OUTPUT4

Same as 730:2 TO 1 ASWITCH1.

DESCRIPTION: This module is a digital switch controlled by a digital connection (ie. a

digital multiplexer). It can be used to switch the source from one digital source to

another.


Co Lock Reset

Destination port: connects to Output if Select = FALSE. NC digital

Destination port: connects to Output if Select = TRUE. NC digital

Destination port: selects between INO and IN1. NC digital

Source port: outputs either INO or IN1. NC digital

760:2 TO 1 DSWITCH2 770:2 TO 1 DSWITCH3

Same as 750:2 TO 1 DSWITCH1. Same as 750:2 TO 1 DSWITCH1.



780:DIGITAL FUNCT1

E77

-780:0P =

-780:INVINO= -780:INVIN1=

780:INVOUT= 780:INO 780:IN1 780:OUTPUT4

DESCRIPTION: This module is a digital function block and allows AND, OR or XOR logic operations to be performed. The two inputs and one output are independently invertible.

Description Default User Lock

Config Lock

Master Reset

Function Operation to be performed on the inputs INO 8 IN1. AND and, or, xor X Invert switch for input INO. FALSE false, true X .1 Invert switch for input IN1. FALSE false, true

- X

-

Invert switch for the output. FALSE false, true X Destination port: first input INO. NC digital

Destination port: second input IN1. NC digital

Source port: the result of the logic operation. NC digital

790:DIGITAL FUNCT2 7A0:DIGITAL FUNCT3

7B0:MOTORISED POT

On'

-7B0:ENABLE=

-7 BO : UPLIM = - 713 0 : LWRLIM= - 780: TIME =

7BO: INC 4-

7BO: DEC 4-

- 7B0 : OUTPUT-,

Same as 780:DIGITAL FUNCT1. Same as 780:DIGITAL FUNCT1.

DESCRIPTION: The motorised potentiometer module allows increment and decrement inputs to control the value of the module's analogue output. Typically this module would be used to allow the motor speed (for example) to be adjusted up or down with the use of two push -buttons. The output value is retained on power down. Description Default Range/Type User

Lock Config Lock

Master Reset

Module enable/disable switch. Disable this module if the

motorised potentiometer function is not required.

FALSE false, true .,( X

Upper limit for output. 100 . 0% -400.0 to +400.0% X Lower limit for output. 0 . 0 % -400.0 to .400.0% X Time for output to span range from LWRLIM to UPLIM. 6 Os 1 to 3000s X Destination port: Increase output level. NC digital

Destination port: Decrease output level. NC digital ../ Source port: the motorised pot output. NC analogue

7CO:PRESET SELECT

e,

7CO:VALUE1= - 7C0 :VALUE2=

7C0 : VALUE3= 7CO:VALUE4=

- 7C0 : VALUE5= 7C0 : VALUE6= 7C0 : VALUE7= 7CO:VALUE8= 7CO: SELO <-

7CO:SEL1 7C0: SEL2 4-

7C0 :OUTPUT -)

DESCRIPTION: The preset select module outputs one of eight user preset values based on the states of three digital inputs. Typically this module would be used to allow the motor speed (for example) to be selected with the use of three switches. Description Default Range/Type User

Lock Config Lock

Master Reset

Selectable preset value 1, output if SELO, SEL1, SEL2=F,F,F 0. 0% -400.0 to +400.0% X Selectable preset value 2, output if SELO, SEL1, SEL2=F,F,T 0. 0% -400.0 to +400.0% X Selectable preset value 3, output if SELO, SEL1, SEL2=F,T,F 0 . 0% -400.0 to +400.0% X Selectable preset value 4, output if SELO, SEL1, SEL2=F,T,T 0. 0% -400.0 to +400.0% X Selectable preset value 5, output if SELO, SELl. SEL2=T,F,F 0. o % -400.0 to +400.0% X ../ Selectable preset value 6, output if SELO, SEL1, SEL2=T,F,T 0. 0% -400.0 to +400.0% X Selectable preset value 7, output if SELO, SEL1, SEL2=T,T,F 0. 0% -400.0 to +400.0% X Selectable preset value 8, output if SELO, SEL1, SEL2=T,T,T 0. 0% -400.0 to +400.0% X Destination pod: Select input O. . NC digital ../ Destination port: Select input I. NC digital ..( Destination port: Select input 2. NC digital

Source port: the preset select output. NC analogue

:: :



(maw If=

7D0:PID CONTROLLER

E7

- 7D0:ENABLE=

-7D0:MODE =

- 7DO:KP - 700:WITS =

- 7DO:WDTS =

7D0:UPLIM =

7D0:LWRLIM= 7D0:KSP =

7D0:TS

- 7DO:REF 7D0: F/B 4-

- 7D0 :OFFSET 4-

- 7 DO : ENABLE 4-

- 7D0:OUTPUT-)

7D0 : ERROR

- 7D0:UPIND

- 7D0 LWRIND4

umniverter unve DESCRIPTION: The PID (proportional, integral, derivative) controller module allows the Omniverter drive to be used in applications requiring closed loop control. The module also incorporates integrator anti- windup.


Config Lock

Master Reset

Module enable/disable switch. Disable this module if no PID

control is required.

FALSE false, true ' X

Control mode: PI or PID controller. For IP control set KSP

(below) to 0.0.

P I PI, PIO X

Proportional gain. 1 . 00 0.00 to 16.00 X

Product of the integral frequency (o) and the sample time

(T.). For an wiTs of 0.1 and a 100% error (ie. ref -

feedback), the integral term will integrate at 10% per sample.

0. 00 1 0.001 to 0.100 X -

Product of the derivative frequency (cod) and the sample time

(Ti). For an codTs of 0.1 and a 10% change per sample in

the feedback signal, the derivative term will equal 100%.

0. 10 0.01 to 0.10 X

Upper level to limit the output. 4 00 . 0 $ -400.0 to +400.0% X

Lower level to limit the output. -4 0 0 . 0 $ -400.0 to +400.0% X

Set-point weighting. Set to 1.0 for PI control, or 0.0 for IP. 1 . 0 0.0 to 1.0 X

Sample time (T.) in milliseconds. Increase T. for slow

processes requiring integral control.

10ms tOms,100ms,ls,10s X

Destination port: input for the reference set-point signal. NC analogue ,./ ,./ ../

Destination port: input for the feedback signal. The

difference between the REF and FIB signals is the control

error which is output to the ERROR source port (see below).

NC analogue ,./

Destination port: input for offsetting the PID controller output.

Normally this would be the speed reference signal and the

PID controller would trim this value before being passed on

to the speed reference input (220:SPDREF).

NC analogue ../

Destination port: input for disabling the PID controller output.

This has the same effect as setting UPLIM and LWRLIM to

zero so the OUTPUT value equals the OFFSET input.

NC digital ,./

Source port: the PID controller output + offset. NC analogue

Source port: difference between the reference input (REF)

and the feedback input (FIB).

NC analogue

Source port: TRUE when the PID OUTPUT is being clamped

by the upper limit 7D0:UPLIM.

NC digital ,./

Source port: TRUE when the PID OUTPUT is being clamped

by the lower limit 700:LWRLIM.

NC digital ../

1p

LE

(OPTS ET

____.#.. d/dt

(UPLIM..

fa ERROR

94-TP I ND

OUTPUT

WM=

Figure 4-1 PID Controller special function module



mivbi =)

INTALUE mi

7E0:SKIP BANDS

E7

-7 EO : ENABLE=

7E0:VALUE1=

-7E0:BAND1 =

7E0:VALUE2= 7E0:BANN = 7E0:VALUE3=

-7E0:BAND3 = 7E0:VALUE4= 7E0:BAND4 = 7E0:INPUT 4-

7E0:OUTPUT4

DESCRIPTION: The skip bands module eliminates specified values from a signal. Most commonly this module would be used to prevent a speed reference signal from requesting frequencies that may cause mechanical resonances to occur. Description Default Range/Type

User Lock

Config Lock

Master Reset

Module enable/disable switch. Disable this module if skip

bands are not required.

FALSE false, true X ../

Centre frequency for the first skip band. 0.0% 0.0 to +400.0% X Bandwidth for the first skip band. 0.0% 0.0 to +400.0% X Centre frequency for the second skip band. 0.0% 0.0 to +400.0%

Bandwidth for the second skip band. 0.0% 0.0 to +400.0% X Centre frequency for the third skip band. 0.0% 0.0 to +400.0% X Bandwidth for the third skip band. 0. 0 % 0.0 to +400.0% X Centre frequency for the fourth skip band. 0.0% 0.0 to +400.0% X Bandwidth for the fourth skip band. 0. 0% 0.0 to +400.0% X Destination port: Input to the skip bands module. NC analogue

Source port: OUTPUT of the skip bands module after any

INPUT value found to be within any of the four bands has

been skipped.

NC analogue

Skip bands specified in module 7E0 may aquire any positive VALUE (ie. centre frequency) and may have a BAND of any width. As the value of the INPUT increases through a skip band the output is held at the lower bound. Once the INPUT exceeds the upper bound the OUTPUT equals the INPUT value. For an INPUT decreasing through a skip band the OUTPUT is held at the upper bound until the INPUT value decreases to less than the lower bound.

The Omniverter drive processes these specified bands, detecting overlapping bands, nested bands and bands which cover zero and converts these as appropriate as Figure 4-2 illustrates.

....v..../...... :- - - - : USER SPECIFIED

- - - -I SKIP BANDS

01;10MN/ SKIP BANDS

USED

OUTPUT-)

NPUT

Figure 4-2 Skip bands special function module

4



7F0:COMPARATOR 1

,e-

[7FO:RAND =

7FO:INO 4-

7FO:IN1 4-

7FO:OUTPUT4

umniverter unve DESCRIPTION: The comparator module compares two analogue input signals and outputs a digital signal to indicate which of the two is higher in value. A hysteresis band is also provided so that the output will be True when INO is greater than IN1 + BAND and False when INO is less than IN1 - BAND.

Description Default User Lock

Config Lock

Master Reset

Hysteresis band for the comparator. 5. 0% 0.0 to +400.0% X

Destination port first input INO. NC analogue

Destination port: first input IN1. NC analogue ../

Source port: True if INO > IN1 + BAND

False if IN1 < INO - BAND

NC digital

7G0:COMPARATOR 2 7H0:COMPARATOR 3

'' ' : ::::::

Same as 7G0:COMPARATOR 2. Same as 7H0:COMPARATOR 3.

