Technical Manuals Water - Queensland Urban Utilities
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
QUEENSLAND URBAN UTILITIES
WATER BOOSTER PUMP STATION WB065 SEIB STREET KILCOY
________________________________ WATER BOOSTER PUMP STATION OPERATION AND MAINTENANCE MANUAL
JPR REFERENCE NUMBER: C63100
Developed by:
J & P RICHARDSON INDUSTRIES CAMPBELL AVENUE WACOL QLD 4076
ABN 23 001 952 325 ACN 001 952 325 Ph. (07) 3271 2911 Fax. (07) 3271 3623
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
WATER BOOSTER PUMP STATION OPERATIONS AND MAINTENANCE MANUAL FOR QUEENSLAND URBAN UTILITIES WATER BOOSTER PUMP
STATION WB065 SEIB STREET, KILCOY
REVISION CONTROL
Version 0
Author Ben Aitcheson
Issue Purpose Draft Issue
Signature
Date 18/02/14
Reviewed by
Version
Author
0
Darren Wedley
Position Project Manager
Signature
Date 18/02/14
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
CONTENTS
1 Electrical Equipment Technical Information
1.1. CIRCUIT BREAKERS & ISOLATORS 1.2. CONTROL DEVICES 1.3. PUSHBUTTONS & SELECTOR SWITCHES 1.4. POWER SUPPLIES, GPOS, PLUGS & SOCKETS 1.5. SURGE PROTECTION & FUSES 1.6. RTU & RADIO 1.7. TERMINALS, LINKS & OTHER ACCESSORIES
2 Pumps
3 Valves
4 Flowmeter
5 Generator
6 Test Results
7 "AS INSTALLED" Drawings
8 Service and Maintenance
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual J & P Richardson Industries Pty Ltd
1 Electrical Equipment Technical Information
1.1 CIRCUIT BREAKERS & ISOLATORS 1.2 CONTROL DEVICES 1.3 PUSHBUTTONS & SELECTOR SWITCHES 1.4 POWER SUPPLIES, GPOs, PLUGS & SOCKETS 1.5 SURGE PROTECTION & FUSES 1.6 RTU & RADIOS 1.7 TERMINALS, LINKS & OTHER ACCESSORIES
C63100-WB065_Manual_DRAFT.doc Revision 0
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual J & P Richardson Industries Pty Ltd
1.1. CIRCUIT BREAKERS & ISOLATORS TERASAKI E125-NJ 63A 63A 3P Moulded Case Circuit Breaker TERASAKI DSRCBH-16-30A 10kA 1P 6A 30mA RCD TERASAKI DTCB10104C 10kA 1P 4A "C" curve Circuit Breaker TERASAKI DTCB10106C 10kA 1P 6A "C" curve Circuit Breaker
TERASAKI DTCB15332C+DTLDC 10kA 3P 32A "D" curve Circuit Breaker + Captive Lock Dog
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
MCCB's
Thermal magnetic type
E125NJ
25kA
Current rating:
12.5 125A
Approvals and Tests: Standards AS/NZS 3947-2, and IEC60947-2
Interrupting capacity:
Voltage AC use 380/415 DC use 250V
Icu
Ics
25
19
25
19
Trip unit: Adjustable thermal (0.63 Ir to 100% Ir) and adjustable magnetic (6 Im to 12 Im)
Dimensions (mm) Poles H W D (less toggle) Toggle cut-out
3 155 90 68 Standard DIN
Ampere Rating NRC
Adj. Ir 1) Min - Max.
Adj. Im 1) Min - Max.
20
12.5 - 20
120 - 240
32
20 - 32
192 - 384
50
32 - 50
300 - 600
63
40 - 63
378 - 756
100
63 - 100
600 - 1200
125
80 - 125
750 - 1500
1)
NRC:
Adj. Ir:
Adj. Im:
Nominal rated current Adjustable thermal setting Adjustable magnetic setting
Cat. No.
E125 NJ 3 20 E125 NJ 3 32 E125 NJ 3 50 E125 NJ 3 63 E125 NJ 3 100 E125 NJ 3 125
Replaces: XS125CJ, Note: check exact ratings or dimenions to suit your application requirement Price Schedule T2
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Innovators in Protection Technology
TEMBREAK 2 MCCBs
OPERATING CHARACTERISTICS
THERMAL MAGNETIC PROTECTION
Adjustment Dials
SECTION 3
1. IR is the thermal element adjustment dial and is used to set the rated current to match the conductor rating.
IR can be set between 0.63 and 1.0 times In.
2. Ii is the magnetic element adjustment dial and is used to set the short circuit tripping threshold to suit the application.
Ii can be set between 6 and 12 times In on 125A and 400A frame models.
Ii can be set between 6 and 13 times In on 250A frame models with ratings of 160A, 200A and 250A.
