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Instruction Manual For Power Monitor (PM) Series 14845 WEST 64th AVENUE • ARVADA, COLORADO 80007 USA PHONE: (1+) 303-425-0800 • FAX: (1+) 303-425-0896 • WEBSITE: WWW.SUNDYNE.COM PM Series_MANUAL_1/07/04 Page 1 Table of Contents Description Page Legal Declarations 3 Model Number Definitions 3 Introduction 4 Basic Power Monitor Product Specifications 4 Wiring Diagrams 3-Phase Models Using Internal CT Only 5 3-Phase Models Using External CT 6 1-Phase Model Using Internal CT Only 7 Terminal Block Connections and Definitions 8 Mounting Information 9 Panel Function Definitions 10 Determining Low and High Trips Limits 11 Application Notes Using an External CT 13 Automatic Reset 13 Utilizing the Analog Output 13 Inverted Relay Operation 13 Troubleshooting 14 Optional Display Panel Product Specifications 15 Wiring Diagram 16 Terminal Block Connections and Definitions 16 Mounting Information 17 Panel Definitions 18 Panel Programming Steps and Function Definitions 19 Application Notes: Using an External CT 20 Automatic Reset 20 Utilizing the 4-20 mA Output 20 Hardware and Software Lock 20 Troubleshooting Set-Up Examples PM Series_MANUAL_1/07/04 21 22 Page 2 WARRANTY Sundyne Corporation warrants to Buyer for a period of twenty-four (24) months that equipment at the time of shipment will be free from defects of design, material and workmanship. If any defects or malperformance occur during the warranty period, Sundyne’s sole obligation shall be limited to alteration, repair or replacement at Sundyne’s expense, F.O.B. Factory, of parts or equipment, which upon return to Sundyne and upon Sundyne’s examination prove to be defective. Equipment and accessories not manufactured by Sundyne are warranty only to extend of and by the original manufacturers’ warranty. Sundyne shall not be liable for damage or wear to equipment caused by abnormal conditions, vibration, failure to properly prime or operate equipment without flow or caused by corrosives, abrasives or foreign objects. THE FOREGING WARRANTY IS EXCLUSIVE AND INLIEU OF ALL OTHER WARRANTIES WHETHER EXPRESSED OR IMPLIED INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. In no even shall Sundyne be liable for consequential or incidental damages. EUROPEAN UNION MACHINERY DIRECTIVE This document incorporates information relevant to the Machinery Directive 98/37/EC. It should be read prior to the use of our equipment. Individual maintenance manuals that also conform to the EU Directive should be read when dealing with all models. Although PM Series power monitor complies with the EMC and Low Voltage Directives, satisfactory performance cannot be guaranteed in high noise environments that are outside the EMC limits. THIRD PARTY APPROVALS The PM Series products are designed to meet the industrial control equipment guidelines outlined by Underwriter’s Laboratories (UL) Bulletin 508 and Canadian Standards Association (CSA) Standard 22.2. Please consult the factory for the specific model approval status. COPYRIGHT All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical, photo copying, recording or otherwise without the prior permission of Sundyne Corporation. 2003 Sundyne Corporation PM Series_MANUAL_1/07/04 Page 3 Introduction: INPUT POWER MOTOR INPUTS The relationships between AC motor current and AC motor input power with respect to motor load are shown in figure 1. The motor current remains almost constant between 0 to 50% of motor load while the motor power increases uniformly with increasing load. Using this linear relationship between input power, the user has a method of linking motor power to the pump performance curve to predict flow rate as long as the motor speed remains constant. Motor output power is calculated by multiplying the measured input power by the motor efficiency marked on the motor nameplate. This motor efficiency can fluctuate by several percentage points over the entire motor load range depending on the motor manufacturer standards. CURRENT 0 50 100 PERCENTAGE OF MOTOR LOAD FIGURE 1 A power monitor is a simple flow indicator that associates a digital (input or calculated output power) value to a specific pump flow rate. The decision-making capability inside the power monitor permits the user to setup a power window of pump operation. This window has a programmable low limit (value just above minimum flow) and a programmable high limit (value equal to the point just prior to end of curve/cavitation). If the pump motor operates outside of this window longer than a defined time period, then the monitor will open a relay contact (electrical mechanical switch) that will cause a controller to remove power from the pump motor, thus stopping the pump operation before damage can occur. -Basic Power MonitorProduct Specifications: Model No. PM 1200 PM 1300 PM 1100 Description - Voltage Sampling Range 3-PH Power Monitor, 230 to 575 VAC 3-PH Power Monitor, 600 to 660* VAC (Optional) 1-PH Power Monitor, 100 to 250 VAC (Optional) *Note: Underwriters Laboratory has a maximum voltage limit of 600 VAC, model PM1300 cannot be UL listed. Motor Current Sampling Range (All Models) 0 – 65 Amp Internal CT N Amp with CT ratio of N: 5 Amp External CT High Trip Limit Low Trip Limit Range Start-Up / Low Trip Delay High Trip Delay Frequency Range Control Supply Relay Output: Rating Type Analog Output Activation Voltage - K Inputs Environment Restriction Operating Temperature Enclosure: Material Mounting Rating Dimensions Third Party Approvals PM Series_MANUAL_1/07/04 FIGURE 2 High Trip = kW range set (adjustable from panel pot) 20 to 80% of kW Power Range (adjustable from panel pot) 1 - 30 seconds (adjustable from panel pot) 1 - 10 seconds (adjustable from panel pot) 45 - 65 Hz 115/230 VAC ± 10%, 50/60 Hz, 1-Ph 5 Amp @ 250 VAC (non-inductive) SPDT, Normally Close 0 –10 VDC (directly proportional to kW range selected). 