:::":::'



umnivener urive

5. Appendix 1 - Index of Configuration Module Ports

5.1 Destination Port Index

Destination Port 1030:LCD DISPLAY L030:USER A+ 030:USER B+

e71130:ANALOGUE OUTPUT 1

1-130:ANA0P1+ '140:ANALOGUE OUTPUT 2

1-140:ANA0P2+ ED160:DIGITAL OUTPUTS - 160:DIGOP1+ - 160:DIGOP2+ -160:RELOP1+ - 160:RELOP2+ 160:RELOP3+

OnlAO:FBUS ANLG OUTPUT -1AO:FBA0P1+ 1AO:FBA0P2+

- 1AO:FBA0P3+ -1AO:FBA0P4+ - 1AO:FBA0P5+ 1AO:FBA0P6+

E:71BO:FBUS DGTL OUTPUT -1BO:FBDOP1+ ,-1BO:FBDOP2+ -1BO:FBDOP3+ -1BO:FBDOP4+ -1BO:FBDOP5+ -1BO:FBDOP6+ 7210:SEQUENCING [210:START +

210:ENABLE+ 210:RESET +

E7220:CONDITIONING - 2ZO:SPDREF+ -220:TRQREF+ -220:TRQMDE+ -220:SPDINV+ - 220:TRQINV+ -220:RAMP2 +

ED730:2 TO 1 ASWITCH1 [730:INO +

730:IN1 +

730:SELECT+ 7740:2 TO 1 ASWITCH2 [740:INO +

740:IN1 +

740:SELECT+

Type

analogue/digital

analogue/digital

analogue

analogue

digital

digital

digital

digital

digital

analogue

analogue

analogue

analogue

analogue

analogue

digital

digital

digital

digital

digital

digital

digital

digital

digital

analogue

analogue

digital

digital

digital

digital

analogue

analogue

digital

analogue

analogue

digital

eD'750:2 TO 1 DSWITCH1 [750:INO +

750:IN1 +

750:SELECT+ CJ'760:2 TO 1 DSWITCH2 [760:INO +

760:IN1 +

760:SELECT+ Of:7770:2 TO 1 DSWITCH3 [770:INO +

770:IN1 +

770:SELECT+ e7180:DIGITAL FUNCT1 L780:INO +

780:IN1 +

1790: DIGITAL FUNCT2 L790:INO +

790:IN1 +

e77AO:DIGITAL FUNCT3 L7AO:INO +

7A0:IN1 +

0=BO:MOTORISED POT L7BO:INC +

7B0:DEC +

/7BO:MOTORISED POT L7BO:INC +

7BO:DEC +

e7CO:PRESET SELECT [7C0:SELO +

7CO:SEL1 +

7CO:SEL2 +

e77DO:PID CONTROLLER [7D0:REF +

7DO:F/B +

7D0:OFFSET+ 7D0:ENABLE+

Vf:77E0:SKIP BANDS L7E0:INPUT +

e77FO:COMPARATOR 1

L7FO:INO +

7FO:IN1 +

(77GO:COMPARATOR 2 L7GO:INO +

7GO:IN1 +

e777HO:COMPARATOR 3

L7HO:INO +

7HO:IN1 +

digital

digital

digital

digital

digital

digital

digital

digital

digital

digital

digital

digital

digital

digital

digital

digital

digital

digital

digital

digital

digital

digital

analogue

analogue

analogue

digital

analogue

analogue

analogue

analogue

analogue

analogue

analogue



5.2 Source Port Index Source Port

e77110:ANALOGUE INPUT 1

1-110:ANAIP14 ED120:ANALOGUE INPUT 2

L120:ANAIP24 e7150:DIGITAL INPUTS -150:DIGIP14 - 150:DIGIP24 - 150:DIGIP34 -150:DIGIP44 -150:DIGIP54 150:DIGIP64

E7170:FIELD BUS SETUP 1-170:FBLOSS4

(7180:FBUS ANLG INPUT -180:FBAIP14 -180:FBAIP24 -180:FBAIP34 -180:FBAIP44 -180:FBAIP54 -180:FBAIP64

?190:FBUS DGTL INPUT -190:FBDIP14 -190:FBDIP24 -190:FBDIP34 -190:FBDIP44 -190:FBDIP54 190:FBDIP64

E71CO:SERIAL COMMS -1CO:SCAIP14 -1CO:SCAIP24 - 1CO: SCAIP34 -1CO:SCDIP14 -1CO:SCDIP24 1CO:SCDIP34

07210: SEQUENCING 1:210:START 4

210:RUN 4

®220: CONDITIONING [220:AT SPD4 220:CURLIM4 220:TRQLIM4

Type

analogue

analogue

digital

digital

digital

digital

digital

digital

digital

analogue

analogue

analogue

analogue

analogue

analogue

digital

digital

digital

digital

digital

digital

analogue

analogue

analogue

digital

digital

digital

digital

digital

digital

digital

digital

Index Number

0

2

3

4

5

6

7

34

35

36

37

38

39

40

41

42

43

44

45

46

63

64

65

66

67

68

24

18

17

15

16

E7230:MONITORING -230:FREQ 4

-230:SPEED 4

-230:VOLTS 4

- 230:TORQUE4 -230:MTRCUR4 -230:POWER 4

-230:/FAULT4 -230:INV OL4

C:7420:MOTOR THERMAL L420:MTR OL4 420:MTRTMP4

e=7710:ANALOGUE PRESETS [710:VALUE14 710:VALUE24 710:VALUE34

E7120:DIGITAL PRESETS 720:VALUE14 720:VALUE24 720:VALUE34

e7130:2 TO 1 ASWITCH1 1-730:OUTPUT4 E7740:2 TO 1 ASWITCH2 L740:OUTPUT4 07750:2 TO 1 DSWITCH1 1-750:OUTPUT4 e7760:2 TO 1 DSWITCH2 1-760:OUTPUT4

0:7770:2 TO 1 DSWITCH3 L770:OUTPUT4

07780: DIGITAL FUNCT1 L780:OUTPUT4

e 790:DIGITAL FUNCT2 1-790:OUTPUT4

eD7AO:DIGITAL FUNCT3 I- 7AO:OUTPUT-) 077BO:MOTORISED POT L7BO:OUTPUT4 e 1C0 :PRESET SELECT 1-7CO:OUTPUT4 77DO:PID CONTROLLER [7DO:OUTPUT4 7D0:ERROR 4

7DO:UPIND 4

7D0:LWRIND4 e777E0:SKIP BANDS L7EO:OUTPUT4

e /FO:COMPARATOR 1

L7FO:OUTPUT4 e77GO:COMPARATOR 2

L7GO:OUTPUT4 e77H0:COMPARATOR 3

I- 7HO:OUTPUT-,

analogue 8

analogue 9

analogue 10

analogue 11

analogue 12

analogue 25

digital 19

digital 21

digital 20

analogue 14

analogue 27

analogue 28

analogue

digital 30

digital 31

digital 32

analogue 26

analogue 47

digital 48

digital 49

digital 50

digital 51

digital 52

digital 53

analogue 33

analogue 54

analogue 55

analogue 56

digital 57

digital 58

analogue 59

digital 60

digital 61

digital 62

, .... ..



Umniverter Drive

6. Appendix 2 - Forms

6.1 Interface Configuration Record Field Connections Schematic Title

110: Analogue Input 1

0 Volts

2 2

Z 3 3

4 4 120: Analogue Input 2

0 Volts

del . 5 5

-3_ 6 6

7 7 -'-`2'-r< 130: Analogue Output 1

0 Volts Z 8 8

9 9 <----

140 : Analogue Output 2

0 Volts

L

-3_ 10 10

11 11 ----fl ... o 150:Digital Input 1

150:Digital Input 2

150:Digital Input 3

150:Digital Input 4

150:Digital Input 5

150:Digital Input 6

12 12 $4 o 13 13

14 14 1= $ 4 o 15 15 'il <..i. 16 16

17 17 a? T +24 Volt / 100mA

Common

0 Volts Z 18 18

19 19

20 20 +24 Volt / 10OrnA

0 Volts Z 21 21

22 22 -p-o--- Z

PTC VP

0 Volts 23 23

24 24 -755P2I- Z 150: Digital Output 1

0 Volts 25 25

26 26 --V7I- Z 160: Digital Output 2

()Volts 27 27

21 28 aii

+ Pot. Supply

- Pot Supply

0 Volts

29 29 1 .tri Z 30 30

31 31

122,Il .4"1" Encoder Supply

Encoder A. Encoder A-

Encoder B+

Encoder B-

0 Volts

32 32 NI 33 33

34 34

35 35 36

KO. KO. 160: Relay Output 1 COM COM

N.C. N.C.

N.O. N.O.

160: Relay Output 2 COM COM

N.C. N.C.

KO. NO. 160: Relay Output 3 COM COM

N.C. KC.

OMNI012a

36 Terminal Control Board (Control PCB# 2001-012 Rev B): Refer to Figure 2-5 for the default interface configuration and Figure 1-3 for the interface specifications and the physical layout of the terminals.

NOTE: For 33 Terminal Control Boards (PCB# 2001-012 Rev A) consult factory.



6.2 Commissioning Schedule

Customer: Date/time:

Site: Engineer:

No. Test OK Comments

PRE-POWER

1 visual checks

1.1 no swarf/wire strands

1.2 no physical damage

1.3 clearances

1.4 no conducting debris

1.5 no insulation damage

1.6 no interference

1.7 pcb connections

1.8 wires out of place

1.9 no heat sink air path blockage

1.10 good ventilation

2 POWER CONNECTIONS

2.1 Ll, L2, L3 continuity input

2.2 U, V, W continuity output

2.3 tight connections

2.4 washers used

2.5 correct glanding .

2.6 filter opt. U,V,W in/out

2.7 no short input to input .

2.8 no short input to gnd

2.9 no short opt to gnd

2.10 motor continuity



umniverter unve

3 EARTH CONTINUITY

3.1 earth to motor

3.2 earth to supply

- 3.3 earth to cable shield at drive

3.4 cable shield to motor frame

3.5 earth to filter if fitted

3.6 earth to cabinet

4 INITIAL POWER UP

4.1 check Li, L2, L3 voltages

4.2 fans operating/air direction

4.3 main heatsink fans

4.4 power tray fans

4.5 EDM filter fans (if used)

4.6 free air path

5 INITIAL SET UP

5.1 enter motor details

5.2 set local speed to zero

(020: KBFREQ= 0 . 0 is)

5.3 ensure mode = speed

(02 0 : LOCMDE=S PEED)

5.4 select Vectorque

(2 4 0 : CNTRL =VECTORQUE)

5.5 set switching frequency to high if EDM filter is in use.

NOTE: If frequency is to be changed, set (610: SWFREQ=HIGH), power drive down, wait for dc bus to discharge then re-power the drive.

6 INITIAL RUN (NO-LOAD IF POSSIBLE)

6.1 check motor free to rotate / no people near

6.2 start and check that drive and motor run normally

6.3 increase speed and check direction

6.4 run at 5% 10% 25% 50% 100% (over if required)



6.5 check output current (LCD display), also waveform, level & balance.

6.6 check input current waveform, level & balance

6.7 check motor noise

6.8 check motor vibration

6.9 check motor voltage.

6.10 check motor stability

7 AT LOAD

7.1 check input current waveform, level & balance

7.2 check output current waveform, level & balance (LCD display)

7.3 check EDM filter dc feedback currents (if used)

7.4 run at full load > 10mins

7.5 check temperature (if possible) of connections

7.6 check hot start

8 USER SETUP

8.1 set up user connections and functions as desired

8.2 check digital inputs (in local)

8.3 check digital outputs

8.4 check analogue output scaling

8.5 check analogue input scaling

8.6 set drive in remote and check correct functioning .