Ii can be set between 6 and 12 times In on 250A frame models with ratings of 125A and less.
Models, Types and Rated Currents of Thermal Elements
Model S125 E125 S125 S125 H125 L125 S160 S160 S160 H160 L160 E250 S250 S250 H250 L250 E400 S400 S400 S400 H400 L400
Type -NF -NJ -NJ -GJ -NJ -NJ -NF -NJ -GJ -NJ -NJ -NJ -NJ -GJ -NJ -NJ -NJ -CJ -NJ -GJ -NJ -NJ
Current Rating In (A) 16, 20, 25, 32, 40, 50, 63, 80, 100, 125 20, 32, 50, 63, 100, 125 20, 32, 50, 63, 100, 125 20, 32, 50, 63, 100, 125 20, 32, 50, 63, 100, 125 20, 32, 50, 63, 100, 125 16, 20, 25, 32, 40, 50, 63, 80, 100, 125, 160 20, 32, 50, 63, 100, 125, 160 50, 63, 100, 125, 160 160 160 20, 32, 50, 63, 100, 125, 160, 200, 250 160, 200, 250 160, 200, 250 160, 250 160, 250 250, 400 250, 400 250, 400 250, 400 250, 400 250, 400
Beyond the StandardTM
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Innovators in Protection Technology
TEMBREAK 2 MCCBs
OPERATING CHARACTERISTICS
THERMAL MAGNETIC CHARACTERISTICS
125A Frame MCCBs
SECTION 3
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Innovators in Protection Technology
TEMBREAK 2 MCCBs
APPLICATION DATA
SELECTIVITY (DISCRIMINATION) AND CASCADE
Selectivity The principle of Selectivity (Discrimination) is based upon an analysis of several circuit breaker characteristics. These include time-current (tripping) curves, peak-let-through current (Ipeak) and energy let-through (I2t).
The figures stated give the maximum selectivity level with the two nominated breakers in series under short-circuit conditions. For an indication on selectivity under overloads refer to the circuit breaker tripping/characteristic curves, or use the NHP TemCurve selectivity analysis software package. Selectivity can be enhanced beyond the breaking capacity of the downstream breaker provided it is backed up by an appropriately selected upstream breaker, which should not trip (unlatch) under the stated short circuit current. Cascade Cascading is achieved by using an upstream device to assist (back-up) a downstream device in clearing a fault current. This principal is necessary should the downstream device be required to clear a prospective short circuit current greater than the devices' breaking capacity. In most cascading applications it is generally necessary for the upstream breaker to trip (unlatch), as well as the downstream breaker to give adequate back-up protection. As such, cascade is commonly used in feeding and protecting non-essential loads, such as basic lighting. For more information on selectivity and cascading please refer to the latest NHP Part C catalogue.
SECTION 4
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Beyond the StandardTM
S250PE H250NE S400NE S400GE H400NE L400NE E630NE S630CE S630GE TL630NE XS800SE XH800SE TL800NE XS1250SE TL1250NE XS1600SE XS2000NE XS2500NE
Selectivity & Cascade Tables @ 400 / 415 V
Upstream MCCBs
Downstream kA
MCCBs
(RMS) 70 125 50
E125NJ
25 25/25 25/65 25/36
S125NJ
36 36/36 36/85 36/50
S125GJ
65 65/65 65/125 50/50
H125NJ
125 70/70 125/125 50/50
S160NJ
36
36/50
S160GJ
65
50/50
H160NJ
125
E250NJ
25
S250NJ
36
S250GJ
65
S250PE
70
H250NJ
125
H250PE
125
E400NJ
25
S400CJ
36
S400NE
50
S400NJ
50
S400GJ
70
H400NJ
125
H400NE
125
E630NE
36
E630CE
50
S630GE
70
XS630CJ 45
XS630NJ 65
XS630PJ
85
XS630SE 50
XH630SE 65
XH630PE 65
XS800NJ 65
XS800SE 50
