Download Aerre2 Single Control Panel Technical Manual

AERRE 2 by Angelo Rossi - Via G .Mazzini, 44/A - 36077 ALTA VILLA VICENT1NA -VI- VENETO ITALY
Tel. & Fax. 0444/370644 P.IVA 03048810240 CF. RSSNGL46S17E970ZR.E.A.N°296449
Reg.Impr.N°90018
Electric control panels for electric pumps - Booster unit pumps – Electronic
level control - Inverters
FOR THE
INSTALLATION, USE AND MAINTENANCE OF
AUTOMATIC EQUIPMENT CONTROLLING SINGLE AND
THREE-PHASE ELECTRICAL PUMPS
TYPE 1QM/CE & 1QT/CE
REDATTO DA: ROSSI
VERIFICATO ED APPROVATO: ROSSI
EMESSO IN DATA: 25/02/04
AERRE2 Via G. Mazzini, 46- 36077ALTAVILLA VICENTINA - VI. Tel. & Fax 0444-370644E mail: [email protected]
NZ Agents: Brown Bros. Engineers Ltd, 124A Hugo Johnston Drive, Penrose Auckland. Ph: 09 525 8282. Fax: 09 525 8284
E-mail: [email protected]
GENERAL INDEX
1
MANUFACTURERS IDENTIFICATION
2
GENERAL SAFETY
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
12.0
13.0
14.0
SAFETY MEASURES
COMPONENTS
CONDITIONS OF USE
TRANSPORTATION
MOVEMENT
PREPARATION FOR INSTALLATION
ELECTRICAL CONNECTIONS
CONNECTIONS TO THE FRONT PRINTED CIRCUIT CARD
JUMPERS (BRIDGES J1,J2 & J3)
WORKING TEMPERATUREE
CONNECTIONS TO THE MOTHERBOARD
CONTROL PANEL
NOTES
1 MANUFACTURER (from CEE 89/392 P.1,7,4, A)
AERRE 2 by Angelo Rossi
Via G: Mazzini, 44/A
36077 ALTAVILLA VICENTINA Tel. & Fax. 444-370644
2 GENERAL SAFETY WARNINGS
FAILURE TO FOLLOW THESE INSTRUCTIONS, OR ANY ALTERATION OR MODIFICATION
TO THE SYSTEM, WILL REMOVE ANY RESPONSIBILITY BY AERRE2, OR ANGELO ROSSI,
SHOULD THERE BE ANY ACCIDENTS CAUSING INJURY OR DAMAGE TO THE CONTROL
PANEL.
Installation should be by trained technicians. Before using this control panel it is
essential that the user reads & understands the operations described in this manual, and
knows how to apply them to the use and maintenance of the equipment. To adjust the
settings, follow all the instructions in this manual.
3 SAFETY MEASURES TO BE FOLLOWED BY THE USER
a) The user must follow the safety rules applicable their country.
b) Isolate the system before repairs to, or maintenance of, the equipment.
Failure to isolate the system can cause serious or fatal accidents.
c) Before using the system check that all connections and electrical safety
devices are working properly.
d) Do not use the system with wet hands or bare feet.
e) The user must not carry out any modifications to this equipment
4 COMPONENTS
All componentry complies with EU requirements. The control panel is built to
European standard EN 60204-1.
5 MODEL SELECTION
The 1QM/CE control panel is ONLY for 240V (+-10%) 50/60Hz SINGLE PHASE
motors.
The 1QT/CE control panel is ONLY for 400V (+-10%) 50/60 Hz THREE PHASE
motors.
6 TRANSPORT
Transport in the original packaging only.
7 REMOVAL
The control panel is designed for fixed installation only. Before moving or
removing, ensure the following is completed: Isolate the control box from the
main supply, disconnect the motor from the panel, finally disconnecting the
transducer, float or pressure switch from the control panel.
8 INSTALLATION
Suitably licensed & competent persons must install this equipment. It is the
responsibility of the installer to Earth this equipment according to local
regulations.
9 ELECTRICAL CONNECTIONS
N.B. Electrical work must be carried out by suitably qualified & licenced persons.