8.7 set up LCD display line

8.8 clear any logged faults

8.9 set configuration locks

8.10 record configuration in manual

8.11 test user setup

6



umniverter unve

7. Appendix 3 - Omniverter Dimensional Drawings See document 4807005 for dimensional drawings.



Umniverter Drive

8. Appendix 4 - Omniverter Recommended Spares

Qty 1 Item No Ancillary Parts

1

1

Basic Maintenance Kit

I Description

0118-611

0118-612

Omniverter Blanking Plate - Yellow

Omniverter Panel Mount Display Surround Kit

1 0118-601 160mm 230Vac main fan

1 0118-602 120mm 24Vdc fan

3 0118-603 350A 660V DIN semiconductor fuse (per module)

5 0118-604 1A 20x5mm 250Vac glass fuse



5 0118-607 2A 32x6.3mm 440Vac ceramic fast fuse

5 0118-608 WA 32x6.3mm 440Vac ceramic fast fuse

Basic Electronic Service Kit Single Module Drive (plus above items)

0100 Control Electronics Spare

0109 Power Electronics - 1 module spare

1 0106 Display Module Spare

Basic Electronic Service Kit Multiple Module Drive (plus above items)

1 0100 Control Electronics Spare

1 0105 Power Electronics - 2 module or larger Omniverter

1 0106 Display Module Spare

Full Electronic Service Kit (plus above items)

1 0101 (capacitor board) Bus PCB - spare

1 0102 Gate Link PCB - spare

3 0103 Gate Select PCB (1 ea per phase) - spare

1 0104 Soft Charge PCB

1 0108 Output Capacitor Board

3 0118-609 SKKH122-12E input rectifier

6 0118-610 SKM200GB123D output IGBT module

5 Yearly Maintenance Kit (per module)

1 0118-601 160mm 230Vac main fan

1 0118-602 120mm 24Vdc fan

1 0101 (capacitor board) Bus PCB - spare



umniverter urive

9. Appendix 5 - Omniverter Fan On/Off Control Suggested wiring for applications in which it is desirable to disable the main fans when the

Omniverter is not running.

Ja

g < E z 3 ce. -

= c Z000 a.

aM8MMEI 0 0 0 0

UMOJ8

Uia.10/UODJO

onmanis

11/#60J8

UCHUO/UilitlEt

0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0

anis

UMOJEUKILIAA

432113101111M -

UMOJEIrdMILMA

1

t /I /I 1 g

3 to 3 - "

11 It I 1$11$//i 1 ! i If g

lailgia.a1111111u4hglgiAliiiil

onig

1

Ill II 11111

0

D O

X 1,1

c 0 IP t.

5 -

C C w

01 c c g

tJ L ,

0

AAA

C.)

E C) Z C.)

r,

C) 3 0 C)

6:

c- o c 2

cl 0

o 00

a

E

z

U

5

C.

9

8

I

I

C.

4 C.



(miniver-ter Drive

10. Appendix 6 - Field Bus I/O Map The following table documents the way in which the I/O memory of the field bus hardware is assigned. Output consists of a Drive Status section, six analogue outputs and six digital outputs. Input is divided into six analogue inputs and six digital inputs. This mapping is independent of the specific field bus in use (ie. DeviceNet, lnterbus-S etc.).

10.1 From Omniverter to Field Bus Byte Offset

Title Description Data Type

0 Status Code (see 10.3 following) unsigned byte

1 Type Code (see 10.4 following) unsigned byte

2 170 : ENABLE Module State (see 10.5 following) BOOLEAN - unsigned byte

3 Reserved unsigned byte

Table 10-1 Status outputs from the Omniverter to the field bus

Byte Offset

Title Description Default Connection

Data Type

4 1A0 : FBAOP 1 4- FB Analogue Output 1 230: SPEED signed 16 bit word'

6 1A0 : FBAOP24- FB Analogue Output 2 230 :MTRCUR signed 16 bit word*

8 1A0 : FBA0P3<- FB Analogue Output 3 signed 16 bit word*

10 1A0 : FBA0P4(- FB Analogue Output 4 signed 16 bit word'

12 1A0 : FBAOP 54- FB Analogue Output 5 signed 16 bit word'

14 1A0 : FBAOP 6+. FB Analogue Output 6 signed 16 bit word'

Table 10-2 Analogue outputs from the Omniverter to the field bus

* Word storage uses the Intel convention - the low byte is stored first, the high byte is stored second. Analogue values are

normalised to 2^13 (8192, 2000h) eg. +100% = +8192 (2000h), -100% = -8192 (E000h).

Byte Offset


Data Type

16 1B0 : FBDOP1+ FB Digital Output 1 210: RUN BOOLEAN - unsigned byte

17 1B0 : FBDOP24 FB Digital Output 2 420:MTR OL BOOLEAN - unsigned byte

18 1B0 : FBDOP34 FB Digital Output 3 230:/FAULT BOOLEAN - unsigned byte

19 1B0 : FBDOP44 FB Digital Output 4 BOOLEAN - unsigned byte

20 1B0 : FBDOP54 FB Digital Output 5 BOOLEAN - unsigned byte

21 180: FBDOP64 FB Digital Output 6 BOOLEAN - unsigned byte

Table 10-3 Digital outputs from the Omniverter to the field bus



10.2 From Field Bus to Omniverter Byte Offset


Data Type

0 18 0 : FBAI P13 FB Analogue Input 1 signed 16 bit word' 2 18 0 : FBAI P24 FB Analogue Input 2 signed 16 bit word' 4 18 0 : FBAI P34 FB Analogue Input 3 signed 16 bit word' 6 180: FBAI P44 FB Analogue Input 4 signed 16 bit word' 8 18 0 : FBAI P 54 FB Analogue Input 5 signed 16 bit word'

10 180: FBAI P64 FB Analogue Input 6 signed 16 bit word'

Table 10-4 Analogue inputs to the Omniverter from the field bus

* Word storage uses the Intel convention - the low byte is stored first, the high byte is stored second. Analogue values are normalised to 2'13 (8192, 2000h) eg. +100% = +8192 (2000h), -100% = -8192 (E000h).

Byte Offset


Data Type

12 190:FBDIP14 FB Digital Input 1 BOOLEAN - unsigned byte 13 190:FBDIP24 FB Digital Input 2 BOOLEAN - unsigned byte 14 1 9 0 : FBDI P34 FB Digital Input 3 BOOLEAN - unsigned byte 15 190:FBDIP44 FB Digital Input 4 BOOLEAN - unsigned byte 16 190:FBDIP54 FB Digital Input 5 BOOLEAN - unsigned byte 17 190: FBDI P64 FB Digital Input 6 BOOLEAN - unsigned byte

Table 10-5 Digital inputs to the Omniverter from the field bus

10.3 Status Code Code Number

0

1

2

3

Description OFF

RUN

STOPPING

FAULT

'



Omniverter Drive

10.4 Type Code Code Number

Hex Dec Description

0 0 (no type applicable)

1 1 U+ DESAT

2 2 U- DESAT

3 3 V+ DESAT

4 4 U- DESAT

5 5 W+ DESAT

6 6 W- DESAT

7 7 CRNT TRIP

8 8 BRK DESAT

9 9 (reserved)

10 A (reserved)

11 B DCV HIGH

12 C LVDC LOW

13 D (reserved)

14 E (reserved)

15 F GROUND

16 10 INV OL

17 11 INV THERM

18 12 MOTOR OL

19 13 MOTOR PTC

20 14 BRK OL

21 15 DC RIPPLE

22 16 (reserved)

23 17 (reserved)

24 18 OVER SPD

25 19 (reserved)

26 1A (reserved)

27 1B (reserved)

28 1C (reserved)

29 1D KB LOST

30 1 E (reserved)

31 1F READY

32 20 HOLD

33 21 CONFIG

34 22 DCV LOW WARNING

35 23 INV OL WARNING

36 24 MOTOR OL WARNING

37 25 CRNT LIM WARNING

38 26 TRQ LIMIT WARNING

See Section 3.5 for explanations of fault types.

10.5 Module State This flag indicates whether the Field Bus module in the Omniverter Drive is enabled (TRUE = 01), or

disabled (FALSE = 00). Modules such as the Field Bus or Motorised POT, for example, can be

disabled if they are not required. If this flag is FALSE, then the Drive will not respond to any input

from the Field Bus and will not update output to the Field Bus. The Field Bus module cannot be

enabled from the Field Bus but it must be enabled from the Omniverter display.

.. .



uminvener LJIIVe

11. Appendix 7 - Serial Communications

11.1 Connecting the Host to the Omniverter A host computer or PLC may control the Omniverter (speed ref, start/stop etc) as well as read and edit the values of parameters.

Connection between a personal computer and the Omniverter via an RS232C link is detailed in Table 11-1. Note that the transmit and receive wires must be swapped in a null modem configuration.

PC Host DB9 Omniverter DB9

Desc. Pin Pin Desc.

TxD

RxD

GND

3

2

5

2

3

5

TxD

RxD

GND

Table 11-1 RS232C serial communications connections

The data format used is:

7 data bits 1 start bit 1 stop bit even parity 9600 baud

11.2 Protocol Details The character-oriented protocol used is industry standard ANSI x 3.28 - 2.5 - A4. Control characters used in messages to and from the Omniverter are listed in Table 11-2. Their use in messages to the Omniverter is explained further in sections 11.3 and 11.4.

Character Purpose ASCII code (HEX)

Control Key

EOT End Of Transmission 04 D

New message begins

ENQ Enquiry 05 E

STX Start of Text 02 B

ETX End of Text 03 C

ACK Acknowledge 06 F

NAK Negative Acknowledge 15 U

(message understood)

Table 11-2 Control characters used in communication with the Omniverter

11.2.1 Serial Address Code

An Omniverter requires a unique serial address code. This four-digit code consists of two repeated digits. The first two repeated digits designate the drive group (1 to 9) while the second two repeated digits designate the drive address (1 to 9). So for an Omniverter in group 1, address 2 the serial address code would be '1122'.



11.2.2 Parameter Identifier

When sending a command or an enquiry to an Omniverter, the four digit parameter identifier field determines which parameter or module port is being addressed. For a list of all parameter identifiers refer to section 11.5.

11.2.3 Block Checksum Character (BCC)

To provide additional security against corrupted transmissions a block checksum character must be included in each command send to the Omniverter. A BCC is also included in the Omniverter reply to an enquiry. The following example in Table 11-3 illustrates hOw the BCC value is calculated frr5rn the ASCII codes of the characters in the parameter and data fields of the example in Figure 11-2.

Character ASCII Code XOR result

1 011 0001

0 011 0000 0000 0001

6 011 0110 0011 0111

8 011 1000 0000 1111

010 1101 0010 0010

8 011 1000 0001 1010

9 011 1001 0010 0011

010 1110 0000 1101

3 011 0011 0011 1110

ETX 000 0011 0011 1101

011 1101

Table 11-3 BCC example calculation for a serial message

NOTE: If the decimal value of the BCC is less than 32 then 32 must be added to the BCC.

11.3 Sending an enquiry If a parameter value is required or information about a configuration connection is required then the host should send a message using the enquiry structure illustrated in Figure 11-1. Refer to Table 11- 2 for a list of control characters. Note that no block checksum character is required in an enquiry.

Control Address code character

EOT 2 2

Parameter Identifier Control character

0 6 8 ENQ

Figure 11-1 Structure of an enquiry from the host to the Omniverter

The structure of an Omniverter reply to an enquiry takes the format shown in Figure 11-2. Note that this includes a block checksum character.