XJ800PJ
85
XH800SE 65
XH800PE 65
XS1250SE 65
XS1600SE 85
70 125 200 36 25/50 25/65 25/85 25/36 36/65 36/85 36/125 36/36 65/70 65/125 65/150 36/36 70/70 125/125 125/200 36/36 36/65 36/85 36/125 36/36 65/70 65/125 65/150 36/36
125/125 125/200 36/36 25/65 25/85 25/36 36/85 36/125 36/36 65/125 65/150 36/36 40/125 70/150 36/36
125/125 125/200 36/36 125/125 125/200 36/36
10/25 10/36 10/36 10/36 10/36 10/36 10/36
50 25/25 36/36 50/50 50/50 36/50 50/50 50/50 25/25 36/36 50/50 50/50 50/50 50/50 10/25 10/36 10/50 10/36 10/50 10/50 10/50
SECTION 4
XX / YY Selectivity/ Cascade
70 25/50 36/65 65/70 70/70 36/50 65/70 70/70 25/50 36/65 65/70 70/70 70/70 70/70 10/50 10/65 10/50 10/70 10/70 10/70 10/70
125 25/25 36/36 65/65 70/70 36/36 65/65 70/70 25/25 36/36 65/65 70/70 70/70 70/70 10/36 10/50 10/50 10/65 10/70 10/70 10/70
50 25/36 36/50 65/50 50/50 36/36 50/50 50/50 25/25 36/36 50/50 50/50 50/50 50/50 25/25 25/36 25/50 25/50 25/50 25/50 25/50 25/36 25/50
65 25/36 36/36 65/65 65/65 36/65 50/65 50/65 25/50 36/36 50/65 50/65 50/65 50/65 25/25 25/36 25/50 25/50 25/50 25/65 25/65 25/36 25/50
125 85 125 100 85 85 25/65 25/25 25/25 25/25 25/25 25/25 36/36 36/36 36/36 36/36 36/36 36/36 65/65 65/65 65/65 65/65 65/65 65/65 65/65 85/50 85/50 100/100 85/85 85/85 36/65 36/36 36/36 36/36 36/36 36/36 50/65 65/65 65/65 65/65 65/65 65/65 50/65 85/65 85/65 100/100 85/85 85/85 25/50 25/25 25/25 25/25 25/25 25/25 36/36 36/36 36/36 36/36 36/36 36/36 50/65 65/65 65/65 65/65 65/65 65/65 50/65 70/70 70/70 70/70 70/70 70/70 50/65 85/85 85/85 100/100 85/85 85/85 50/65 85/85 85/85 100/100 85/85 85/85 25/36 25/25 25/25 25/36 25/25 25/25 25/50 36/36 36/36 36/50 36/36 36/36 25/50 50/50 50/50 50/50 50/50 50/50 25/65 50/50 50/50 50/65 50/50 50/50 25/65 70/36 70/36 70/85 70/70 70/70 25/65 125/85 125/85 125/100 125/85 125/85 25/65 125/85 125/85 125/100 125/85 125/85 25/36 36/36 36/36 36/36 36/36 36/36 25/50 50/50 50/50 50/50 50/50 50/50
70/70 70/70 70/70 70/70 70/70 30/45 30/45 30/45 35/45 35/45 30/65 30/65 30/65 35/65 36/65 30/85 30/85 30/85 35/85 35/85 30/65 30/65 30/85 30/85 30/85 30/65 30/65 30/85 30/85 30/85 30/65 30/65 30/85 30/85 30/85 15/65 15/65 20/65 35/65 35/65 15/50 15/50 20/50 35/50 35/50 15/85 15/85 20/85 35/85 35/85 15/65 15/65 20/65 35/65 35/65 15/65 15/65 20/65 35/65 35/65
20/65 35/65 35/65 35/85 35/85
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Innovators in Protection Technology
TEMBREAK 2 MCCBs
APPLICATION DATA
SELECTIVITY TABLES
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Innovators in Protection Technology
TEMBREAK 2 MCCBs
APPLICATION DATA
CASCADE TABLES
L250NJ H250NE H250NJ S250PE S250GJ S250NJ E250NJ L160NJ H160NJ S160GJ S160NJ L125NJ H125NJ S125GJ S125NJ E125NJ
SECTION 4
CASCADE @ 380 415 V AC 1)
Downstream kA MCCBs (RMS) 25 36 65 125 200 36 65 125 200 25 36 65 70 125 125 200
E125NJ S125NJ S125GJ H125NJ S160NJ S160GJ H160NJ S250NJ S250GJ S250PE H250NJ E400NJ S400CJ S400NJ S400GJ H400NJ
25
36 36 65 85 36 36 65 85
36 36
65 65 85
36
50 85 125 50 85 125
85 85 125
65
125 150
125 150
65 125 125 150
125
200
- 200
65
200
36
65
65 85 125
65 65 85 85 125
65
125 150
70 125 125 150
125
200
-
200
36
65
65 85 85 125
65
70 125 125 150
70
125 125 150
125
200
25
36 65 65
36
50 70 70
50
50 65 85 85
70
50 125 125
125
Note: 1) Ratings have not been verified where a dash "" is shown.