12 – 30 VDC The unit must be kept away from moisture. +5 to +122°F (-15 to +50 °C) Upper:White Lexan (UL94-V0), Lower:Black Noryl (UL94-V0) 35 mm DIN Rail NEMA 1 Type (IP 20) 2.76 in. x 3.38 in. x 2.28 in. (70 mm x 86 mm x 58 mm) CE (UL and C-UL pending) Page 4 Wiring Diagram: 3-Phase Unit with Internal CT Only PHASE L3 PHASE L2 PHASE L1 INTERNAL CURRENT SENSOR 1 L1 2 3 L2 NC 13 C 14 NO 15 16 4 5 L3 6 7 230 VAC 8 CONTROL VOLTAGE 9 115 VAC 10 11 STARTING COIL VOLTAGE N 12 +12V 17 K1 18 K2 19 K3 20 GND 21 VD + 22 VP 23 VN 24 STOP OPTIONAL DISPLAY 0 - 10 VDC START AUX. MOTOR STARTER OL M M M M AC 3-PHASE MOTOR FIGURE 3 Note: The normally closed (NC) relay contact is closed when the unit is powered and no trip condition exists. ! CAUTION The PM Series power monitor is directly connected to the AC supply that powers the motor. Dangerous voltage potentials are present. Qualified personnel must perform all installation and servicing with the AC supply disconnected and locked out. PM Series_MANUAL_1/07/04 Page 5 Wiring Diagram: 3-Phase Unit with External CT PHASE L3 PHASE L2 HI PHASE L1 X2 X1 EXTERNAL CURRENT TRANSFORMER INTERNAL CURRENT SENSOR 1 L1 NC C NO 2 3 L2 +12V K1 K2 K3 GND VD + VP VN L3 6 7 230 VAC 8 CONTROL VOLTAGE 9 115 VAC 10 11 N 12 STARTING COIL VOLTAGE 14 15 16 4 5 13 STOP 17 18 19 20 21 OPTIONAL DISPLAY 22 23 24 0 - 10 VDC START AUX. MOTOR STARTER OL M M AC 3-PHASE MOTOR M M FIGURE 4 Note: The normally closed (NC) relay contact is closed when the unit is powered and no trip condition exists. WIRE WITH MOTOR CURRENT FLOWING Using an External Current Transformer 1. The external CT must be rated for wattmeter usage to obtain correct power reading. 2. The “XI” wire lead from the transformer is passed through the internal CT and is connected to the other wire lead, X2. 3. To maintain proper current direction, the wire from the power supply must enter the core of the external CT from the side marked “HI”. 4. Refer to the page 13 in application notes for further details. ! FIGURE 4 SECONDARY WIRES CONNECT THRU INTERNAL CT EXTERNAL CT WITH ONE TURN FIGURE 5 CAUTION The PM Series power monitor is directly connected to the AC supply that powers the motor. Dangerous voltage potentials are present. Qualified personnel must perform all installation and servicing with the AC supply disconnected and locked out. PM Series_MANUAL_1/07/04 Page 6 Wiring Diagram: 1-Phase Unit with Internal CT PHASE L2 PHASE L1 INTERNAL CURRENT SENSOR 1 L1 2 3 L2 NC 13 C 14 NO 15 16 4 5 +12V 17 6 K1 18 K2 19 K3 20 GND 21 VD + 22 VP 23 VN 24 7 230 VAC 8 CONTROL VOLTAGE 9 115 VAC 10 11 STARTING COIL VOLTAGE N 12 STOP OPTIONAL DISPLAY 0 - 10 VDC START AUX. MOTOR STARTER OL M M M AC 1-PHASE MOTOR FIGURE 6 Note: The normally closed (NC) relay contact is closed when the unit is powered and no trip condition exists. ! CAUTION The PM Series power monitor is directly connected to the AC supply that powers the motor. Dangerous voltage potentials are present. Qualified personnel must perform all installation and servicing with the AC supply disconnected and locked out. PM Series_MANUAL_1/07/04 Page 7 Terminal Block Connections and Definitions: INTERNAL RELAY CONTACTS (NO, NC) REMOTE RESET AND TRIP INHIBIT INPUTS EXTERNAL DISPLAY SIGNAL ANALOG OUTPUT SIGNAL (0 - 10 VDC) 1. It is strongly recommended that all wiring be done according to local electrical codes. 24 13 13 14 15 16 17 18 19 20 21 22 23 24 4 5 6 . 4 5 6 2. The terminal block will accept a maximum of 12-gauge wire (2 mm). 5 4 5 6 Loa d 73 7 73 82 8 0 82 10 Ts 9 9 1 9 1 HighDelay(s) 0 0 Hig h Limit / Range (kW) 15 Sta rt- T Hig h T rip Low Lo w T rip 0 30 PM Seri es Ts Delay(s) Limit (% ) In t. C T 52 15 44 M ax65A 60 Reset 36 68 0 30 28 76 Low Delay(s) L1 L2 L3 20 3 2 x10 1 1 0 2 3 4 5 6 7 8 3. Maximum recommended installation torque for the terminal block screws is 7 lb-in (0.79 N-m). 4. The internal CT opening has maximum opening of 0.39 in. (10 mm) that limits the wire size to #6 (4.1 mm). 9 10 11 12 1 Field Wiring Guidelines 12 5. Use copper wire only. CONTROL VOLTAGE (115 /230 VAC, 50/60 Hz, PH 1) MOTOR SAMPLE VOLTAGE INPUT No. 1 2 3 4 5 6 7 8 9 10 11 12 FIGURE 7 Description Phase Voltage L1 Input Do not use Phase Voltage L2 Input Do not use Phase Voltage L3 Input Do not use 230 VAC Do not use 115 VAC Do not use N Do not use No. 13 14 15 16 17 18 19 20 21 22 23 24 Description Relay Contact, Normally Closed Relay Contact, Pole Relay Contact, Normally Open Do not use +12 VDC Unregulated (For ”K” Inputs Only) K1, External and Automatic Reset K2, Disable Low Trip Function K3, Disable High Trip Function Isolated DC Ground VD+, Display input VP, Analog Output VN, Analog Output Remote Reset and Inhibit Inputs: The control inputs are isolated (2500 Vrms) by means of opto-couplers. Connecting terminal 17 (isolated 12 VDC, unregulated supply) to one of the inputs will activate it. The inputs can also be wired for PLC operation: Analog Output: A non-isolated monitoring signal (0 – 10 VDC) is available at terminals 23 (VP) and 24 (VN) that can be connected to a voltmeter for digital visualization of the measured input power. Zero kW Power High Trip (kW Range Setting) Minimum Load Impedance PM Series_MANUAL_1/07/04 0V 10 V 1 Meg. Ohms 12 - 30 VDC 16 +12V 17 K1 18 K2 19 K3 20 GND 21 VD + 22 VP 23 VN 24 PLC DC SUPPLY COMMON 0 - 10 VDC FIGURE 8 Page 8 Mounting Information: The power monitor must be installed inside either a motor starter control cabinet or a similar electrical enclosure to shield it from moisture. The unit attaches to a standard 35 mm DIN rail (not supplied by Sundyne). 