Control Parameter Identifier Data Field Control Block

character character Checksum (BCC)

STX 0 6 9 3 ETX

Figure 11-2 Structure of the reply from the Omniverter to an enquiry from the host

When an enumerated parameter (ie. a parameter which displays a word in the LCD display data field eg. '220:STRMDE= SPIN') is being queried, the Omniverter will return an index number in the data



umnivener urive field. In Section 11.5 each enumerated parameter lists the index numbers for each of the selections which are displayed on the LCD display eg. 0=NORMAL, 1=SPIN.

Module connections are completely defined by the connections made to destination ports (module inputs). When using the serial communications interface to the Omniverter only destinatipn ports can be queried. Only one connection can be made to a destination port and this connection can be

queried by the host using the destination port's parameter identifier in the enquiry format of Figure 11-1 eg. section 11.5 lists 220:SPDREF as having a parameter identifier of 2024. The Omniverter will reply with an index number in the data field corresponding to the source port of this connection eg. 0=110ANAIP1. The source port can be determined from this index number by looking up the table in Section 11.5.2.

11.4 Sending a command To change a parameter or module connection the host should send a command to the Omniverter using the format shown in Figure 11-3. The parameter identifiers for all available parameters and module destination ports are listed in section 11.5, along with the parameter identifiers for the various status indicators and predefined meters.

Control ti Control Control Address code Parameter Identifier Data Field

character character character

EOT 2 2 [STX 0 6 8 8 9 3 ETX

Block Checksum

(BCC)

Figure 11-3 Structure of commands from the host to the Omniverter

When changing an enumerated parameter (ie. a parameter which displays a word in the LCD display data field eg. 220:STRMDE=SP1N), the index number of the desired selection should be sent in the data field, not the actual text of the label eg. to select 'SPIN' from the start modes available for '220:STRMDE' the data field should contain the index number '1'. The index number of each selection can be found by looking up the parameter in section 11.5.

Module connections are completely defined by the connections made to destination ports (module inputs). When using the serial communications interface to the Omniverter only destination ports can be changed. Only one connection can be made to a destination port and this connection can be

changed by the host using the destination port's parameter identifier in the command format of Figure 11-3 eg. 220:SPDREF has a parameter identifier of 2024. The host should specify the index number in the data field corresponding to the source port of this connection eg. 0=110ANAIP1. The source port's index number can be found by looking up the table in Section 5.2.

11.4.1 Omniverter Reply to a command

When a command is addressed to an individual Omniverter, it will reply with an 'ACK' control character (ie. acknowledge) if the command was completed successfully, or a `NAK' control character (ie. negative acknowledge) if the command was not completed successfully. To determine why the command was unsuccessful the host should query the Omniverter serial communications status parameter '0000'. The index number returned by the Omniverter will indicate which of the errors in Table 11-4 in section 11.5.1 has occurred.

When a command is addressed to all drives or to a group of drives, the Omniverter will not send a

reply.



11.5 Table of Parameter Identifiers Status Title

OMNI COMMS STATUS 1

OMNI DRIVE STATUS " OMNI STATUS TYPE 1"

Parameter

Identifier

0000 0001 0002

Meter Title (see Section 4 for

information about meters)

FREQUENCY CURRENT SPEED REF SPEED TORQUE REF TRQ BUS VOLTS OUT VOLTS POWER MOTOR TMP kWh INV ON MOTOR RUN USER A USER B

030:LINE Index Numbers

0 1

2 3

4

5

6

7

8

9

10 11

12 13

14

Parameter Identifier

0003 0004 0005 0006 0007 0008 0009 0010 0011 0012 0013 0014 0015 0016 0017

Menu Title Index Numbers Parameter Identifier

1000:MENU CONFIG - 7010 :LOCKS

010:CONFIG= 0=UNLOCK 1=LOCK

010:USER = 0=UNLOCK 1=LOCK

010:FCTRY =

1000

1001

1002

-E020:LOCAL CONTROL -020:LOCREM= 0=LOCAL 1003

1=REMOTE -020:LOCMDE= 0=SPEED 1004

1=TORQUE -020:KBFREQ= -020:KBTORQ= -020:KB S/R= 0=LOC ONLY

1=LOC & REM -020:EXTS/R= 0=REM ONLY

1=LOC & REM

1030:LCD DISPLAY 030:LINE2 = iv

030:LINE3 = iv

030:LINE4 = iv

030:USER A4- *

030:USER B4-*

1005 1006 1007

1008

1009 1010 1011 2000 2001

Refer to Section 11.5.1 for a list of comms index numbers.

II Refer to Section 10.3 for a list of drive status index numbers.

iiiRefer to Section 10.4 for a list of drive status type index numbers.

iv Refer to the Meter parameters above for a list of 030:LINE index numbers.

Refer to Section 5.2 for a list of source port index numbers.

....... .

7100:INTERFACE e7110:ANALOGUE INPUT 1

-110:TYPE = 0=CURRENT 1012 1=VOLTAGE

-110:LOW = 1013 -110:HIGH = 1014 -110:ANAIP14 -110:ANAIP1= 1015

-C-120:ANALOGUE INPUT 2


-120:LOW = 1017 -120:HIGH = 1018 -120:ANAIP24 -120:ANAIP2= 1019

-e:7130:ANALOGUE OUTPUT 1


-130:LOW = 1021 130:HIGH = 1022

-130:ANA0P14- * 2002 130:ANA0P1= 1023

0-140:ANALOGUE OUTPUT 2

140:TYPE = 0=CURRENT 1024 1=VOLTAGE

140:LOW = 1025 140:HIGH = 1026 140:ANA0P24- * 2003 140:ANA0P2= 1027

C,150: DIGITAL INPUTS -150:DIGIP1-, -150:DIGIP1= 0=FALSE

1=TRUE -150:DIGIP24 -150:DIGIP2= 0 =FALSE

1=TRUE -150:DIGIP3e -150:DIGIP3= 0=FALSE

1=TRUE -150:DIGIP49 -150:DIGIP4= 0=FALSE

1=TRUE -150:DIGIP54 -150:DIGIP5= 0=FALSE

1=TRUE -150:DIGIP64 150:DIGIP6= 0=FALSE

1=TRUE

1028

1029

1030

1031

1032

1033

-e7160:DIGITAL OUTPUTS -160:DIGOP14- * 2004 -160:DIGOP1= 0=FALSE 1034

1=TRUE -160:DIGOP24- * 2005 .160:DIGOP2= 0=FALSE 1035

1=TRUE -160:RELOP14- * 2006 -160:RELOP1= 0=FALSE 1036

1=TRUE



160:RELOP2+ * 160:RELOP2= 0=FALSE

1=TRUE 160:RELOP34- *

2007 1037

2008

-71130:FBUS

umnivener urive DGTL OUTPUT

-1BO:FBDOP14- * 2015 -1BO:FBDOP1= 0=FALSE 1060

1=TRUE

160:RELOP3= 0=FALSE 1038 -180:FBDOP2+ * 2016 1=TRUE -1BO:FBDOP2= 0 =FALSE 1061

1=TRUE

-1170:FIELD BUS SETUP -1BO:FBDOP34- * 2017

170:ENABLE= 0=FALSE 1039 -1BO:FBDOP3= 0=FALSE 1062 1=TRUE 1=TRUE

170:FBTRIP= 0=FALSE 1040 -1BO:FBDOP44-* 2018 1=TRUE -1BO:FBDOP4= 0=FALSE 1063

170:FBLOSS4 1041 1=TRUE

170:FBLOSS= 0=FALSE 1042 -1BO:FBDOP54- * 2019 1=TRUE -1B0:FBDOP5= 0=FALSE 1064

1=TRUE

E:7180: FBUS ANLG INPUT -1BO:FBDOP64-* 2020 -180: FBAIP1 4 1BO:FBDOP6= 0=FALSE 1065

-180: FBAIP1= 1043 1=TRUE

-180: FBAIP2 4 -180: FBAIP2= 1044 ED1C0:SERIAL COMMS -180: FBAIP3 4 -1CO:STATUS= 1066

-180: FBAI P3= 1045 -1CO:ADDRSS= 1067

-180: FBAI P4 4 -1CO:SCAIP14 -180: FBAIP4= 1046 -1CO:SCAIP1= 1068

-180: FBAI P5 4 -1CO:SCAIP24 180: FBAIP5= 1047 1CO:SCAIP2= 1069

180: FBAI P64 1CO:SCAIP34

180: FBAIP6= 1048 1CO:SCAIP3= 1070 1CO:SCDIP14

-'190:FBUS DGTL INPUT 1CO:SCDIP1= 0=FALSE 1071

190:FBDIP14 1=TRUE -190:FBDIP1= 0=FALSE 1048 1CO:SCDIP24

1=TRUE 1CO:SCDIP2= 0=FALSE 1072

190:FBDIP24 1=TRUE 190:FBDIP2= 0 =FALSE 1049 1CO:SCDIP34

1=TRUE 1CO:SCDIP3= 0=FALSE 1073

190:FBDIP34 1=TRUE

-190:FBDIP3= 0 =FALSE 1050 1=TRUE /200: CONTROLLER

190:FBDIP44 -E7210:SEQUENCING 190:FBDIP4= 0=FALSE 1051 -210:STRMDE= 0=NORMAL 1074

1=TRUE 1=SPIN 190:FBDIP54 -210:STPMDE= 0=NORMAL 1075

190:FBDIP5= 0=FALSE 1052 1=SPIN 1=TRUE 2=COAST

190:FBDIP64 -210:START 4-* 2021

190:FBDIP5= 0=FALSE 1053 -210:START = 0=FALSE 1076

1=TRUE 1=TRUE -210:ENABLE+ * 2022

:71A0: FBUS ANLG OUTPUT -210:ENABLE= 0=FALSE 1077

-1A0: FBA0P14- * 2009 1=TRUE

-1A0: FBA0P1= 1054 -210:RESET F * 2023

- 'AO : FBA0P24- * 2010 -210:RESET = 0=FALSE 1078

-1A0: FBA0P2= 1055 1=TRUE

-1A0 : E1BAOP34- * 2011 -210:START 4

-1A0: FBA0P3= 1056 -210:START = 0=FALSE 1079

-1A0: FBA0P44- * 2012 1=TRUE

-1A0: FBA0P4= 1057 -210:RUN 4

-1A0: FBA0P54- * 2013 -210:RUN = 0=FALSE 1080

-1A0: FBA0P5= 1058 1=TRUE

-1A0: FBA0P6 * 2014

1AO: FBA0P6= 1059 I Refer to Section 11.5.1 for a list of comms index numbers.