All pick-up and time delay settings are to be set at a maximum for upstream MCCB's
Upstream MCCBs
XS1600SE
XS1250SE
TL800NE
XH800SE
XS800NJ
XS800SE
TL630NE
S630GE
S630CE
E630NE
L400NE
L400NJ H400NJ H400NE S400GE S400GJ S400NE S400NJ S400CJ
CASCADE @ 380 415 V AC 1)
Downstream kA MCCBs (RMS) 36 50 70 125 200 200 36 50 70 125 65 65 65 200 65 85
E125NJ S125NJ S125GJ H125NJ S160NJ S160GJ H160NJ E250NJ S250NJ S250GJ S250PE H250NJ E400NJ S400CJ S400NJ S400GJ H400NJ
25 36 36 50 65 85 85 36
- 50 36 36 36
36 50 65 85 125 125
- 65 50 50
65
70 125 150 150 50 70
65
125
200 200
-
65 50
36 50 65 85 125 125 50 50
65 65
65
70 125 150 150
70
125
200 200
65 65
25 36 36 50 65 85 85 36 50
36 50
36 50 65 85 125 125
65
65
65
70 125 150 150
70
70
125 150 150
125
200 200 -
25 36 36 50 65 85 85 36 50 36
36 36
36 50 65 70 100 100
65 50
50 50
50
70 85 125 125 36 70 65
50 65 65
70
125 150 150 36
50 36 85
125
200 200
Note: 1) Ratings have not been verified where a dash "" is shown.
All pick-up and time delay settings are to be set at a maximum for upstream MCCBs
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SECTION 4
H400NJ S400GE S400GJ S400CJ S250GJ S250NJ H125NJ S125GJ S125NJ E125NJ
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Innovators in Protection Technology
TEMBREAK 2 MCCBs
APPLICATION DATA
SELECTIVITY AND CASCADE TEMBREAK 2 MCCBs AND DIN-T / SAFE-T MCBs
Upstream MCCB
SELECTIVITY / CASCADE @ 415 V AC
Downstream MCB
DTCB6
DTCB10
DSRCBH / DSRCD Din-T10H DTCH15
Safe-T SRCB
Amp rating 2 20 25 63 0.5 32 40 63 0.5 32
40 80 125 0.5 32 40 63 16 20 16 20
kA (RMS) 25 36 65 36 65 36 70 125
6 18/18 25/25 35/35 35/35 35/35 6 18/18 20/25 20/25 30/30 30/30 10 18/18 30/30 30/50 35/35 40/50 35/35 40/50 40/50 10 18/18 20/25 25/25 30/30 30/30 30/30 30/30 30/30 10 18/18 30/30 30/50 35/35 40/50 35/35 40/50 40/50 10 18/18 20/25 25/25 30/30 30/30 30/30 30/30 30/30 10 4/18 4/25 4/25 15/15 15/15 10/10 10/10 15 18/18 30 30/50 35/35 40/50 35/35 40/50 40/50 15 18/18 20 25/25 30/30 30/30 30/30 30/30 30/30 6 3/10 3/10 3/10 6 3/10 3/10 3/10
Guide XX / YY
Selectivity
Cascade
Notes: All figures stated are at 400/415 V AC.
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SECTION 4
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Innovators in Protection Technology
TEMBREAK 2 MCCBs
APPLICATION DATA
MOTOR STARTING TYPE 1 CO-ORDINATION TABLES
Short-Circuit Co-Ordination Motor Starting Table
Type `1' Terasaki MCCB's & Sprecher + Schuh KT7's DOL starting 50/65 kA @ 400/415 V to AS/NZS 60947.4.1
TYPE 1 50/65 kA
Motor Size (kW) 0.37 0.55 0.75 1.1 1.5 2.2 3 4 5.5 7.5 11 15 18.5 22 30 37 45 55 5 0 10 32 60 00
Approx. amps @ 400/415 V (A) 1.1 1.5 1.8 2.6 3.4 4.8 6.5 8.2 11 14 21 28 34 40 55 66 80 100 130 155 200 225 270 361
Terasaki Combinations
MCCB
Contactor
XM30PB/1.4 XM30PB/2 XM30PB/2.6 XM30PB/4.0 XM30PB/5 XM30PB/8 XM30PB/10 XM30PB/12 S125GJ/20 S125GJ/20 S125GJ/32 S125GJ/50 S125GJ/50 S125GJ/63 S125GJ/100 S125GJ/100 S125GJ/125 S125GJ/125 S250PE/250 S250PE/250 S250PE/250 S400GE/400 S400GE/400 S400GE/400
CA7-9 CA7-9 CA7-9 CA7-9 CA7-9 CA7-9 CA7-9 CA7-9 CA7-12 CA7-16 CA7-23 CA7-30 CA7-37 CA7-43 CA7-60 CA7-72 CA7-85 CA6-110 CA6-140 CA6-180 CA6-210 CA6-210 CA6-300 CA6-420
Notes: · Thermal or electronic overload relays may be used. · XM30PB MCCB's can be replaced with S125GJ/20 if required. · Combinations based on the thermal overload relay tripping before the circuit. breaker at overload currents up to the motor locked rotor current.