2.28 IN. (58 MM) 13 24 1 3 1 4 15 1 6 1 7 18 19 20 21 2 2 23 24 4 5 6 . 4 5 4 6 5 5 6 3 7 3 7 3 7 2 8 2 8 2 8 x10 1 0 Hi gh Trip 9 1 0 9 0 L imit / Ran ge ( kW) 9 1 S tart-T Lim it (% ) 52 60 44 Int. CT Ma x 65A 36 68 28 L2 1 2 Ts High 15 3.38 IN. (86 MM) Low Low Tri p PM Series L1 Load 0 10 Hig h De lay(s ) L3 3 4 5 6 20 76 7 0 30 T s De lay(s ) 15 Reset 0 30 Low Delay (s) 8 9 1 0 11 12 1 12 2.76 IN. (70 MM) 0.39 IN. (10 MM) MOUNT RELEASE CORE OF INTERNAL CURRENT TRANSFORMER FIGURE 9 The unit must be kept away from moisture. +5 to +122°F (-15 to +50 °C) Upper: White Lexan (UL94-V0), Lower: Black Noryl (UL94-V0) 35 mm DIN Rail NEMA 1 Type (IP 20) 2.76 in. x 3.38 in. x 2.28 in. (70 mm x 86 mm x 58 mm) Environment Restriction Operating Temperature Enclosure: Material Mounting Rating Dimensions ! Warning The PM Series products are not to be located in Hazardous Areas, which are defined as areas where there is a presence or possible presence of a flammable gas/air mixture. PM Series_MANUAL_1/07/04 Page 9 Panel Function Definitions: HIGH LIMIT MULTIPLIER HIGH LIMIT SETTING (3-DIGIT) 13 24 13 14 15 16 17 18 19 20 21 22 23 24 4 3 2 x10 5 6 . 4 5 4 6 7 3 8 2 5 5 6 1 0 9 1 0 9 1 0 9 Limit / Rang e (kW) 36 1 2 3 4 5 15 Rese t 68 28 L3 6 20 High 0 30 T s Delay(s) Limit ( %) 52 60 44 In t. CT Max 65A 15 Ts Lo w Low Trip P M Se rie s L2 0 10 High Delay(s) St art-T High Trip L1 L oad 7 8 73 82 30 0 76 Low Delay( s) 7 8 HIGH TRIP TIME DELAY SETTING LOAD MEASURED LED START TIME DELAY STATUS HIGH TRIP STATUS LOW TRIP STATUS RELAY CONTACT STATUS START-UP TIME DELAY SETTING LOCAL RESET BUTTON 9 10 11 12 12 1 LOW TRIP TIME DELAY SETTING LOW LIMIT SETTING FIGURE 10 Marking Function Description X1 - X10 High Limit Multiplier: Adjusts the High Trip limit setting value by a factor of 10. High Trip Limit High Limit Setting: Upper power limit of the operating window is defined by this value. If the measured power is higher than this value, then a trip condition is recognized. High Trip Delay High Trip Delay Time Setting: When the measured power exceeds the High Trip setting, an internal timer is activated. The measured power must return below this limit within a defined time period or a trip condition will be accepted. This time period is defined as the High Trip Delay. Load Load Measured LED: Will be on when the measured load is higher than 5% of kW setting, otherwise it will flash at 1/2-second intervals. Ts Start Time Delay Status: The LED is on when start-up timer is active. High High Trip Status: The LED is on when High Trip condition is recognized, and the LED flashes (0.5 second on-off) when High Trip condition is accepted. Low Low Trip Status: The LED is on when High Trip condition is recognized, and the LED flashes (0.5 second on-off) when High Trip condition is accepted. Relay Contact Status: The LED is on when the internal, normally closed relay contact is closed. Ts(s) Start Up Time Delay Setting: The High and Low trip functions are disabled during motor start-up (power-up) for a fixed period of time. Reset Local Reset Button: Push to clear all trip functions to close relay contact Low Trip Delay Low Trip Delay Time Setting: When the measured power falls below the Low Trip setting, an internal timer is activated. The measured power must return above this limit within a defined time period or a trip condition will be accepted. This time period is defined as the Low Trip Delay. Low Trip Limit Low Limit Setting: Lower power limit of the operating window is defined by this value. If the measured power is lower than this value, then a trip condition is recognized. PM Series_MANUAL_1/07/04 Page 10 Determining the Low and High Trip Limits: The basic power monitor performs three tasks once it is connected to a pump drive motor: • • • Measure the electrical input power in kW Compare the measured power value to a minimum and maximum power settings Set and latch an internal relay contact (open or close) based on the comparison result The minimum (Low) limit is the input power measurement setting that is associated with: • • Low Flow Severe Cavitation • • Magnetic Decoupling (Magnetic Drive Pumps) Reduction in Fluid Viscosity The maximum (High) limit is the input power measurement setting that is associated with: • • • Seizure of Rotating Parts High Flow Operation (Operating at the end of pump curve) Increase in Fluid Viscosity The High and Low limits (trips) can be estimated from the pump performance curve: 1. Write down the motor output power (POUT @ min. and POUT @ max.) values for the minimum and maximum flow points that are defined by application sheet. 2. Calculate the percentage ratio of minimum power to the maximum power: (POUT @ Min / POUT @ Max) x 100 3. Set the Low Limit (%) dial to this percentage value or to the nearest percentage value above it. (for example, if 41.5 % is calculated, then choose 44%) 4. Multiply the POUT @ Max by the specific gravity (S.G.) of the fluid to be pumped. 