'300: FAULT INFO C7220:CONDITIONING E7310: FAULT LOG 220:TRQLIM= 1081 -310:FAULT1= 1108 220:LWRSPD= 1082 -310:FAULT2= 1109 220:UPSPD = 1083 -310:FAULT3= 1110 220:ACCEL1= 1084 -310:FAULT4= 1111 220:DECEL1= 1085 -310:FAULT5= 1112 220:ACCEL2= 1086 -310:FAULT6= 1113 220:DECEL2= 1087 -310:FAULT7= 1114 220:SPDREF4 * 2024 -310:FAULT8= 1115 220:SPDREF= 1088 310:FAULT9= 1116

-220:TRQREF4- * 2025 220:TRQREF= 1089 -CD320:AUTO RESET 220:TRQMDE4-* 2026 1117 -220:TRQMDE= 0=FALSE

[320:NUMBER= 1090 320:DELAY = 1118

1=TRUE 320:PERIOD= 1119 -220:SPDINV4-* 2027 -220:SPDINV= 0=FALSE 1091 E7400:MOTOR

1=TRUE C7410:MOTOR NAMEPLATE -220:TRQINV4- * 2028 410:VOLTS = 1120 -220:TRQINV= 0=FALSE 1092 -410:AMPS = 1121

1=TRUE -410:POWER = 1122 -220:RAMP2 (-* 2029 -410:RPM = 1123 -220:RAMP2 = 0=FALSE 1093 -410:FREQ = 1124

1=TRUE -220:AT SPD4 7420:MOTOR THERMAL -220:AT SPD= 0=FALSE 1094 -420:F COOL= 0=OFF 1125

1=TRUE 1=ON -220:CURLIM4 420:STRTIM= 1126 -220:CURLIM= 0=FALSE 1095 420:TRIP = 0=OFF 1127

1=TRUE 1=ON -220:TRQLIM4 420:MTR OL4 -220:TRQLIM= 0=FALSE 1096 420:MTR OL= 0=FALSE 1128

1=TRUE 1=TRUE 420:MTRTMP4

-07230:MONITORING 420:MTRTMP= 0=FALSE 1129 -230:FREQ 4 1=TRUE -230:FREQ = 1097 -230:SPEED 4 -E7430:MOTOR MODEL -230:SPEED = 1098 430:RS = 1130 -230:VOLTS 4 430:RR = 1131 -230:VOLTS = 1099 430:IMAG = 1132 -230: TORQUE-, 430:LKG = 1133 -230:TORQUE= 1100 -230:MTRCUR4 7500:VECTOR CONTROL -230:MTRCUR= 1101 -7510:SETTINGS -230:POWER 4 510:HOIST = O =OFF 1134 -230:POWER = 1102 1=ON -230: /FAULT- 0=FALSE 510:IBOOST= 1135

1=TRUE 510:J COMP= 1136 -230:/FAULT= 1103 510:FWK PT= 1137 -230:INV OL4 230:INV OL= 0=FALSE 1104 e7520:GAINS

1=TRUE -520:WLPKP = 1138 -520:WLPKI = 1139

C7240:0PERATING MODES -520:WLPKD = 1140 240:CNTRL = 0=V/Hz 1105 -520:PHLPKP= 1141

1=VECTORQUE -520:PHLPKI= 1142 240:LOAD = 0=CONST TRQ 1106 -520:FRLPKP= 1143

1=VAR TRQ -520:FRLPKI= 1144 240:LVTRIP= 0=OFF 1107

1=ON ' Refer to Section 10.4 for a list of drive status type index numbers.



}-520:ILPKP = 520:ILPKI =

0600:INVERTER 1610:WAVEFORM L-610:SWFREQ= 0=LOW

1=HIGH

C-620:CALIBRATION 620:CTSCLE= 620:RATING= 620:TSTMDE= 0=FALSE

1=TRUE 620:VER =

- 2630:DYNAMIC BRAKE [630:DBDUTY= 630:TIME =

630:ENABLE= 0 -FALSE 1=TRUE

7700:SPECIAL FUNCTION -E,710:ANALOGUE PRESETS -710:VALUE1= -710:VALUE2= -710:VALUE3= -710:VALUE14 -710:VALUE24 -710:VALUE34

-E:7720:DIGITAL PRESETS -720:VALUE1= 0=FALSE

1=TRUE -720:VALUE2= 0=FALSE

1=TRUE -720:VALUE3= 0=FALSE

1=TRUE -720:VALUE14 -720:VALUE24 -720:VALUE34

-en730:2 TO 1 ASWITCH1 -730:INO + *

-730:INO = -730:IN1 F *

-730:IN1 = -730:SELECT+ * -730:SELECT= 0=FALSE

1=TRUE -730:OUTPUT4 730:OUTPUT=

-740:2 TO 1 ASWITCH2 -740:INO + *

-740:INO =

-740:IN1 4-*

-740:IN1 =

-740:SELECT+ * -740:SELECT= 0=FALSE

1=TRUE 740:OUTPUT4 740:OUTPUT=

umniverter unve

1145 -750:2 TO 1 DSWITCH1 1146 -750:INO 4- *

-750:INO = 0=FALSE 1=TRUE

-750:IN1 4-*

1147 -750:IN1 = 0=FALSE 1=TRUE


1148 1=TRUE 1149 -750:OUTPUT-, 1150 -750:OUTPUT= 0=FALSE

1=TRUE 1151

- 1760:2 TO 1 DSWITCH2 -760:INO 4-*

1152 -760:INO = 0=FALSE 1153 1=TRUE 1154 -760:IN1 4-*

-760:IN1 = 0=FAISE 1=TRUE


1155 1=TRUE 1156 -760:OUTPUT-) 1157 '760:OUTPUT= 0=FALSE

1=TRUE

1158

1159

1160

2030 1161 2031 1162 2032 1163

1164

2033 1165 2034 1166 2035 1167

1168

E7770:2 TO 1 DSWITCH3 770:INO 4- *

770:INO = 0=FALSE 1=TRUE

770:IN1 4- *

770:IN1 = 0=FALSE 1=TRUE

770:SELECT+ * 770:SELECT= 0=FALSE

1=TRUE 770:OUTPUT4 770:OUTPUT= 0=FALSE

1=TRUE

E7780:DIGITAL FUNCT1 -780:0P = 0=AND

1=OR 1=XOR

-780:INVINO= 0=FALSE 1=TRUE

-780:INVIN1= 0=FALSE 1=TRUE

-780:INVOUT= 0=FALSE 1=TRUE

-780:INO 4-*

-780:INO = 0=FALSE 1=TRUE

-780:IN1 + *

-780:IN1 = 0=FALSE 1=TRUE

-780:OUTPUT-) 780:OUTPUT= 0=FALSE

1=TRUE

2036 1169

2037 1170

2038 1171

1172

2039 1173

2040 1174

2041 1175

1176

2042 1177

2043 1178

2044 1179

1180

1181

1182

1183

1184

2045 1184

2046 1186

1187



-7790:DIGITAL FUNCT2 -7CO:SELO 4- 2053 -790:0P = 0=AND 1188 -7CO:SELO = 0=FALSE 1217

1=OR 1=TRUE 1=XOR -7CO:SEL1 * 2054

-790:INVINO= 0=FALSE 1189 -7CO:SEL1 = 0=FALSE 1218 1=TRUE 1=TRUE

-790:INVIN1= 0=FALSE 1190 -7CO:SEL2 4-* 2055 1=TRUE -7CO:SEL2 = 0=FALSE 1219

-790:INVOUT= 0=FALSE 1191 1=TRUE 1=TRUE -7CO:OUTPUT4

-790:INO 4-* 2047 7CO:OUTPUT= 1220 790:INO = 0=FALSE 1192

1=TRUE -ED7DO:PID CONTROLLER 790:IN1 4- 2048 7DO:ENABLE= 0=FALSE 1221 790:IN1 = 0=FALSE 1193 1=TRUE

1=TRUE ,-7DO:MODE = 0=PI 1222 790:OUTPUT4 1=PID 790:OUTPUT= 0=FALSE 1194 7DO:KP 1223

1=TRUE 7DO:WITS = 1224 7DO:WDTS = 1225

17AO:DIGITAI FUNCT3 7DO:UPLIM = 1226 7A0:0P = 0=AND 1195 7DO:LWRLIM= 1227

1=OR 7DO:KSP = 1228 1=XOR 7DO:TS = 0=10ms 1229

7AO:INVINO= 0=FALSE 1196 1=100ms 1=TRUE 2=ls

7AO:INVIN1= 0=FALSE 1197 3=10s 1=TRUE 7D0: REF 4- * 2056

7AO:INVOUT= 0=FALSE 1198 7DO:REF 1230 1=TRUE 7DO:F/B F 2057

7AO:INO F * 2049 7DO:F/B 1231 7AO:INO = 0=FALSE 1199 7DO:OFFSET+ * 2058

1=TRUE 7DO:OFFSET= 1232 7AO:IN1 F * 2050 7DO:ENABLE4- * 2059 7AO:IN1 = 0=FALSE 1200 7DO:ENABLE= 0=FALSE 1233

1=TRUE 1=TRUE 7AO:OUTPUT4 7DO:OUTPUT4 7AO:OUTPUT= 0=FALSE 1201 7DO:OUTPUT= 1234

1=TRUE 7DO:ERROR 4

7DO:ERROR = 1235 77BO:MOTORISED POT 7DO:UPIND 4 -7BO:ENABLE= 0=FALSE 1202 7DO:UPIND = 0 =FALSE 1236

1=TRUE 1=TRUE -7BO:UPLIM = 1203 -7DO:LWRIND4 -730:LWRLIM= 1204 -7DO:LWRIND= 0=FALSE 1237 -7BO:TIME = 1205 1=TRUE -7BO:INC 4-

* 2051 -7BO:INC = 0=FALSE 1206 -0-7E0:SKIP BANDS

1=TRUE -7E0:ENABLE= 0=FALSE 1238 -7BO:DEC 4-

* 2052 1=TRUE -780:DEC = 0=FALSE 1207 -7E0:VALUE1= 1239

1=TRUE -7E0:BAND1 = 1240 -7BO:OUTPUT4 -7E0:VALUE2= 1241 -7BO:OUTPUT= 1208 -7E0:BAND2 = 1242

-7E0:VALUE3= 1243 -e77CO:PRESET SELECT -7E0:BAND3 = 1244 -7CO:VALUE1= 1209 -7E0:VALUE4= 1245 -7CO:VALUE2= 1210 -7E0:BAND4 = 1246 -7CO:VALUE3= 1211 -7E0:INPUT 4-* 2060 -7CO:VALUE4= 1212 -7E0:INPUT = 1247 -7CO:VALUE5= 1213 -7E0:OUTPUT4 -7CO:VALUE6= 1214 -7E0:OUTPUT= 1248 -7CO:VALUE7= 1215 -7CO:VALUE8= 1216



IJIIVe

e,7FO:COMPARATOR 1 7GO:IN1 f * 2064

7FO:BAND = 1249 7G0:IN1 = 1255

7FO:INO 4- * 2061 7GO:OUTPUT4

7FO:INO 1250 7GO:OUTPUT= 0=FALSE 1256

7FO:IN1 2062 1=TRUE

7FO:IN1 1251

7FO:OUTPUT4 E=77HO:COMPARATOR 3

7F0:OUTPUT= 0=FAISE 1252 -7HO:BAND = 1257

1=TRUE -7HO:INO f* 2065 -7HO:INO = 1258.