Terasaki Combinations
Overload Relay CT 7-24 CT 7-24 CT 7-24 CT 7-24 CT 7-24 CT 7-24 CT 7-24 CT 7-24 CT 7-24 CT 7-24 CT 7-24 CT 7-45 CT 7-45 CT 7-45 CT 7-75 CT 7-75 CT 7-100 CEF 1-11/12 CEF 1-11/12 CEF 1-11/12 CEF 1-41/42 CEF 1-41/42 CEF 1-41/42 CEF 1-41/42
Thermal Setting (A) 1.0 - 1.6 1.0 - 1.6 1.6 - 2.4 2.4 - 4.0 2.4 - 4.0 4.0 - 6.0 6.0 - 10 6.0 - 10 10 - 16 10 - 16 16 - 24 18 - 30 30 - 45 30 - 45 45 - 60 60 - 75 70 - 90 20 - 180 20 - 180 20 - 180 160 - 400 160 - 400 160 - 400 160 - 400
Sprecher + Schuh Combinations
KT7 Circuit Breaker KTA7-25S-1.0A KTA7-25S-1.6A KTA7-25S-2.5A KTA7-25S-2.5A KTA7-25S-4.0A KTA7-25S-6.3A KTA7-25S-6.3A KTA7-25S-10A KTA7-25H-16A KTA7-25H-16A KTA7-45H-20A KTA7-45H-32A KTA7-45H-45A KTA7-45H-45A KTA3-100-63A KTA3-100-90A KTA3-100-90A KTA3-160S-100A KTA3-160S-160A KTA3-160S-160A KTA3-250S-200A KTA3-250S-250A KTA3-400S-320A KTA3-400S-400A
Contactor
CA7-9 CA7-9 CA7-9 CA7-9 CA7-9 CA7-9 CA7-9 CA7-9 CA7-12 CA7-16 CA7-23 CA7-30 CA7-37 CA7-43 CA7-60 CA7-72 CA7-85 CA6-110 CA6-140 CA6-180 CA6-210 CA6-250 CA6-300 CA6-420
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SECTION 4
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Innovators in Protection Technology
TEMBREAK 2 MCCBs
APPLICATION DATA
MOTOR STARTING TYPE 2 CO-ORDINATION TABLES
Short-Circuit Co-Ordination DOL Motor Starting Table
Type `2' Terasaki MCCB's & Sprecher + Schuh KT7's DOL starting 50/65 kA @ 400/415 V to AS/NZS 60947.4.1
TYPE 2 50/65 kA
Motor Size (kW) 0.37 0.55 0.75 1.1 1.5 2.2 3 4 5.5 7.5 11 15 18.5 22 30 37 45 55 75 90 110 132 160 200
Approx. amps @ 400/415 V (A) 1.1 1.5 1.8 2.6 3.4 4.8 6.5 8.2 11 14 21 28 34 40 55 66 80 100 130 155 200 225 270 361
Terasaki Combinations
MCCB
Contactor
XM30PB/1.4 XM30PB/2 XM30PB/2.6 XM30PB/4.0 XM30PB/5 XM30PB/8 XM30PB/10 XM30PB/12 S125GJ/20 S125GJ/20 S125GJ/32 S125GJ/50 S125GJ/50 S125GJ/63 S125GJ/100 S125GJ/100 S125GJ/125 S250PE/160 S250PE/250 S250PE/250 S250PE/250 S400PE/400 S400PE/400 S400PE/400
CA7-9 CA7-9 CA7-9 CA7-16 CA7-16 CA7-16 CA7-30 CA7-30 CA7-30 CA7-30 CA7-30 CA7-43 CA7-43 CA7-43 CA7-72 CA7-72 CA6-105 CA6-105 CA6-140 CA6-170 CA6-210 CA6-210 CA6-300 CA6-420
Notes: · Thermal or electronic overload relays may be used. · XM30PB combinations can be replaced with S125GJ/20 and CA7-30 if required. · Combinations based on the thermal overload relay tripping before the circuit breaker at overload currents up to the motor locked rotor current.