5. Add any magnetic coupling (PMC) losses (if any) to this value. HIGH LIMIT 6. Determine what motor size (or rating) is needed to operate the pump for the maximum flow. Load 7. Select a motor from a manufacturer’s catalog, and record Ts the motor efficiency value at full load. High St art -T High Trip Low 8. Divide the adjusted maximum power value by the motor Low T rip PM Series efficiency value. (Note: If this power value is not in kW, Reset then convert it) 9. Set the High Limit (3-digit) to this value. x1 4 5 3 2 x1 0 6 . 4 5 73 82 1 0 6 4 5 7 8 9 1 9 9 1 0 0 Lim it / Ra ng e ( kW) 0 30 T s Dela y(s) 15 44 36 Note: The motor power required by the pump can change if the fluid property (specific gravity, viscosity, temperature) changes in the application. 0 10 High Dela y(s) 15 Limit (%) 52 60 Int. CT Max 6 5A L1 5 6 7 3 8 2 L2 LOW LIMIT L3 28 68 20 76 0 30 Low Delay( s) FIGURE 11 To operate the monitor when the limits are not known, it is recommended to set the pots to values shown and/or calculated from this table: Marking Ts(s) High - Tr(s) Low - Tr(s) Low Limit High Limit Adjust Monitor Panel Pots for Initial Start-Up as Follows Definition Initial Set Value Start Time Delay 5 Seconds (Approximately) High Trip Delay 5 Seconds (Approximately) Low Trip Delay 5 Seconds (Approximately) Low Trip Value 20% Motor rated power (hp) x 0.746 / 0.81 High Trip Value2 Motor rated power (kW) / 0.81 Note: 1. The monitor measures input power in kW, so this equation estimates the input power value in kW of the pump motor at 100% of rated load. The equation assumes that the motor is 80% efficient. 2. If external CT is to be used, then refer to application section on page 13 for kW range setting limits on the monitor. PM Series_MANUAL_1/07/04 Page 11 A simple way to set the Low and High Trip values is to operate the pump at the two extreme flow rates (maximum and minimum) defined in application parameters. 1. Make sure that the suction pipe and the pump are filled with liquid, and the suction valve is completely open. 2. Start the pump, and adjust the discharge valve until the application maximum flow is reached. ! PUMP OPERATION Do not run out on the pump curve if throttling is necessary because cavitation may occur. 3. Decrease kW setting value slowly until the HIGH LED turns on. The motor starter can and will switch off at this point after the time delay is completed. (Press the Reset button on monitor panel to clear any trips.) DELAY TIMERS SETTINGS 4. Start the pump again and verify that the pump does shut-off at this point. The HIGH LED will be on, and Contact LED is off. Note: The time to shut-off the pump from a start-up condition is equal to the sum of start time (Ts) and the High Limit Delay Setting (High-Tr). 5. If the pump does not shut off, then repeat steps 3 and 4 until the pump does shut off at this flow point. x1 4 5 3 2 x1 0 6 . 4 5 6 4 5 5 6 73 7 3 7 82 8 2 8 1 0 9 1 0 9 1 0 9 Lim it / Ra ng e ( kW) St art -T High Trip Limit (%) 52 60 44 Int. CT Max 6 5A 36 L2 Ts High 15 Low Low T rip PM Series L1 Load 0 10 High Dela y(s) L3 28 68 20 76 6. Press the Reset button on the monitor panel to clear any trips. 0 30 T s Dela y(s) 15 Reset 0 30 Low Delay( s) FIGURE 12 7. Start the pump again and adjust the discharge value for the normal operating flow point. Note: Only two LEDs (LOAD and Contact) should be on after Ts LED is off. 8. Adjust the discharge valve to the minimum flow point required in the application. If this value is very close to no flow condition, then consult with the pump manufacturer for cautionary advice. ! PUMP OPERATION Try to limit pump operation time at minimum flow for no more than a few seconds until the Low Trip Limit is set. Do not exceed 5-10 seconds at any one time. 9. Increase the LOW Trip limit setting until the LOW LED is on. The motor starter can and will switch off at this point after the time delay is completed. (Press the Reset button on monitor panel to clear any trips) 10. Start the pump again and adjust the discharge valve until the normal operating flow is reached. Only two LEDs (Load and Contact) should be on after Ts LED is off. 11. Verify the limits by adjusting the discharge valve for the two flow conditions. Fine-tune the trip limits where it is needed. (Time delays may also need tuning to reduce nuisance tripping.) Note: Let the pump run for a few hours to allow the AC motor to warm-up. The trip values may need to be fine-tuned to compensate for power variation between cold (not used for 24 hours) motor and hot (operating for 2 hours or more) motor. PM Series_MANUAL_1/07/04 Page 12 Application Notes: Using an External CT with the Power Monitor The kW range on the monitor must be adjusted to accept only the 0 – 5 amps current range from the CT secondary. The recommended kW value is shown in this chart for the nominal line voltage or a value can be calculated from the basic power equation given: The maximum kW range with external CT (N:5) is defined: Max. kW = N (primary value) x kW Setting (monitor) x 0.2 Note: The nominal motor voltage can influence this maximum kW setting for the Monitor. If the calculated kW value is higher than the kW setting shown for the voltage indicated, then use the kW setting shown for the voltage as the maximum kW setting. Nominal Voltage 208 VAC 230 VAC 380 VAC 415 VAC 460 VAC 575 VAC 600 VAC kW Setting 1.80 1.99 3.29 3.59 3.98 4.98 5.20 Basic Power Equation kW Setting = Nom. Volt x .00866 Automatic Reset Connecting a wire jumper between terminals 17 and 18 will enable the Automatic Reset feature. This reset feature will automatically clear a trip condition after a trip has been recognized. WIRE JUMPER 16 +12V 17 K1 18 K2 19 K3 20 GND 21 Utilizing the Analog Output VD + 22 A non-isolated monitoring signal (0 – 10 VDC) is available at terminals 23 (VP) and 24 (VN) that can be connected to a voltmeter (or a process meter with scaling) for digital visualization of the measured power. The linear relationship of signal to the measured power is defined by this equation: VP 23 VN 24 Note: When this feature is used, it is strongly recommended that a separate start command be required to start the motor thus preventing unexpected system start-up. 0 - 10 VDC FIGURE 13 Measured kW = analog output value (from monitor) x kW setting value (from monitor) x 0.1 Note: Terminal 24 (VN) is connected to the measured ground reference formed by (3) Mega ohm resistors arranged in Y-configuration across three-phase line. The voltage potential is relative low, but connecting this terminal to external equipment may result in measurement errors. Inverted Relay Operation Depending on the specific control logic requirements, the internal relay contact action may need to be reversed where a close contact will indicate a trip condition instead of an open contact. To obtain this inverted relay operation, the user is advised to use the normally open relay contact (terminal 15) instead of normally closed contact (terminal 13). Note: When control power is applied to the monitor and no trip condition exists, terminal 15 will be open. NC C NO 13 14 15 16 +12V 17 FIGURE 14 PM Series_MANUAL_1/07/04 Page 13 Troubleshooting: Condition Suggestion The wire direction for the current sampling is reversed through the internal CT in the Monitor. The wire from the power supply side must enter the internal CT core from the top (terminal block side marked 13-24) of the Monitor. The Monitor Load LED is not on when the motor is running. The current sampling is not done on the same phase wire that is connected to terminal 1 (L1) on Monitor. Have a qualified person check the wiring. The measured power is less than 5% of kW setting, so the kW setting must be lowered. Adjust the kW setting to equal the motor rating (in kW) times 1.25 (assuming an 80% motor efficiency). Contact Sundyne for further assistance. No LEDs are on when the monitor is powered up. The control power supply at terminals 7 and 9 or 8 and 9 of the Monitor does not have the proper voltage. Have a qualified person check the fusing and wiring. Contact Sundyne for further assistance. The High Trip limit may be set too high. Lower the High Trip setting until the High Trip LED goes on. The motor does not trip on the High Trip setting. The High Trip time delay is set too high, and may need to be lowered. The K3 input (High Trip Inhibit) at terminal 20 is activated. The Contact LED is off, but the motor is still running. The trip contact may be welded together. Have a qualified person check the continuity of the contact. Contact Sundyne for further assistance. The Low Trip limit may be set too low. Increase the Low Trip setting until the Low Trip LED goes on. The motor does not trip on the Low Trip setting. The Low Trip time delay is set too high, and may need to be lowered. The K2 input (Low Trip Inhibit) at terminal 19 is activated. The unit trips the motor during short underload or overload conditions. Remote Reset and Trip Inhibits do not operate properly. Increase the trip time delays or adjust the trip limits to compensate for the intermittent load surges. The remote switch contact may be rated for 10 A. or higher, and this contact may have oxidized causing high circuit resistance. Replace the switch with one that has a low current (1A. or less) rating. The DC common of an external driver (PLC or other control device) is not connected to the monitor common (terminal 21). PM Series_MANUAL_1/07/04 Page 14 - Optional Display PanelModel Description Number PM-2000 Display Panel Only PM-2011 Display Panel with Model PM-1100 Monitor PM-2012 Display Panel with Model PM-1200 Monitor PM-2013 Display Panel with Model PM-1300 Monitor Note: The power monitor specifications are listed on page 4 of this manual. Product Specifications: FIGURE 15 Product Type Display Panel Digital Screen LED, 3 digit, 0.3 in. (7.62 mm) High Power Requirements 10 VDC / 50 mA (Provided from Power Monitor) Analog Output (Passive) Range Input Voltage Range Maximum Load Resistance Short Circuit Protection Reverse Voltage Protection 4 –20 mA ± 1% @ 24 VDC (proportion to power range set) 15 to 30 VDC R= (Vp-12)/0.022, Vp=Input Voltage (i.e. 545 Ohms @ 24VDC) Yes Yes Activation Voltage - K Inputs 12 – 30 VDC Start-Up Timer 1 – 999 seconds High and Low Trip Delays 1 – 99 seconds Trip Range 5% to 100% of Maximum Power Value Display Power Units HP, kW, or % kW Parameter Program Lock Software Hardware Embedded command entered from keypad Closed connection between terminals 6 and 7 Communication Distance The maximum wire distance between the Power Monitor and the Display Panel is 25 ft (7.62 m). A twisted wire pair is recommended for the distance between 1 ft (0.3 m) to 6 ft (1.82 m), and shielded wire for distance over 6 ft (1.82 m) Environment Restriction Keep the unit out of direct sunlight Operating Temperature +5 to +122°F (-15 to +50 °C) Enclosure: Flame Resistant Noryl Panel 2.83 in. x 2.83 in. x 2.70 in. (72 mm x 72 mm x 68.6 mm) NEMA-12 Type (IP- 54) NEMA-4X (IP- 66) with optional translucent, plastic hood* Material Mounting Dimensions Rating Third Party Approvals *Note: CE (UL and C-UL is not required if supply is under 32 VDC) Contact the factory for further information on the optional translucent, plastic hood. PM Series_MANUAL_1/07/04 Page 15 Wiring Diagram: OPTIONAL DISPLAY PANEL NC C NO +12V K1 K2 K3 GND VD + VP VN 13 14 1 15 2 16 3 17 4 18 5 19 6 20 7 21 8 22 9 23 10 24 DV+ GND PM 2000 K1 K2 K3 V+ K GND Iout Vin VOLTAGE INPUT FOR 4-20 mA 4-20 mA OUTPUT FIGURE 16 POWER MONITOR Terminal Block Connections and Definitions: Field Wiring Guidelines BACK OF DISPLAY 1. The terminal block will accept a maximum of 12-gauge wire (2 mm). 