-e777GO:COMPARATOR 2 -7HO:IN1 f° 2066

= 1253 -7HO:IN1 = 1259 [7GO:BAND 7G0:INO ++ 2063 -7HO:OUTPUT4 7GO:INO = 1254 7HO:OUTPUT= 0=FALSE 1260

1=TRUE



11.5.1 Omniverter Serial Communications Status Index Numbers

Index Number Serial Communications Status

0 OK

2 RANGE ERR

3 NO PRMTR

5 OVRUN ERR

6 FRAME ERR

7 PARITY ERR

8 BCC ERR

9 CONFG ERR

10 USER LCK

11 DRIVE LCK

12 FCRTY LCK

13 BAD PORT

14 READ ONLY

Description

No error.

The value specified in a command is outside the allowable range for that parameter.

No parameter matching the specified parameter number exists.

A character could not be received by the Omniverter because the receive buffer had not been

cleared.

A framing error occurred. The stop bit was not detected.

A receive parity error occurred. Even parity is expected.

Block Checksum Character error. The block checksum character sent in the command did not

match that calculated by the Omniverter.

The configuration lock is active so the requested connection change between modules is not

allowed.

The user lock is active so the requested change in parameter value is not allowed.

The drive is running so the requested change in parameter value is not allowed until the drive

has stopped.

The factory lock is active so the requested change in parameter value is not allowed.

The port specified in a requested connection change is incompatible ie. an analogue port should

be connected to an analogue port, a digital port should be connected to a digital port.

The requested change in parameter value is not allowed because the parameter is a read-only

parameter such as a meter.

Table 11-4 Omniverter serial communications status index numbers and descriptions



11.5.2 Omniverter Source Port Index Numbers

Index Number

Source Port Type

En110:ANALOGUE INPUT 1

0 L110:ANAIP14 analogue


1 I-120:ANAIP24 analogue

En150:DIGITAL INPUTS 2 -150:DIGIP14 digital

3 -150:DIGIP24 digital





En230:MONITORING 8 -230:FREQ 4 analogue

9 -230:SPEED 4 analogue

10 -230:VOLTS 4 analogue

11 -230:TORQUE4 analogue

12 -230:MTRCUR4 analogue

:7420:MOTOR THERMAL 14 I-420:MTRTMP4 analogue

E7220:CONDITIONING 15 220:CURLIM4 digital

16 220:TRQLIM4 digital

17 220:AT SPD4 digital

En210:SEQUENCING 18 L210:RUN 4

n230:MONITORING digital

19 I-230:/FAULT4 digital

En420:MOTOR THERMAL 4 I-420:MTR OL4 digital

7230:MONITORING 21 L230:INV OL4 digital

8210: SEQUENCING 24 L210:START 4 digital

En230:MONITORING 25 L-230:POWER 4 analogue

:7730:2 TO 1 ASWITCH1 4 L730:OUTPUT4 analogue

E7710:ANALOGUE PRESETS 27 710:VALUE14 analogue

28 710:VALUE24 analogue

29 710:VALUE34 analogue

1720:DIGITAL PRESETS 30 720:VALUE14 digital

31 720:VALUE24 digital

32 720:VALUE34 digital

ED/BO:MOTORISED POT 33 L7BO:OUTPUT4 analogue

7170:FIELD BUS SETUP 34 I-170:FBLOSS4 digital

1180:FBUS ANLG INPUT I-180:FBAIP14 analogue

36

37

38

40

ulmilveiter unve

-180:FBAIP24 -180:FBAIP34 180:FBAIP44 180:FBAIP54 180:FBAIP64

En190:FBUS DGTL INPUT

analogue

an4logu

analogue

analogue

analogue

41 -190:FBDIP14 digital


43 190:FBDIP34 digital




E1740:2 TO 1 ASWITCH2 47 1-740:OUTPUT4 analogue

E7750:2 TO 1 DSWITCH1 48 1-750:OUTPUT4 digital

En760:2 TO 1 DSWITCH2 49 L760:OUTPUT4 digital

E7770:2 TO 1 DSWITCH3 50 L770:OUTPUT4 digital

En780:DIGITAL FUNCT1 51 L780:OUTPUT4 digital

En790:DIGITAL FUNCT2 52 1-790:OUTPUT4 digital

En/AO:DIGITAL FUNCT3 53 1-7AO:OUTPUT4 digital

En7C0 :PRESET SELECT 54 L7CO:OUTPUT4 analogue

L77DO:PID CONTROLLER 55 7DO:OUTPUT4 analogue

56 7D0: ERROR 4 analogue

57 7D0:UPIND 4 digital

58 7D0 :LWRIND4 digital

O77E0:SKIP BANDS 59 L7E0:OUTPUT4 analogue

En7FO:COMPARATOR 1

60 L7FO:OUTPUT4 digital

E77GO:COMPARATOR 2

61 L7GO:OUTPUT4 digital

77HO:COMPARATOR 3 62 L7HO:OUTPUT4 digital

71CO:SERIAL COMMS 63 -1CO:SCAIP14 analogue

64 -1CO:SCAIP24 analogue

65 -1CO:SCAIP34 analogue

66 -1CO:SCDIP14 digital

67 -1CO:SCDIP24 digital

1C0 :SCDIP34 digital



Omniverter Drive

12. Appendix 8 - Configuration Modules Quick Reference

The following tables which outline the Omniverter drive parameters relate to drive software version 6.0 or later.

12.1 Configuration Modules

if:7 000 :MENU CONFIG - 010 :LOCKS

[010 : CONFIG= 010 :USER =

010 : FCTRY =

- 0=7 02 0 : LOCAL CONTROL

- 02 0 : LOCREM=

- 02 0 : LOCMDE=

02 0 : KBFFtEQ=

02 0 : KBTORQ=

020:KB S/R=

-020:EXTS/R=

User Default Range/Type

LOCK unlock, lock

UNLOCK unlock, lock

0.00 User

- 030: LCD DISPLAY - 030 : LINE2 =

- 030 :LINE3 = - 030 :LINE4 =

User

- 030:USER A+ - 030 :USER B+

0 4 0 : MASTER RESET

I- 040 : FtESET (ENTER) ?

Default

0.0010 655.35

Range/Type

REMOTE remote, local

SPEED speed, torque

0. 0% -400.0 to *400.0%

0. 0% -400.0 to +400.0%

LOC & REM LOC ONLY,

LOC & REM ,

REM ONLY REM ONLY,

LOC & REM

Default Range/Type

CURRENT

SPEED REF SPEED NC analogue/digital

NC analogue/cigital

Description

The master reset command will re-initialise drive parameters and connections to factory defaults.

Parameters NOT affected by the master reset are the inverter calibration constants

(620:CALIBRATION), the motor nameplate data (410:MOTOR NAMEPLATE) and the local

control data (020:LOCAL CONTROL).

' frequency (inverter, Hz), current (output, A), speed (% synchronous), ref speed (% synchronous), torque (% motor rated), ref torque (% motor

rated), bus volts (VDC), output volts (inverter, Vrrns), power (electrical output, kW) , motor amp (% motor rated temperature), kWh (kW hours), kw on

(inverter on-time, hours), motor run (motor run-time, hours), user A, user B



C1100: INTERFACE - 0:7110 :ANALOGUE INPUT 1 user

110: TYPE =

110:LOW =

110:HIGH =

110 : ANAI P14

-(7 120 :ANALOGUE INPUT 2 user

120:TYPE = 120: LOW = 120:HIGH = 120 : MAI P24

- E, 130 :ANALOGUE OUTPUT 1 User

= [130:TYPE 130:LOW = 130:HIGH = 130 : ANAOP1-

- e:7140 : ANALOGUE OUTPUT 2 user

[140:TYPE =

140:LOW =

140:HIGH =

140 : ANA0P24-

- 17150: DIGITAL INPUTS User

-150:DIGIP13 -150:DIGIP29 -150: DIGIP34 - 150:DIGIP44 -150:DIGIP54 150:DIGIP6 -,

- 1:1160: DIGITAL OUTPUTS user

- 160: DIGOP1 . - 160: DIGOP2 t- - 160: FtELOP1 +

- 160: RELOP24-

160: RELOP34 - 17170: FIELD BUS SETUP User

[170: ENABLE= 170: FBTRIP= 170: FBLOSS 4

- e:7180: FBUS ANLG INPUT User

- 180: FBAI P14 - 180: FBAI P24

-180:FBAIP34 - 180: FBAIP44 -180: FBAI P54 - 180: FBAIP64

- ef:/ 190: FBUS DGTL INPUT User

-190: FBDI P19 - 190: FBDIP24 - 190: FBDI P34 - 190: FBDIP44 -190: FBDIP59 190: FBDIP64

Default Range/Type

VOLTAGE voltage, current

0% -40010+400%

100% -40010+400%

220S PDREF analogue

Default Range/Type


0% -40010+400%

100% -400 to +400%

22 OTRQREF analogue

Default Range/Type


0% -40010+400%

100% -40010+400%

230S PEED analogue

Default RangefType


0% -40010+400%

100% -40010+400%

23 OMTRCUR analogue

Default Range/Type

210START digital

210ENABLE digital

210RESET digital

22 OTRQMDE digital

220S PDINV digital

22 OTRQINV digital

Default Range/Type

NC digital

NC digital

210RUN digital

420MTR OL digital

230/FAULT digital

Default Range/Type

FALSE false, true

FALSE false, true

NC digital

Default Range/Type

NC analogue

NC analogue

NC analogue

NC analogue

NC analogue

NC analogue

Default RangefType

NC digital

NC digital

NC digital

NC digital

NC digital

NC digital



- E:71A0 : FBUS ANLG OUTPUT user

1AO: FBA0P1 1A0: FBA0P2 (-

1A0: FBAO P3 +

-'AO: FBA0P4 +

- 1A0 : FI3A0P5 +

- 1A0 : FBAOP 6 +

- E,1BO : FBUS DGTL OUTPUT user

-1BO: FBDOP1

- 1130: FBDOP2

- 1B0 : FBDOP3+ - 1B0 : FBDOP4 +

- 1B0 : FBDOP5 +

1B0 : FBDOP6+ 1C0: SERIAL COMMS User

1C0 : STATUS= ok, range err, no prmtr, ovrun err, frame err, parity err, bcc err, confg Ick,