Terasaki Combinations
Overload Relay CT 7-24 CT 7-24 CT 7-24 CT 7-24 CT 7-24 CT 7-24 CT 7-24 CT 7-24 CT 7-24 CT 7-24 CT 7-24 CT 7-45 CT 7-45 CT 7-45 CT 7-75 CT 7-75 CT 7-100 CEF 1-11/12 CEF 1-11/12 CEF 1-11/12 CEF 1-41/42 CEF 1-41/42 CEF 1-41/42 CEF 1-41/42
Thermal Setting (A) 1.0 - 1.6 1.0 - 1.6 1.6 - 2.4 2.4 - 4.0 2.4 - 4.0 4.0 - 6.0 6.0 - 10 6.0 - 10 10 - 16 10 - 16 16 - 24 18 - 30 30 - 45 30 - 45 45 - 60 60 - 75 70 - 90 20 - 180 20 - 180 20 - 180 160 - 400 160 - 400 160 - 400 160 - 400
Sprecher + Schuh Combinations
KT7 Circuit Breaker KTA7-25S-1A KTA7-25S-1.6A KTA7-25S-2.5A KTA7-25S-2.5A KTA7-25S-4A KTA7-25S-6.3A KTA7-25S-6.3A KTA7-25S-10A KTA7-25H-16A KTA7-25H-16A KTA7-45H-20A KTA7-45H-32A KTA7-45H-45A KTA7-45H-45A KTA3-100-63A KTA3-100-90A KTA3-100-90A KTA3-160S-100A KTA3-160S-160A KTA3-160S-160A KTA3-250S-200A KTA3-250S-250A KTA3-400S-320A KTA3-400S-400A
Contactor
CA7-9 CA7-9 CA7-9 CA7-9 CA7-9 CA7-9 CA7-9 CA7-9 CA7-12 CA7-16 CA7-23 CA7-30 CA7-37 CA7-43 CA7-60 CA7-72 CA7-85 CA6-110 CA6-140 CA6-180 CA6-210 CA6-250 CA6-300 CA6-420
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SECTION 4
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Innovators in Protection Technology
TEMBREAK 2 MCCBs
APPLICATION DATA
MOTOR STARTING TYPE 2 CO-ORDINATION
Short-Circuit Co-Ordination DOL Motor Starting Table
Type `2' Terasaki MCCB's & Sprecher + Schuh KT7's DOL starting 85 kA @ 400/415 V to AS/NZS 60947.4.1
TYPE 2 85 kA
Motor Size (kW) 0.37 0.55 0.75 1.1 1.5 2.2 3 4 5.5 7.5 11 15 18.5 22 30 37 45 55 75 90 110 132 160 200
Approx. amps @ 400/415 V (A) 1.1 1.5 1.8 2.6 3.4 4.8 6.5 8.2 11 14 21 28 34 40 55 66 80 100 130 155 200 225 270 361
Terasaki Combinations
MCCB
Contactor
XM30PB/1.4 XM30PB/2 XM30PB/2.6 XM30PB/4.0 XM30PB/5 XM30PB/8 XM30PB/10 XM30PB/12 H125NJ/20 H125NJ/20 H125NJ/32 H125NJ/50 H125NJ/50 H125NJ/63 H125NJ/100 H125NJ/100 H125NJ/160 H160NJ/160 H250PE/250 H250PE/250 H250PE/250 H400NE/400 H400NE/400 H400NE/400
CA 7-9 CA 7-9 CA 7-9 CA 7-16 CA 7-16 CA 7-30 CA 7-30 CA 7-30 CA 7-30 CA 7-30 CA 7-30 CA 7-43 CA 7-43 CA 7-43 CA 7-72 CA 7-72 CA 6-105 CA 6-105 CA 6-210 CA 6-210 CA 6-210 CA 6-210 CA 6-300 CA 6-420
Notes: · Thermal or electronic overload relays may be used. · XM30PB combinations can be replaced with H125GJ/20 and CA7-30 if required. · Combinations based on the thermal overload relay tripping before the circuit breaker at overload currents up to the motor locked rotor current.
Terasaki Combinations
Overload Relay CT 7-24 CT 7-24 CT 7-24 CT 7-24 CT 7-24 CT 7-24 CT 7-24 CT 7-24 CT 7-24 CT 7-24 CT 7-24 CT 7-45 CT 7-45 CT 7-45 CT 7-75 CT 7-75 CT 7-100 CEF 1-11/12 CEF 1-11/12 CEF 1-11/12 CEF 1-41/42 CEF 1-41/42 CEF 1-41/42 CEF 1-41/42
Thermal Setting (A) 1.0 - 1.6 1.0 - 1.6 1.6 - 2.4 2.4 - 4.0 2.4 - 4.0 4.0 - 6.0 6.0 - 10 6.0 - 10 10 - 16 10 - 16 16 - 24 18 - 30 30 - 45 30 - 45 45 - 60 60 - 75 70 - 90 20 - 180 20 - 180 20 - 180 160 - 400 160 - 400 160 - 400 160 - 400
Sprecher + Schuh Combinations
KT7 Circuit Breaker KTA7-25S-1A KTA7-25S-1.6A KTA7-25S-2.5A KTA7-25H-2.5A KTA7-25H-4A KTA7-25H-6.3A KTA7-25H-6.3A KTA7-25H-10A KTA7-45H-16A KTA7-45H-16A KTA7-45H-20A KTA7-45H-32A KTA7-45H-45A KTA7-45H-45A KTA3-100-63A KTA3-100-90A KTA3-100-90A -
Contactor
CA 7-9 CA 7-9 CA 7-9 CA 7-9 CA 7-9 CA 7-9 CA 7-9 CA 7-9 CA 7-12 CA 7-16 CA 7-23 CA 7-30 CA 7-37 CA 7-43 CA7-60 CA7-72 CA7-85 -