1 2 3 4 5 6 7 8 9 10 FIGURE 17 No. 2. Maximum recommended installation torque for the terminal block screws is 4 lb-in (0.6 N-m). 3. Use copper wire only. Description No. Description 1 DV+, Supply Signal from Monitor 6 K3, Hardware Parameter Lock 2 GND, DC Common 7 V+, DC Supply (For K Inputs Use Only) 8 K GND, DC common for K Inputs Only 3 , Cable Shield Connection 4 K1, Remote Reset 9 Iout, 4-20 mA Output 5 K2, Do Not Use 10 Vin, Voltage Input for 4-20 mA Note: The I/Os on Monitor are internally switch-off when the Display Panel is connected: • Control Inputs (K1, K2, K3) • High / Low Limit Pots • Panel LEDs (Start-T, Low, High) • Delay Timer Pots Remote Reset and Control Inputs: The control inputs are isolated (2500 Vrms) by means of opto-couplers. Local operation is accomplished by connecting terminal 7 (V+) to inputs (K1 or K3) to activate them, but terminal 8 (K GND) must be connected to terminal 2 (GND). The inputs can also be wired for PLC operation: Analog Output: DC SUPPLY COMMON 12 - 30 VDC 1 2 PLC Zero Measured Power Max. Measure Power 4 mA 20 mA 136 Ohms@ 15V Maximum Load Impedance 818 Ohms@ 30V Note: See the application notes on page 20. PM Series_MANUAL_1/07/04 3 4 An isolated (2500 VAC to measured voltage), passive monitoring signal (4-20 mA) is available at terminals 9. 5 6 7 8 4-20 mA OUTPUT VOLTAGE INPUT FOR 4-20 mA DV+ GND 9 10 K1 K2 K3 V+ K GND Iout Vin FIGURE 18 Page 16 Mounting Information: 2.83 IN. (72 MM) TM 0.25 IN. (6.35 MM) PM Series 2.50 HP PRGM PWR Max Ext. CT MTR Eff PTR kW kW kW % Aux Locked Start-T Trip Pt. T-Delay HIGH LOW DETACHABLE TERMINAL BLOCK Mode 2.63 IN. (66.5 MM) Reset PM-2000 2.70 IN. (68.6 MM) 2.83 IN. (72 MM) FIGURE 19 The Display Panel is normally mounted to a control cabinet door or a similar electrical enclosure. The supplied neoprene rubber gasket or a similar sealing device is required to seal the air gap between the cutout opening and the enclosure from the outside environment. To obtain NEMA-4X rating, an optional translucent plastic hood is fitted over the front panel before it is mounted to the panel door. ADJUSTABLE BRACKET (TWO ARE SUPPLIED) 2.68 IN. (68 MM) RECOMMENDED 2.68 IN. (68 MM) CUTOUT DIMENSIONS OPTIONAL TRANSLUCENT PLASTIC HOOD Environment Restriction Operating Temperature Enclosure: Material Mounting Dimensions Rating NEOPRENE RUBBER GASKET SUPPLIED WITH THE UNIT PANEL WALL FIGURE 20 Keep away from direct sunlight +5 to +122°F (-15 to +50 °C) Flame Resistant Noryl Panel 2.83 in. x 2.83 in. x 2.70 in. (72 mm x 72 mm x 68.6 mm) NEMA-12 Type (IP - 54) NEMA-4X (IP- 66) with optional translucent, plastic hood* * Note: Contact the factory for further information on the optional translucent, plastic hood. ! Warning The PM Series products are not to be located in Hazardous Areas, which are defined as areas where there is a presence or possible presence of a flammable gas/air mixture. PM Series_MANUAL_1/07/04 Page 17 Panel Definitions: PM Series 2.50 HP PRGM PWR Max Ext. CT MTR Eff PTR kW kW kW % Aux Locked Start-T Trip Pt. T-Delay HIGH LOW DISPLAY SCREEN UP ARROW KEY DOWN ARROW KEY Mode MODE ARROW KEY Reset RESET ARROW KEY PM-2000 FUNCTION LEDS Function LEDs Notes HP The power reading is shown in horsepower. kW The power reading is shown in kilowatt. % kW Aux FIGURE 21 The power reading is shown in percent of kilowatt. Not used. Locked The parameters settings are protected by either software or hardware lock. Start-T The start-up time delay (1 to 999 seconds) entered. Trip Pt The displayed power value is a trip point. T- Delay The time delay (1 to 99 seconds) entered for a trip (limit) point. PRGM The monitor is in the program mode. PWR Max The maximum motor rating entered. Ext. CT The external current transformer (CT) ratio (off, 50 to 500) entered. MTR Eff The motor efficiency value (50 to 100%) entered. PTR kW The recommended kW value for Monitor Range is shown on display screen. High The displayed value is a High Trip (limit) point. Low The displayed value is a Low Trip (limit) point. Buttons Notes f Up Arrow Button: Push to increase value. g Down Arrow Button: Push to decrease value. Mode Mode Switch Button: Push to advance to next function in program mode. Reset Local Reset Button: Push to clear all trip functions and to close relay contact. Program Exit Button: Push to exit from program mode. PM Series_MANUAL_1/07/04 Page 18 Panel Programming Steps and Function Definitions: Step Press Button LEDs On 1 Mode PRGM, Locked On or Off An internal software lock can be engaged to prevent unwanted parameter changes. This software lock will automatically be switched on, if no button is pushed within a 60-second time period. PRGM, Locked On or Off Press T and S together to toggle the lock on or off. (Default=On) 2 T and S Display Value Function Definition The High and Low trips are disabled during motor start-up for a fixed period of time (start-up delay). (Default =15 seconds) The T or S are used to enter a value from 1 - 999 seconds. 