user Ick, drive Ick, fctry Ick, bad port, read only

1CO:ADDRSS= - 1CO: SCAIP14

1CO: SCAI P24 -1CO:SCAIP34 -1CO:SCDIP19 -1C0:SCDIP2 -1CO:SCDIP39

1E77200 : CONTROLLER - 210: SEQUENCING

- 210: STRMDE=

-.210: STPMDE=

User

- 210: START +

-210: ENABLE+ ^ 210: RESET

- 210: START

210:RUN 4

220: CONDITIONING - 220: TRQLIM= - 220: LWRSPD=

220:UPSPD = - 220 : ACCEL1=

220: DECEL1= 220 : ACCEL2= 220: DECEL2=

- 220: SPDREF+

- 220: TRQREF+

- 220: TRQMDE+

- 220: SPDINV+ - 220: TRQINV+ - 220: RAMP2 4-

- 22 0 :AT SPD4

- 220: CURLIM9

User

220:TRQLIM3 -E7Y230:MONITORING

[230:FREQ 9

230:SPEED 4

230:VOLTS 4

230:TORQUE4

User

Omniverter Drive

Default

NC

Range/Type

analogue

NC analogue

NC analogue

NC analogue

NC analogue

NC analogue

Default Ran

NC digital

NC digital

NC digital

NC digital

NC digital

NC digital

Default Range/Type

11 11to99

NC analogue

NC analogue

NC analogue

NC digital

NC digital

NC digital

Default Range/Type

NORMAL normal, spin

NORMAL normal, spin, coast

150DIGIP1 digital

150DIGIP2 digital

150DIGIP3 digital

NC digital

160RELOP1 digital

Default Range/Type

150% 0 to 300%

-110% -200% to 220:UPSP0

110% 220:LWRSPD to 200%

60 . Os 0.1 to 3000 seconds

60. Os 0.1 to 3000 seconds



110ANAI P1 analogue

12 OANAI P2 analogue

150DIGIP4 digital

NC digital

NC digital

NC digital

NC digital

N C digital

NC digital

Default Range/Type

NC analogue

13 OANAOP 1 analogue

NC analogue

NC analogue



230:MTRCUR4 230:POWER 4

230:/FAULT4 230:INV OL4

e7 240 :OPERATING MODES User

240: CNTRL = 240: LOAD =

240: LVTRI P=

NC analogue

NC analogue

160RELOP3 digital

N C digital

Default RangefType

VECTORQUE Vil-tz, Vectorque

CONST TRQ const trq, var trq

OFF off, on

300

- E, : FAULT INFO 310: FAULT LOG User

- 310: FAULT1= Default RangelType

- 310: FAULT2= - 310 : FAULT3= - 310: FAULT4= -310: FAULTS= - 310: FAULT6= - 310: FAULT7= - 310: FAULT 8= 310: FAULT9=

e:7320 :AUTO R

[320:NUMBER= 320:DELAY =

320:PERIOD=


O 0 to5

30s 0 to 100 seconds

3600s 0 to 3600 seconds * See section 3.5 for the list of all possible fault indications.



(7 400 :MOTOR -k7 410 : MOTOR NAMEPLATE

410:VOLTS =

410:AMPS =

410: POWER =

410:RPM =

410 : FREQ =

-V7 420 :MOTOR THERMAL 420 : F COOL=

420 : STRTIM=

420: TRIP =

420:MTR 0L4

420 :MTRTMP +

-(:1 430 :MOTOR MODEL

User

Omniverter Drive

Default Range/Type

400V 50 to 1000V

OA 0 to 2000A

0 kW 0 to 1000kIN - Orpm 0 to 65535nom

5 0Hz _

OW 1C0Hz

= [430:RS

930: RR =

430 : IMAG =

430 : LKG =

User

User

Default Range/Type

OFF off, on

10. 0 s 0 to 60seconds

ON off, on

16 ORELOP2 digital

NC analogue

Default Range/Type

1.0% Ow100%

1.0% OW100%

50.0% _

OW500%

16.7% Oto150.0%

e7500:VECTOR CONTROL e7 510 : SETTINGS

510 :HOIST =

510: IBOOST= 510 : J COMP=

510 : EWK PT=

Vf:7 52 0 : GAINS

- 52 0 : WLPKP = - 520 :WLPKI =

- 520 :WLPKD =

- 520 : PHLPKP= - 520 : PHLPKI= - 520 : FRLPKP= - 520 : FFtLPKI=

- 520 : ILPKP =

- 520 : ILPKI =


OFF off, on

0 % -250 to +250%

0 . Os 0 to 100 seconds

120% 80 to 150%


16000 0 to 65535

20 2010 65535

0 0 to 65535

10000 0 to 65535

400 20 to 65535

3000 0 to 65535

800 20 to 65535

2000 0 to 65535

400 20 to 65535

e7600:INVERTER -e7610:WAVEFORM L610:SWFREQ=

User

-7 620:CALIBRATION [620:CTSCLE= 620:RATING= 620:TSTMDE= 620:VER =

e7630:DYNAMIC [630:DBDUTY= 630:TIME =

630:ENABLE=

User

Default Range/Type

LOW low, high

Default Range/Type

N/A 0 to 65535

N/A 2000A

N/A false, true

N/A READ ONLY

BRAKE User Default Range/Type

10% 1010100%

10 s 1 to 500 seconds

OFF off, on



1E7 700 : SPECIAL FUNCTION 710: ANALOGUE PRESETS

- 710 :VALUE1= - 710 : VALUE2=

User

- 710 : VALUE3=

-710:VALUE1-, - 710 : VALUE2 4 - 710 : VALUE3 4

- 1E7 72 0 : DIGITAL PRESETS - 720: VALUE1= - 72 0 : VALUE2= - 72 0 : VALUE3= - 72 0 :VALUE14 -7 20 : VALUE2 4 - 72 0 : VALUE3 4

- 1E, 730:2 TO 1 ASWITCH1 [730: INO 4-

730:IN1 +

7 30 : SELECT + 7 30 : OUTPUT 4

- e7/ 7 4 0 : 2 TO 1 ASWITCH2 [740:INO +

740:IN1 +

7 4 0 : SELECT + 7 4 0 : OUTPUT 4

- er7 750 : 2 TO 1 DSWITCH1 [750:INO +

750: IN1 +

750:SELECT+ 750 : OUTPUT

- 1 7 60 : 2 TO 1 DSWITCH2 [760: INO +

760:1N1 +

7 60 : SELECT + 7 60 : OUTPUT -,

-17 7 7 0 : 2 TO 1 DSWITCH3 [770:INO +

770:IN1 +

7 7 0 : SELECT + 77 0 : OUTPUT 4

- 1 7 8 0 : DIGITAL FUNCT 1

-780:0P =

-7 8 0 : INVINO= -7 8 0 : INVIN1= -7 80 : INVOUT= - 780:INO +

- 780:IN1 +

-7 8 0 : OUTPUT 4

User

User

Default Range/Type

0. 0% -400.0 to +400.0%

0. 0% -400.0 to +400.0%

0. 0% -400.0 to +400,0%

NC analogue

NC analogue

NC analogue

Default Range /type

FALSE false, true

FALSE false, true

FALSE false, true

NC digital

NC digital

NC digital

Default Range/Type

NC analogue

NC analogue

NC digital

NC analogue


NC analogue

NC analogue

NC digital

NC analogue


NC digital

NC digital

NC digital

NC digital

User Default

NC digital

NC digital

NC digital

NC digital

User Default

User

Rangerrype

NC digital

NC digital

NC digital

NC digital

Default Range/Type

AND and, or, xor

FALSE false, true

FALSE false, true

FALSE false, true

NC digital

NC digital

NC digital



t7 7 90 : DIGITAL FUNCT2

-790:0P = - 790 : INVINO= -7 90 : INV1N1=

- 790 : INVOUT=

- 790: INO 4-

- 790: IN1 - 790:OUTPUT-)

- On' 7A0 : DIGITAL FUNCT3

- 7A0: OP =

- 7A0 : INVINO= - 7A0 : INVIN1=

7A0 : INVOUT= - 7A0 : INO 4-

- 7A0 : IN1

Omniverter Drive

User Default

User

- 7A0 : OUTPUT -)

- 7 B 0 :MOTOR' S ED POT

-7 BO : ENABLE=

- 7B0 : UPLIM = -7 BO : LWRLIM=

- 7B0 : TIME = - 7B0 : INC 4-

- 7B0 : DEC 4-

User

- 7B0 : OUTPUT-, - gf:i 7 CO : PRESET SELECT

- 7C0 : VALUE1= - 7C0 : VALUE2= - 7C0 : VALUE3= - 7C0 : VALUE4= -7 C 0 : VALUES= -7 C 0 : VALUES= - 7C0 : VALUE7= - 7C0 : VALUE8= - 7C0 : SELO 4-

- 7C0 :SEL1 4-

7C0 : SEL2 4-

-7 CO : OUTPUT

User

-E77DO:PID CONTROLLER

-7DO:ENABLE= - 7DO:MODE =

-7DO:KP =

- 7DO:WITS =

-7DO:WDTS =

-7DO:UPLIM =

-7DO:LWRLIM= -7DO:KSP =

-7DO:TS -7DO:REF 4-

-7DO:F/B 4-

-7DO:OFFSET4- -7DO:ENABLE4- -7DO:OUTPUT4 - 7DO:ERROR 4

-7DO:UPIND 4

-7DO:LWRIND-)

User

Range/Type

AND and, or, xor

FALSE false, true

FALSE false, true

FALSE false, true

NC digital

NC digital

NC . digital

Default Range/Type

AND and, or, xor

FALSE false, true

FALSE false, true

FALSE false, true

NC digital

NC digital

NC digital

Default Range/Type

FALSE false, true

100 . 0% -400.0 to +403.0%

0. 0 % -400.0 to +400.0%

6 0 s 1 to 3000s

NC digital

NC digital

NC analogue

Default Range/Type

0. 0% -400.0 to +400.0%

0. 0 % -403.0 to +400.0%

0. 0% -400.0 to +400.0%

0. 0% -400.0 to +400.0%

0. 0% -400.0104400.0%

0. 0% -400.0 to +400.0%

0. 0% -400.0 to +400.0%

0. 0% -400.0 to +400.0%

NC digital

NC digital

NC digital

NC analogue

Default Range/Type

FALSE false, true

PI PI, PID

1. 0 0 0.00 to 16.00

0. 001 0.001 to 0.1C0

0.10 0.01 to 0.10

4 0 0. 0 % -400.0 to +400.0%

-4 0 0. 0 % -400.0 to +400.0%

1. 0 0.0 to 1.0

10ms 10ms,100ms,1s,10s

NC analogue

NC analogue

NC analogue

NC digital

NC analogue

NC analogue

NC digital

NC digital



-C77E0:SKIP BANDS -7E0:ENABLE=

User

- 7E0:VALUE1=

-7E0:BAND1 =

-7E0:VALUE2= -7E0:BAND2 = -7E0:VALUE3=

7E0:BAND3 = 7E0:VALUE4= 7E0:BAND4 = 7E0:INPUT 4.

7E0:OUTPUT+ -'7FO:COMPARATOR 1 User

7FO:BAND =

7FO:INO 4-

7FO:IN1 4-

7FO:OUTPUT+ -E:77GO:COMPARATOR 2

Default Range/Type

FALSE false, true

0.0% 0.O to

o.o% 0.0 to

o.o% 0.ft,..400.0%

o.o% 0.O to

o.o% 0.O to

o.o% 0.O to

o.o% 0.0 to

o.o% 0.0 to

NC analogue

NC analogue

Default Rmgerype

5. 0% 0.0 to +400.0%

NC analogue

NC analogue

NC digital

User Default

7GO:BAND = 7G0:INO 4-

7GO:IN1 4-

7GO:OUTPUT+ -77HO:COMPARATOR 3

[7HO:BAND =

7HO:INO 4.

7H0:IN1 4-

7HO:OUTPUT+

Range/Type

5.0% 0.Oto+400.0%

NC analogue

NC analogue

NC digital

User Default Range/T

5.0% 0.0 to +400.0%

NC analogue

NC analogue

NC digital



Omniverter Drive

13. Appendix 9 - Bearing Filters - Protecting Motor Bearings

13.1 Review of problem Common mode voltages present in the output waveforms of all PWM ac drives pose some risk to motor bearings from unintentional flow of electrical current through the bearings (resulting in electrical discharge machining (EDM) of the bearings). Not all motors or installations are affected and it is not always possible to predict susceptibility, but risks do increase with larger size motors. Though three different mechanisms can be responsible, all risks can be minimised by appropriate methods, or the use of special common mode (bearing) fitters.