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SECTION 4
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Innovators in Protection Technology
TEMBREAK 2 MCCBs
APPLICATION DATA
MOTOR STARTING TYPE 2 CO-ORDINATION
Short-Circuit Co-Ordination DOL Motor Starting Table
Type `2' Terasaki MCCB's & Sprecher + Schuh KT7's DOL starting 100 kA @ 400/415 V to AS/NZS 60947.4.1
TYPE 2 100 kA
Motor Size (kW) 0.37 0.55 0.75 1.1 1.5 2.2 3 4 5.5 7.5 11 15 18.5 22 30 37 45 55 75 90 110 132 160 200
Approx. amps @ 400/415 V (A) 1.1 1.5 1.8 2.6 3.4 4.8 6.5 8.2 11 14 21 28 34 40 55 66 80 100 130 155 200 225 270 361
Terasaki Combinations
MCCB
Contactor
H125NJ/20 H125NJ/20 H125NJ/20 H125NJ/20 H125NJ/20 H125NJ/20 H125NJ/20 H125NJ/20 H125NJ/20 H125NJ/20 H125NJ/32 H125NJ/50 H125NJ/50 H125NJ/63 H125-NJ/100 H125-NJ/100 H125-NJ/125 H250-NE/160 H250-NE/250 H250-NE/250 H250-NE/250 H400-NE/400 H400-NE/400 H400-NE/400
CA 7-30 CA 7-30 CA 7-30 CA 7-30 CA 7-30 CA 7-30 CA 7-30 CA 7-30 CA 7-30 CA 7-30 CA 7-30 CA 7-43 CA 7-43 CA 7-43 CA 7-60 CA 7-72 CA 7-85 CA 6-95 CA 6-140 CA 6-140 CA 6-180 CA 6-420 CA 6-420 CA 6-420
Notes: · Thermal or electronic overload relays may be used. · Combinations based on the thermal overload relay tripping before the circuit breaker at overload currents up to the motor locked rotor current.
Terasaki Combinations
Overload Relay CT 7-24 CT 7-24 CT 7-24 CT 7-24 CT 7-24 CT 7-24 CT 7-24 CT 7-24 CT 7-24 CT 7-24 CT 7-24 CT 7-45 CT 7-45 CT 7-45 CT 7-75 CT 7-75 CT 7-100 CEF 1-11/12 CEF 1-11/12 CEF 1-11/12 CEF 1-41/42 CEF 1-41/42 CEF 1-41/42 CEF 1-41/42
Thermal Setting (A) 1.0 - 1.6 1.0 - 1.6 1.6 - 2.4 2.4 - 4.0 2.4 - 4.0 4.0 - 6.0 6.0 - 10 6.0 - 10 10 - 16 10 - 16 16 - 24 18 - 30 30 - 45 30 - 45 45 - 60 60 - 75 70 - 90 20 - 180 20 - 180 20 - 180 160 - 400 160 - 400 160 - 400 160 - 400
Sprecher + Schuh Combinations
KT7 Circuit Breaker KTA7-25S-1A KTA7-25S-1.6A KTA7-25S-2.5A KTA7-25H-2.5A KTA7-25H-4A KTA7-25H-6.3A KTA7-25H-6.3A KTA7-25H-10A KTA7-45H-16A KTA7-45H-16A KTA7-45H-20A KTA7-45H-32A KTA7-45H-45A KTA7-45H-45A -
Contactor
CA 7-9 CA 7-9 CA 7-9 CA 7-9 CA 7-9 CA 7-9 CA 7-9 CA 7-9 CA 7-12 CA 7-16 CA 7-23 CA 7-30 CA 7-37 CA 7-43 -
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TEMBREAK 2 MCCBs
INSTALLATION
INSULATION DISTANCE IN mm (AT 440V AC MAXIMUM)
Model
E125 S125 S125 S125 H125 L125 S160 S160 S160 H160 L160 E250 S250 S250 S250 H250 H250 L250 E400 S400 S400 S400 S400 H400 H400 L400 L400 E630 S630 S630
Type A
B1
B2
C
NJ
50
10
10
0
NF
50
10
10
0
NJ
50
10
10
0
GJ
75
45
25
0
NJ
100 80
60
0
NJ
100 80
60
0
NF
50
40
30
0
NJ
50
40
30
0
GJ
100 80
60
0
NJ
100 80
60
0
NJ
100 80
60
0
NJ
50
40
30
0
NJ
50
40
30
0
GJ
100 80
30
0
PE
100 80
60
0
NJ
100 80
60
0
NE
100 80
60
0
NJ
100 80
60
0
NJ
100 80
40
0
CJ
100 80
40
0
NJ
100 80
40
0
GJ
100 80
40
0
GE
100 80
40
0
NJ
120 120
80
0
NE
120 120
80
0
NJ
120 120
80
0
NE
120 120
80
0
NE
120 100
80
0
CE
120 100
80
0
GE
120 100
80
0
D
E
25
*(1)
25
*(1)
25
*(1)
25
*(1)
50
*(1)
50
*(1)
25
*(1)
25
*(1)
50
*(1)
50
*(1)
50
*(1)
25
*(1)
25
*(1)
25
*(1)
50
*(1)
50
*(1)
50
*(1)
50
*(1)
30
*(1)
30
*(1)
30
*(1)
30
*(1)
30
*(1)
80
*(1)
80
*(1)
80
*(1)
80
*(1)
80
*(1)
80
*(1)
80
*(1)
*Note: (1) Insulate the exposed conductor until it overlaps the moulded case at the terminal, or the terminal cover.