To connect to the main supply, use a suitably sectioned conductor, paying
attention to the cable run & supply voltage. CONNECT THE EARTH FIRST. This
conductor (YELLOW-GREEN) must be connected to the earth terminal, in the
electrical control panel, without passing through the main Switch.
10 CONNECTING THE TRANSDUCER
The electronic board mounted on the cover of the control panel, besides having
cables that connect it to the control push buttons, the selector and a ribbon cable
that connects the mother card to the front card, also has a 4 pole connection
block, numbered 1-4 left to right. Three wires connect the transducer to the
electronic card, as shown in Fig.1; failure to follow the correct sequence will
damage the transducer.
11 JUMPERS J1-J2-J3
On the electronic card (code 900328), fitted to the cover of the control box, are
three JUMPERS labeled J1, J2 and J3, which, with or without bridges, control the
various working modes of the control panel.
J1,J2 Without bridge: The control panel works as a pressure system using a
transducer.
J1 without, J2 with bridge: The control panel empties a tank controlled by level
Transducer
J1 with bridge, J2 without bridge: The panel is designed to fill a tank using level
probes, the probe cables must not exceed 10 meter.
J1 & J2, With bridge: The panel is designed to empty a tank controlled either by a
Pressure switch OR a float switch.
NB: THE J3 Function (either 1 or 3 phase) IS PRESET BY THE MANUFACTURER.
12 TEMPERATURE LIMITS
The control panel can work at any temperature between -25 C and +55 C. Below 25C the liquid in the display solidifies and becomes transparent.
13 CONNECTIONS TO THE MAIN CARD OF THE CONTROL PANEL
For 1QM/CE control panel (single phase pump): Connect the main supply 240
VAC 50/60Hz to terminals 1 & 2 of the Main Switch, Connect P TO 1 & N TO 2.
The motor is connected to the contactor terminals 2 & 4.
For 1QT/CE control panel (three-phase pump) connect the main supply
400VAC 50/60 Hz, to the main switch at terminals 1, 2 & 3, The motor must be
connected to the contactor terminals 2,4 & 6.
All Earth connections to the brass terminal PE block
14 CONTROL PANEL
Liquid crystal display: Shows the various functions:
Alarms: The control panel has a visual alarm (flashing LED) and a buzzer.
Data settings: Entered through the push buttons, SCRN, ▲ , ▼ & RESET.
Line: The LED, when illuminated, indicates that the control box is LIVE.
Pump on: The motor LED indicates that the motor is energised
LED general alarm: The LED general alarm illuminates for any alarm (cumulative
alarm)
DESCRIPTION OF THE COMPONENTS ON THE CONTROL PANEL
TYPE 1QM/CE AND 1QT/CE
On the front of the control panel there are start button (white), stop button (black)
and a selector (aut-0-man) switch. The start button is used to start the pump in
automatic or manual mode, the stop button to stop the pump, and a selector with
three positions to select the desired operating mode of the pump: automatic, off &
manual. Every time that the selector is changed from automatic to manual, or vice
versa, the start button must be pressed. There are also four momentary contact
buttons in the CONTROLS section, which have the following commands:
SCRN - Used to change the pages of the display, a press and release of the button
advances the pages showing the data singly, or by holding it depressed, the pages
automatically advance.
▲
- Used to increase a value.
▼
- Used to decrease a value.
RESET - Used to clear the system alarm, or alarms, on the display.
TO ENTER PROGRAMMING MODE
To enter the programming mode, press and hold both buttons, ▲▼ while switching the
MAIN switch “ON”. Hold the buttons until the words “AERRE 328” disappear; you can
now adjust the program to your requirements.
When data entry is complete, switch the MAIN switch “OFF” to memorise the data.
DESCRIPTION OF THE PROGRAM SCREENS
The following settings assume a 10 Bar transducer is fitted. If a 20 Bar Transducer is
used, increase the maximum values available accordingly & ensure that SCRN 16 is
correctly set.
SCREEN 1: As the control panel is supplied, the words "AERRE 328” indicate the
number of the project. (Not changeable)
SCREEN 2: This screen differs in its display, depending on the operation mode
selected: for Mode 1 “P1 OFF/WORK p 0.0” for Mode 2 “P1 OFF/LEV.000” for modes
3 & 4 “P1OFF/COSf0.00”
SCREEN 3:
This page displays the input line voltage (500VAC max.)