The most dangerous effect arises due to imperfect earthing of the motor, leading to non-zero motor frame to ground voltages with resultant possibility of ground current leakage via the bearings and motor shaft to the load (particularly when the load is earthed independently to the motor). While the coifed application of fully shielded cable (ie bonded to both the motor frame and drive motor earth points) will minimise frame-ground voltage, this becomes increasingly impractical with the large cables required for bigger drives.

If separate phase and earth cables must be run, additional protection should be provided to block possible bearing currents:

- insulate both motor bearings, or

- insulate the non-drive-end (nde) bearing and use an insulated coupling, or

- fit a Vectron Bearing Filter between drive and motor.

Other lesser effects (capacitive rotor charging and circulating currents) are also overcome by the above methods.

Note that the insulating methods can leave sufficient voltage across insulation boundaries to cause sparking if inadvertently shorted so these methods are not recommended for explosive atmospheres - use a fitter in such applications.

Vectron strongly recommend against the fitting of shaft earthing brushes as these have been shown to exacerbate problems in some cases (create a greater problem for bearings at the opposing end of the motor, or transfer the problem to load bearings).

Contact Vectron for papers giving a more in depth review of this Issue.

13.2 Vectron Bearing Filters Vectron has developed _a range of filters to protect motor bearings. The function of these is to eliminate the drive output common mode voltages which are responsible for bearing currents. Over 90% attenuation of common mode voltage is achieved.

Table 13-1 lists the bearing filters available. The filters are modular in design and sized to match the drive modules.

Note: The bearing filters are designed for use at 4kHz switching frequency or higher. The Omniverter must be set for high switching frequency and the reduced 4kHz current and temperature ratings of the Omniverters must therefore be observed.



13.3 Bearing Filter Installation The filters are connected in series with the motor and must be physically situated near the drive (refer Figure 13-1). Connection is also made to the drive dc bus.

The filters incorporate a normally closed combined fault (thermal and overload protection) circuit which should be arranged to stop the inverter in the event of filter fault. This may be achieved via the Omniverter Motor PTC circuit, a specially configured stop input, or separate (eg PLC) control.

When the filters are employed, it is usually not strictly necessary to screen motor cables, though this practise always remains preferable.

Product No.

Description Current (50deg C)

W x H x D Weight Loss

0120 Single EDM filter 170A 300 x 422 x 280

0121 Dual EDM filter 300A 540 x 422 x 280

0122 Triple EDM filter 450A 780 x 422 x 280

0123 Four module EDM fitter 600A 1020 x 422 x 280

0124 Five module EDM filter 750A 1260 x 422 x 280

0125 Six module EDM filter 900A 1500 x 422 x 280

Table 13-1 Bearing Filter Selection Chart

s's



230V AC FAN SUPPLY

PE

E , 1111111111

.:. W OUT. ' .. V OUT :::' ir : OUT

W V W In

CitrOJN Breaker

E

MOTOR\( jPE

Figure 13-1 Omniverter Bearing Filter Wiring

Omniverter Drive

*1) The overtemp / trip fault circuit should be wired back to the drive or process to stop the drive (eg use motor PTC cct).

*2) The fitter should be positioned near the drive (within 1-2m).



Omniverter Drive

14. Appendix 10 - Mains Harmonic Reduction

14.1 Harmonic Currents in AC Drives AC drives generally use six pulse rectifiers which draw relatively high levels of harmonic current (typically around 30 - 40%, adding, rrns-wise, about 8% total current, or reducing total power factor by about 8%). If drives represent more than about 40% of the total load of an installation, or if particularly high impedance supplies are planned (eg use of generators), issues of harmonic distortion should be considered. Vectron engineers have considerable experience in such applications and can carry out the necessary simulations to determine whether a problem is likely, and if so what the best solution will be. For more information about harmonics and harmonic reduction options, contact your supplier.

14.2 12 Pulse Omniverter Option Vectron offers standard 12 pulse versions of it's Omniverters for harmonic sensitive applications. As the 12 pulse conversion requires adaption of the Omnidrive and supply of a special transformer, it is necessary to specify this option at the time of order.

Table 1-1 shows the levels of harmonic current reduction are typically achieved with the Vectron 12 pulse system.

Harmonic 6 pulse (typical)

OD4-300 OD4-450 OD4-600 OD4-750 OD4-900

5th

7th

11th

13th

17th

19th

total THDi

Table 14-1 Harmonic Current Reduction by. Omniverter 12 Pulse System

14.3 12 Pulse Conversion and Installation The details contained in this section are commercially sensitive and are supplied separately with 12 pulse Omnidrive systems.

s.wenow.



12 pulse conversion of the Omniverter involves special adaption of the Omniverter rectifier assembly which is carried out during manufacture. The rectifiers, usually all operating in parallel, are split into two sections. One section is fed via the Omniverter's normal (internal) line reactors, the other via a separate phase shifting transformer. The transformer itself is simply fed from the same supply as the directly fed Omniverter input. In this way, only normal three phase, three wire power and protection is required to be supplied by the user:

The transformer is sized appropriately to the number of Omniverter modules it is driving. Transformer short circuit protection is provided by supply protection, while overload protection is achieved through the use of thermal switches embedded in each phase winding. The switches are normally closed and should be connected into the system protection (eg use the Omniverter motor PTC Input, allocate a separate stop digital input, or connect the sensors into a supervisory PLC system).

All six Omniverter supply inputs and transformer connections are insensitive to phase orientation. Refer to Figure 14-1 for further installation details.

Typical transformer details are provided in Table 14-2. Traniforthers are unenclosed and intended for switchboard installation. They are rated for class H temperature rise with convection cooling to 50 deg C maximum ambient. Ensure cooling of the switchboard is adequate for the rated transformer dissipation.

No. Modules to be phase shifted

kVA LxBxH Weight Loss

1 140 660x500x650 460kg 2900W 2 280 800x600x850 840kg 6150W 3 420

Table 14-2 Omniverter Phase Shift Transformer Details



Omniverter unve

RA L1

L2

13

Notes:

001 ANA

.4

L J

1 - Supply: All local Electrical Safety Regulations must be obeyed. Extemal isolation and supply protection as required Power Factor correction is not required. The Omniverter provides cos+ > 0.95.

2 - Supply Cabling: No special requirements are placed on input cables Omniverter chassis must be solidly bonded to electrical earth (using one PE terminal only)

before energising the drive (high levels of earth leakage currents can flow from ac drives) Input is not phase sensitive

3 - Special Aspects of 12 Pulse Input: 'Transformer input short circuit protection to be supplied by supply protection. Transformer orientation is not phase sensitive Do not connect transformer neutral Transformer connects to Omniverter inputs L4, L5, L6

Connect transformer thermal switches to stop drive in event of overload Where a RFI suppression capacitor board is supplied separately, this should be connected

directly at the switchboard mains input using short connecting leads

The transformer shield and transformer frame should be connected together and directly to switchboard chassis bulk earth (as well as board PE)

4 - Output Cabling: Output isolation (if required) should only be operated off load (ie with Omniverter stopped).

Symmetrical three-cored screened cables are preferred. The cable screen should be solidly bonded to both motor frame and inverter motor earth (ME) terminal only not anywhere else).

If motor and load frames are electrically isolated, but electrically connected via shafts, install an isolated coupling in the shafts or bond motor and load using a wide flat (25mm) conductor such as braid or copper foil using the shortest possible connecting route (don't rely on common earth connections back to switch boards).

'Some regulations may require an earth to be run in addition to using the cable screen. If required this earth should run externally to the screened cable.

Power factor correction capacitors must not be connected to Omniverter output. If facility for electrical bypass of the motor to mains is required, the Omniverter output must be

isolated from the motor first (the Omniverter output must never be connected to mains supply).

Figure 14-1 12 Pulse Power Connection Details



15. Index

airflow, 1-7 analogue

inputs, 4-3 outputs, 4-3

commissioning, 3-4 schedule, 6-2

control configuration, 2-4 quick reference, 11-1

control panel, 1-6 current

overload, 1-5 ratings, 1-5

default control configuration, 2-11 interface configuration, 2-9

destination ports explained, 2-5 how to use, 2-6 quick reference index, 5-1

digital inputs, 4-4 outputs, 4-4

dimensions, 1-7 Displacement Factor (COSO), 1-5 Distortion Factor, 1-5 dynamic brake, 1-4, 4-14 electrical installation

control cabling, 3-2 EMC, 3-2 power cabling, 3-2

fault auto reset, 4-9 displays, causes and solutions, 3-8 log, 4-9

field bus analogue inputs, 4-4 analogue outputs, 4-5 digital inputs, 4-5 digital outputs, 4-5 drive status codes, 10-2 drive type codes, 10-3 I/O map, 10-1 setup, 4-4 trip on loss of communication, 4-4

harmonic distortion, 1-3, 1-4 interruption ride through, 1-5, 4-8 inverter rating

at 40 degrees C, 1-3, 1-5, 1-6, 2-9 at 50 degrees C, 1-6, 2-9

keyboard. See LCD display LCD display, 2-2, 4-1

menu display line, 2-2 status line, 2-2 user selectable meters, 4-2

limits torque, speed, accel, decel, 4-7

Omniverter Drive

local/remote control, 4-2 locks, 4-1 mechanical installation

cooling, 3-1 mounting, 3-1

menu system, 2-3 navigation, 2-4 structure, 2-4

models available, 1-2, 1-7, 3-2 motor

derating, 2-12 parameters, 4-10 thermal model protection, 4-10

open collector outputs, 4-4 option

RS 485 serial interface, 1-6 options

4-quadrant regenerative unit, 1-4 harmonic reduction, 1-4

output frequency, 1-5 voltage, 1-5

parameters auto-calculate motor model, 4-10 explained, 2-5 fine-tuning motor model, 4-11 fine-tuning vector gains, 4-13 how to use, 2-6

power connection, 1-5 power factor, 1-4 protection, 1-3, 3-8

inverter, 1-6 motor, 1-6

reduced flux operation, 4-8 relay outputs, 4-4 reset

master, 4-2 module, 2-6

safety, 1- 4,3-3, 3-4 set points - references

torque, speed, 4-7 source ports

explained, 2-5 how to use, 2-8 quick reference index, 5-2

spares list, recommended, 8-1 special functions, 4-15

2 to 1 analogue switch (mux), 4-15 2 to 1 digital switch (mux), 4-16 digital functions(AND,OR,XOR), 4-16 motorised potentiometer, 4-16 presets, 4-15



speed mode, 4-7 standards, 1-4 start and stop modes, 4-6 start/stop/reset, 4-6 switching frequency, 4-14 terminals

wiring, 2-9 torque mode, 4-2, 4-7 V/Hz Mode, 2-9

selected, 4-8

vector control sensorless. See Vectorque

Vectorque explained, 2-9 mode selected, 4-8 options and settings, 4-12

voltage input, 1-5 tolerance, 1-5

weight, 1-7