3 Mode PRGM, Start-T #Value 4 T or S PRGM, Start-T #Value 5 Mode PRGM, Trip Pt., High #Value Upper power limit of the operating window is defined by this value. If the measured power is higher than this value, then a trip condition is recognized. (Default value = max. power value) 6 T #Value The T or S are used to enter a value. 7 Mode #Value Lower power limit of the operating window is defined by this value. If the measured power is lower than this value, then a trip condition is recognized. (Default value = 5% of max. power value) 8 T or S PRGM Trip Pt., Low #Value The T or S are used to enter a value. 9 Mode PRGM T-Delay, High #Value When the measured power exceeds the High Trip setting, an internal timer is activated. The measured power must return below this limit within a defined time period or a trip condition will be accepted. This period is the High Trip Delay. (Default =5 seconds) or S PRGM T-Delay, High or S 10 T 11 Mode 12 T or S 13 Mode 14 T 15 16 T 17 18 T or S 19 Mode PRGM, Trip Pt., High PRGM Trip Pt., Low PRGM T-Delay, Low PRGM T-Delay. Low #Value The T or S are used to enter a value from 1 - 99 seconds. #Value When measured power falls below this Low Trip setting, an internal timer is activated. The measured power must return above this limit within a defined time period or a trip condition will be accepted. This period is the Low Trip Delay. (Default =15 seconds) #Value The T or S are used to enter a value from 1 - 99 seconds. PRGM Hp or kW or %kW PRGM Hp or kW or %kW P.Un Select the power units (horsepower, kilowatt, or % of kW) that measured electrical power will be displayed in. P.Un The T or S are used to select the power units. Mode PRGM, PWR Max. #Value Enter motor output rating. The decimal point can be repositioned in the step 18, if required. or S PRGM, PWR Max #Value The T or S are used to enter a value. Mode PRGM, PWR Max #Value Place the decimal point in PWR Max. value. PRGM, PWR Max #Value The T or S are used to shift the decimal point. (X.xx, XX.x, or XXX) PRGM, Ext. CT #Value When the motor current is higher than 65 amps, an external CT is required. The unit will work with external CTs with ratio of xxx: 5. PRGM, Ext. CT #Value The T or S are used to select the external CT setting: Off =No Ext. CT, 50 =50:5 CT, 60 =60:5 CT, 75 =75:5 CT, 100 =100:5 CT, 125 = 125:5 CT, 150 =150:5 CT, 200 =200:5 CT, 250 =250:5 CT, 300 =300:5 CT, 400 =400:5 CT, 500 =500:5 CT. (Default = Off) or S 20 T or S 21 Mode PRGM, MTR Eff. #Value 22 T or S PRGM, MTR Eff. #Value #Value This is the maximum kW range value (calculated internally by the 3 panel display) that should be entered on the power monitor. #Value Reads measured motor power. 23 Mode PRGM, PTR kW, kW 24 Mode Hp or kW or %kW Notes: 1. 2. 3. The efficiency value for 100% of motor full load is used to internally calculate the maximum input power range in kW. The T or S are used to enter a value from 50 to 100. (Default=100) Press the Reset button on Display Panel to exit any time from the Program Mode. An automatic “exit” signal is generated internally, if no buttons are pushed within 30 seconds while in the Program Mode. When an external CT is used, the nominal motor voltage influences the maximum kW setting for the Monitor. The maximum kW range value for the monitor cannot be higher than the kW setting listed on page 20 in the application notes for that nominal motor voltage. PM Series_MANUAL_1/07/04 Page 19 Application Notes: Using an External CT with Display Panel Nominal Voltage 208 VAC 230 VAC 380 VAC 415 VAC 460 VAC 575 VAC 600 VAC The Display Panel calculates a maximum kW value for the Monitor under the PTR kW function. When an external CT is used, the nominal motor voltage can influence this maximum kW setting. If the calculated kW value is higher than the kW setting shown for the voltage indicated, then use the kW setting shown for the voltage as the maximum kW setting. Note: If the specific motor voltage is not shown, then use the basic equation to calculate the maximum kW setting. kW Setting 1.80 1.99 3.29 3.59 3.98 4.98 5.20 Basic Power Equation kW Setting = Nom. Volt x .00866 Automatic Reset Connecting a wire jumper between terminals 4 and 7 on the Display will enable the Automatic Reset feature. This reset feature will automatically clear a trip condition after a trip has been recognized. 1 2 Note: When this feature is used, it is strongly recommended that a separate start command be required to start the motor thus preventing unexpected system start-up. WIRE JUMPER DV+ GND 3 4 5 6 Utilizing the 4-20 mA Output 7 An isolated (2500 VAC from the Power Measuring side) monitoring signal (4 – 20 mA) is available at terminals 9 (Iout) that can be connected to a process meter or to a PLC for a process feedback signal. This signal requires an external DC supply (15 to 30 VDC) to be connected to terminal 10 (Vin) for the output to work. The linear relationship of 4-20 mA signal to the measured power is defined by this equation: 9 8 10 K1 K2 K3 V+ K GND Iout Vin VOLTAGE INPUT FOR 4-20 mA 4-20 mA OUTPUT FIGURE 22 Equation Definitions Notes Measured power = Current value (mA) x Slope + Intercept Slope = Power Max. (Value entered