SCREEN 4:
running.
"IMP.CURR./00.0 (0-25A) Displays the current drawn by the Pump when
SCREEN 5: “SET MIN/PRES0.0b” Sets the MINIMUM working pressure. (0-9.9Bar)
Use ▲ or ▼ to change data.
SCREEN 6: “SET MAX/PRES0.0B” Sets the MAXIMUM working pressure ( 0-9.9 bar).
Use ▲ or ▼ to change data.
SCREEN 7: "MIN LEV/000cm.” Sets the MINIMUM height in cm. of the liquid. Only
when in Mode 2,—draining a tank with a level transducer. Use ▲ or ▼ to change data.
SCREEN 8: "MAX.LEV/000cm" The MAXIMUM height in cm. between 170cm & 320
cm (depending on which transducer is used). If the level exceeds this by 30 cm, then
“MAX.LEV/ALARM” is automatically displayed. Use ▲ or ▼ set the level below the
above maximum.
SCREEN 9: "SET CURR/…A" Set to the maximum motor plate data +5%. If this
level is exceeded “OVER/CURR.PUM” alarm is displayed. Use ▲ or ▼ to change the set
point.
SCREEN 10: "DELAY T/P00SEC" Sets the run on time after reaching
MAXIMUM pressure (Mode 1) OR when the probes ARE submerged (Mode
3) OR NOT submerged (Mode 4) Changed using ▲ or ▼ 1-180 seconds.
SCREEN 11: "SILL.COS/0.00" Recommend using 0.5 for 3 phase
motors (contact the motor manufacturer for 1 phase motor
recommendation) If the value of Cos. ǿ falls below the set point, then after
30 sec. the pump stops & the alarm “NO/WATER” is displayed. Use ▲ or
▼ set the Cos. factor.
SCREEN 12: "MIN.CURR/0.0A" (Only for single phase units).
Recommended setting 30% below the nominal value of the motor. If the
absorbed current falls below this figure for 30 sec. the pump stops with
the alarm “NO/WATER” Adjusted using ▲ or ▼.
SCREEN 13: "SET onT./1/24h" restart delay after the alarm “NO
WATER” is activated. Reset can also be used to restart the pump (Ensure
sufficient water available). Adjusted using ▲ or ▼.
SCREEN 14:
"TRANSDUCER/200cm 300 cm” Selected using ▲ or
▼.
SCREEN 15: "LINE/ENABLE 0/1" monitors the settings
"MIN.LINE/TENSION" or “MAX.LINE/Tension".
If "LINE/ENABLE 1" is set: If the set points for “MIN.LINE/VOLTAGE"
or "MAX.LINE/VOLTAGE" are exceeded for 1 minute the pumps will shut
down.
If "LINE/ENABLE 0" is set: Then the pump continues to work, and the
alarms "MIN.LINE/voltage" or "MAX.LINE/voltage" are not shown.
SSREEN 16: Selects the pressure sensor used, either 10 Bar or 20 Bar
ALARMS
SCREEN 17: “SEQ.OR/PHASE F" Means there is an error in the Phase
sequence, or a missing phase. If, when switching the Main Switch on, the
display shows “SEQ.OR/PHASE F" switch off the control panel and invert
two of the incoming phases. Switch the control panel on again and the
alarm should have cleared. If not then switch off again and check the
electrical supply.
SCREEN 18: "OVER/CURR.PUM" This alarm indicates an overloaded
pump, exceeding the value set on Screen 12 Remove the cause & press
“RESET” to clear
SCREEN 19: "NO WATER" Is displayed in when the setting for Cos. ǿ
(screen 11) or the value of “MIN CURR” (Screen 12) is breached.
SCREEN 20: "MAX.LEV/ ALARM” Is shown when the “MAX.LEV”
(Screen 8) is exceeded by 30 cm
SCREEN 21: "MIN.LINE/VOLTAGE" This alarm appears on the display
when the three-phase voltage of 400VAC, or single-phase 230VAC, falls
15% of the nominal voltage.
SCREEN 22: "MAX.LINE/VOLTAGE" This alarm appears on the display
when the three-phase voltage 400VAC or single-phase 230VAC exceeds
10% of the nominal voltage.
PROGRAMMING EXAMPLES
CONTROL PANEL 1QM/CE AND 1QT/CE
These control panels may be programmed to operate in four different modes. These may
be selected by the client according to requirements.
MODE 1: Pressure system controlled by Transducer:
J1 & J2 without bridges.
Bridge XT1 pins 1 & 2 and bridge 3 & 4, also bridge 6, 7 & 8 together. (See connections
Fig 1)
Description
If the pressure falls below the value set at “SET.MIN/0.0b” The pump ramps up, as
soon as the pressure rises above the value set at “SET.MAX./P0.0b” the timer setting
at “DELAY T./00SEC” times out, and then the pump stops.
Worked example, To set up a 3 Phase, 3Kw pumpset, electrical load 5.7A with a
minimum pressure of 3 Bar, a maximum pressure of 4 Bar, & a Cosǿ of 0.50Start the
controller in programming mode as detailed on page 6. NB release the buttons when
“WORKp/0.0b” appears, which indicates that this mode can be set.
SCREEN 2:
SCREEN 3:
“P1 OFF/WORK p 0.0”
This page displays the input line voltage (500VAC max.)
SCREEN 4: "IMP.CURR./00.0 (0-25A) displays the current drawn by
the Pump when running.
SCREEN 5:
“SET MIN/PRES0.0b” Set to 3.oo Bar
SCREEN 6:
“SET MAX/PRES0.0B” Set to 4.oo Bar
SCREEN 9:
"SET CURR/…A" Set to 6A
SCREEN 10:
& 180 sec)
"DELAY T/P00SEC" Set to 2 seconds (variable between 1
SCREEN 11:
"SILL.COS/0.00" initial setting 0.50
SCREEN 13:
24 Hr)
"SET onT./1/24h" Set to 1 hour (Variable between 1 &
SCREEN 15: "LINE/ENABLE 1" Set so that if the set points for
MIN.LINE/VOLTAGE" or "MAX.LINE/VOLTAGE" alarms are exceeded
for 1 minute the pumps will shut down.
SCREEN 16: “SENSOR/10b/20b” Select 10 Bar
When all values are set, switch the main switch “OFF”, wait for a few seconds to
memorise the data then switch “ON” The memorised data will be retained for up to 10
years without power.
Turn the selector switch to “AUTO” and press the white “ON” button. The pump will ramp
up & continue pumping until it reaches 4 Bar & after a 2 sec delay the pump ramps
down. If there is no further demand, the pump will stop. If there is a continuing demand,
the pump will match the supply to the demand ramping up & down as necessary. If the
demand is so excessive, or the supply insufficient, that the pump cannot maintain 3 Bar,
the pump will stop with the alarm “NO/WATER” The pump will automatically reset after
1 Hour (SCRN 13), or can be manually re-started by the sequence: RESET, STOP & GO.
A float switch may be connected to XT1 (on the main board) terminals 1 & 2 OR 3 & 4,
to function as a minimum level over-ride for supplies from a tank or similar. When the
float switch closes i.e. the tank refills, the controller automatically re-starts.
MODE 2: To empty a tank, depth 0 to 1.99m or 0 to 3.49m using a level
transducer. J1 without bridge, J2 with bridge. Bridge XT1, 1 & 2 and bridge 3 & 4,
also bridge 6, 7 & 8 together. (See connections Fig 1)
SETTING THE LEVEL TRANSDUCER “ZERO” POINT
1)After connecting the Transducer to the front panel, the Transducer Zero point, must be
set by holding SCRN,▲&▼ depressed while switching the main switch “ON” (This
procedure is necessary because all transducers are not identical). When “AERRE 328”
disappears from the screen, release the buttons. This procedure MUST be concluded with
the transducer dry & upright before installing in the pumpset.
2)If a display differing from “P1/ON (or OFF)/LIV 00.0” appears after AERRE 328
disappears, repeat the above instructions.
Description
To empty a tank to a set level, between 0 & 1.70m using a type 2mt transducer. If the water
level rises above the value set at “MAX.LEV/00.0cm” the pump starts. When the level falls
below the value set at “MIN.LEV/00.0cm” the pump stops. If the level rises 30cm above
Maximum level set, the alarm “MAX.LEV/ALARM” is generated.