at PWR Max. Step) / 16 Intercept = Power Max. – (20 x Slope) Current value = 4-20 mA signal from the Display In a trip condition, the output current value is less than 1 mA. Hardware and Software Lock To prevent unwanted changes to the parameter values entered into the Display, a software or hardware lock is used. The software lock will automatically be switched on, if no button is pushed within a 60-second time period. Software (Panel Entered) Lock Hardware (Terminal Block) Lock • Press the Mode button once • Press T and S buttons together each time to change the lock state. Connect terminal 6 and 7 together to switch on the parameter lock. To use terminal 7, terminal 8 (K Gnd) must be connected to terminal 2 (Gnd) Note: The parameter lock status will be displayed on LED screen. PM Series_MANUAL_1/07/04 Note: The hardware lock cannot be turned off from the front panel. Page 20 Troubleshooting: Condition Suggestion The wire direction for the current sampling is reversed through the internal CT in the Monitor. The wire from the power supply side must enter the internal CT core from the top (terminal block side marked 13-24) of the Monitor. The Display Panel does not read motor power when the motor is running. The current sampling is not done on the same phase wire that is connected to terminal 1 (L1) on Monitor. Have a qualified person check the wiring. The measured power is less than 5% of kW setting, so the kW setting must be lowered. Adjust the kW setting to equal the motor rating (in kW) times 1.25 (assuming an 80% motor efficiency). Contact Sundyne for further assistance. Display Panel does not light up when power is applied to Monitor. The motor does not trip on the High Trip setting. The Display Panel reads power when High or Low LEDs indicated a Trip. The motor does not trip on the Low Trip setting. The T and S buttons do not work in Program Mode. The remote Reset and Hardware Lock inputs do not operate properly. The two wire connections from the Monitor to the Display Panel maybe reversed. Have a qualified person check the control power wiring to power monitor. The High Trip limit may be set too high. Lower the High Trip setting until the High and Trip Pt. LEDs go on. The High Trip time delay is set too high, and may need to be lowered. The trip contact on the monitor may be welded together. Have a qualified person check the continuity of the contact. Contact Sundyne for further assistance. The trip contact on the Monitor may not be wired properly to the motor starter control circuit. Have a qualified person check the control wiring from starter to Monitor. The Low Trip limit may be set too low. Increase the Low Trip setting until the Low and Trip Pt. LEDs go on. The Low Trip time delay is set too high, and may need to be lowered. A parameter lock command is on. Turn software lock off and make sure terminals (6 and 7) on the Display Panel are disconnected. Contact Sundyne for further assistance. The remote switch contact may be rated for 10 A. or higher, and this contact may have oxidized causing high circuit resistance. Replace the switch with one that has a low current (1A. or less) rating. The DC common of an external driver (PLC or other control device) is not connected to the Display K GND (terminal 8). PM Series_MANUAL_1/07/04 Page 21 Setup Example: Pump Model Type Ansimag K326 Diameter 6.00 in. Speed 3500 rpm Max. Flow 265 gpm Min. Flow 15 gpm AC Motor Power Rating 15 hp Nominal Voltage 460 VAC Full Load Amp 17.6 Efficiency 88.2 Phase 3 Pump Performance Curve Performance BHP Chart Definitions: 180 160 BHP = Brake Horsepower TDH = Total ∆ Head 10 hp TDH (ft) 140 13 hp 120 Notes: This pump curve is derived from Ansimag K+ performance catalog sheet of K326 pump with the following conditions: 7.5 hp 100 2.5 hp 80 5 hp 60 40 20 0 0 25 50 75 100 125 150 175 200 225 250 275 300 Liquid S.G. = 1.00 Motor Speed = 3500 rpm Impeller Trim = 6.00 in. Capacity (gpm) LOW TRIP FIGURE 23 HIGH TRIP Before starting the pump drive motor, data (parameter information) must be entered into the Display’s memory for it to operate correctly. For our example, the following information will be entered into the Display’s memory: Data Entry HP Start-T3 Trip Pt. – High2 Trip Pt. – Low2 T-Delay – High3 T-Delay – Low3 PTR Max. Ext. CT MTR Eff PTR kW Display P. un 15 10.5 4.9 5 10 15.0 15.0 Off 88 12.74 Comments Select HP for power Units Start-Up Timer Delay Value in Seconds (1 – 999) High Trip Value in HP Low Trip value in HP High Trip Delay Value in Seconds (1 – 99) High Trip Delay Value in Seconds (1 – 99) Enter Motor Horsepower Rating Use T and S buttons to position the Decimal Point, if required Set external CT value to off. Enter motor efficiency value of 88 Internal calculated input kW value for Monitor Notes: 1. If the parameters cannot be changed, then the Locked function is on. The procedure to switch off the parameter lock is listed on page 19 in the application notes. 2. The estimated BHP values (4.9 hp @ 15 gpm and 10.5 hp @ 265 gpm) from a pump curve are normally used, but the trips values are adjusted further after running the pump in the application. Specific gravity must be factored into the data derived from the standard pump curves. 3. The time values are practical times that can be adjusted according to the application needs. 4. The kW range on the Monitor is set to this value before operating the pump. PM Series_MANUAL_1/07/04 Page 22 Notes PM Series_MANUAL_1/07/04 Page 23