Worked Example: Again using a 3 Phase, 3Kw pumpset, electrical load 5.7A with required
levels of min 50 cm & max 160 cm. It is essential that the transducer is Zeroed as
noted.
Start the controller in programming mode as detailed on page 6. NB release the buttons
when “P1OFF LEV 00.0cm” appears, which indicates that this mode can be set.
SCREEN 2:
“P1OFF LEV 00.0cm”
SCREEN 3:
This page displays the input line voltage (500VAC max.)
SCREEN 4:
"IMP.CURR./00.0 (0-25A) displays the current drawn by the Pump when
running.
SCREEN 7:
SCREEN 8:
“MIN.LEV/000 cm” set to 50 cm
“MAX.LEV/…Cm” Set to 160 cm (allowing a reserve of 30 cm to the top)
SCREEN 9:
"SET CURR/…A" Set to 6A
SCREEN 11:
"SILL.COS/0.00" initial setting 0.50
SCREEN 13:
"SET onT./1/24h" Set to 1 hour (Variable between 1 & 24 Hr)
SCREEN 14:
“TRANSDUC/200cm or 350cm” set to whichever transducer is being
used
SCREEN 15:
"LINE/ENABLE 1" Set so that if the set points for
“MIN.LINE/VOLTAGE" or "MAX.LINE/VOLTAGE" alarms are exceeded
for 1 minute the pumps will shut down.
When all values are set, switch the main switch “OFF”, wait for a few seconds to
memorise the data then switch “ON” The memorised data will be retained for up-to 10
years without power.
For example, we wish to drain a near full 2.00mt high tank, we select & install a 200cm
transducer. The pump is switched to “Automatic” and the white “ON” button pressed.
The pump starts and pumps the level down below 50cm then the pump ramps down &
stops. The pump will only restart when the level rises above 160cm. If the level rises to
190cm (160cm+30cm reserve) the controller generates the alarm “MAX.LEV/ALARM”
A float switch (or a pressure switch) may be connected to XT1 (on the main board)
terminals 1 & 2 OR 3 & 4, opening the contacts stops the control panel working. When
the contacts re-close, the controller will automatically re-start. Turning the selector
switch to the central position will ensure that the pump remains “OFF”, positioning it to
“MAN” enables the manual stop/start switches.
MODE 3: Filling a tank using electrical probes, pressure or float switches. J1
with bridge, J2 without bridge. Bridge XT1,1 & 2, connect switch to 3 & 4 (no time delay to
pump stop) If a time delay is required, Bridge 3 & 4 also, then connect the switch to XT1
pins 6 & 7 and also bridge 7 to 8 (See connections Fig 2,3,4 or 5)
Description:
To fill a tank using a probe system. The pump runs when the 3 probes are submerged,
and conversely, stop when they are not. Pressure/Float switches operate the pumps
when the contacts close.
Worked Example: Once again using a 3 Phase, 3Kw pumpset, electrical load 5.7A
Start the controller in programming mode as detailed on page 6. NB release the buttons
when “P1OFF/COSf0.00” appears, which indicates that this mode can be set.
SCREEN 2:
“P1OFF/COSf0.00”
SCREEN 3:
This page displays the input line voltage (500VAC max.)
SCREEN 4:
"IMP.CURR./00.0 (0-25A) displays the current drawn by the Pump when
running.
SCREEN 9: "SET CURR/…A" Set to 6A
SCREEN 10: “DELAY T. /P00sec” Set to 2 seconds (variable between 1 & 180 sec)
after the water level reaches the probes or the pressure/float switches
close)
SCREEN 11:
"SILL.COS/0.00" initial setting 0.50
SCREEN 13:
"SET ON T./1/24h" Set to 1 hour (Variable between 1 & 24 Hr) Allows
automatic reset after the “NO/WATER” alarm is activated
SCREEN 15:
"LINE/ENABLE 1" Set so that if the set points for
“MIN.LINE/VOLTAGE" or "MAX.LINE/VOLTAGE" alarms are exceeded
for 1 minute the pumps will shut down.
When all values are set, switch the main switch “OFF”, wait for a few seconds to
memorise the data then switch “ON” The memorised data will be retained for up-to 10
years without power
A float switch (or a pressure switch) may be connected to XT1 (on the main board)
terminals 1 & 2 OR 3 & 4, opening the contacts stops the control panel working. When
the contacts close, the controller automatically re-starts. Turning the selector switch to
the central position will ensure that the pump remains “OFF”, positioning it to “MAN”
enables the manual stop/start switches.
MODE 4: Emptying a tank using pressure or float switches or probes: J1 & J2
with bridges.
Bridge XT1, 1 & 2, 6 & 7, 7 & 8. Connect switch to 3 & 4 (no time delay to pump stop).
If a time delay is required, Bridge 3 & 4 as well, then connect the switch to XT1 pins 6 &
7 and also bridge 7 to 8 (See connections Fig 2,3,4 or 5. When using probes, they MUST
be fitted into the Supply tank.
Description
The pump runs when the probes are submerged, and conversely, stop when they are
not. Pressure/Float switches operate when the contacts close.
Worked Example: Still using a 3 Phase, 3Kw pumpset, electrical load 5.7A
Start the controller in programming mode as detailed on page 6. NB release the buttons
when “P1OFF/COSf0.00” appears, which indicates that this mode can be set.
SCREEN 2:
“P1OFF/COSf0.00”
SCREEN 3:
This page displays the input line voltage (500VAC max.)
SCREEN 4:
running.
"IMP.CURR./00.0 (0-25A) displays the current drawn by the Pump when
SCREEN 9:
"SET CURR/…A" Set to 6A
SCREEN 10: “DELAY T. /P00sec” Set to 2 seconds (variable between 1 & 180 sec)
after the water level reaches the probes or the pressure/float switches open
SCREEN 11:
"SILL.COS/0.00" initial setting 0.50
SCREEN 13: "SET onT./1/24h" Set to 1 hour (Variable between 1 & 24 Hr) Allows
automatic reset after the “NO/WATER” alarm is activated
SCREEN 15: "LINE/ENABLE 1" Set so that if the set points for
“MIN.LINE/VOLTAGE" or "MAX.LINE/VOLTAGE" alarms are exceeded for 1 minute
the pumps will shut down.
When all values are set, switch the main switch “OFF”, wait for a few seconds to
memorise the data then switch “ON” The memorised data will be retained for up-to 10
years without power
A float switch (or a pressure switch) may be connected to XT1 (on the main board)
terminals 1 & 2 OR 3 & 4, opening the contacts stops the control panel working. When
the contacts re-close, the controller automatically re-starts
Turning the selector switch to the central position will ensure that the pump remains
“OFF”, positioning it to “MAN” enables the manual stop/start switches.
"SEQ. OR/PHASE F."
No supply from pump
Wrong phase connection
Broken cable to the start switch
Motor fuses burnt out
Supply cable to pump motor
loose/broken
Motor rotation wrong
"No Water" Alarm
"Over Curr" Alarm
"Minimum Voltage" Alarm
"Maximum Voltage" Alarm
Pressure/float switch contact
Probable Cause
Main Switch OFF
Power disconnected
Main indicator off
Supply cable loose
Transformer fuse (0-230-400) blown
Transformer burnt/shorted/open circuit
Main Switch OFF
Supply cable loose or disconnected
No Display
Transformer fuse (0-230-400) blown
Transformer burnt/shorted/open circuit
Display damaged/broken
No pressure in system
No pressure/height display
Low level transducer U/S
Transducer U/S
Problem
Errors
CheckPhasing on 3 phase motors
Check supply/Tank level
Check for 3 Phases, or pump jammed
Check supply within tolerance
Check supply within tolerance
Invert 2 of the incoming phases at the
main switch
Check/Tighten
Repair
Turn to I
Check supply
Check/tighten connections
Check/change fuses
Return to manufacturer/Agent
Turn to I
Check/tighten connections
Check/change fuses
Return to manufacturer/Agent
Return to manufacturer/Agent
Check connection colour sequence
Change the Transducer
Change the Transducer
If the power LED is on, check the
remote contacts
Check/repair both ends of the cable
Check/Change