SECTION 6
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TEMBREAK 2 MCCBs
INSTALLATION
TEMPERATURE RATINGS & DERATINGS
Calibration Temperature: 45°C
MCCB Type
E125-NJ S125-NJ S125-GJ
Connection Type
Front Rear Plug-in
H125-NJ L125-NJ
Front Rear Plug-in
S160-NJ S160-GJ
Front Rear Plug-in
H160-NJ L160-NJ
E250-NJ
Front Rear Plug-in Front Rear Plug-in
E250-NJ S250-NJ S250-GJ H250-NJ L250-NJ
E400-NJ S400-CJ S400-NJ S400-GJ H400-NJ L400-NJ
Front Rear Plug-in Front Rear Plug-in Front Rear Front Rear Plug-in
Front Rear Plug-in
Rating at calibration temperature (50°C)
20A 32A 50A 63A 100A 125A 20A 32A 50A 63A 100A 125A 20A 32A 50A 63A 100A 125A 160A
160A
20A 32A 50A 63A 100A 125A 160A 250A
160A
250A
250A 400A
250A 400A 250A 400A
Calibration Temperature: 30°C
MCCB Type
H250-NJ L250-NJ
Connection Type
Plug-in Conn.
Rating at calibration temperature (30°C)
250A
Rated Current (A)
50°C 55°C 60°C
19
18.5
18
31
30.5
30
48
45
43
60
57
55
97
94
90
121
117
113
19
18.5
18
31
30
29
48
47
45
61
59
57
97
95
92
121
118
114
19
18.5
18
31
30
29
48
46
44
61
59
57
97
94
91
121
117
113
156
151
146
156
151
147
19
18.5
18
31
30
29
48
46
44
61
59
57
97
94
91
121
117
113
156
151
146
243
235
227
65°C 17.5 29 41 52 87 109 17.5 28 44 55 89 111 17.5 28 42 55 88 109 141
143
17.5 28 42 55 88 109 141 219
156
151
147
143
244
237
230
223
244
237
230
223
390
380
369
358
243
237
230
223
390
381
371
361
243
237
231
224
392
384
376
368
Rated Current (A) 35°C 40°C 45°C
244
236
225
50°C 55°C 219 209
60°C 65°C 200 190
SECTION 6
MCCB Type
S250-PE H250-NE
S400-NE S400-GE
H400-NE L400-NE
Connection Type Front Rear
Plug-in Front Rear Plug-in Front Rear Plug-in
E630-NE S630-CE S630-GE
Front Rear*
Rating
250A
250A 250A 400A
250A 400A 250A 400A 630A
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30°C 250
35°C 250
40°C 250
Rated Current (A)
45°C 50°C
55°C
250
237.5
225
250 237.5 225 225
200
200
250
250
250 250
250
250
400
400
400 400
400
380
250
250
250 250
400
400
400 400
250
250
250 250
400
400
400 400
630
630
630 630
250 400 250 400 598.5
250 380 250 380 598.5
60°C 200
157.5 225 360
225 360 225 360 567
65°C 200
157.5 200 320
200 320 200 320 504
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
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TEMBREAK 2 MCCBs
DIMENSIONS
E125-NJ, S125-NJ, S125-GJ
SECTION 7
8.5(max.) 132
17 8.5
154±1
3P
4P
Interpole barrier
(removable)
Mounting hole
47
HL
HL
Operating knob CL
154
Front panel t2 24
M8 screw
Preparation of conductor ø9
17(max.) max.t5
Drilling plan
3P
4P
HL
HL
155
134
60
14.5 21.5
90
90
30 30 30
45
75
10
Connector plug
45 8 61
45
106
5.5
164.5
28(max.)
M4x0.7 Mounting screw
30
30
M4x0.7 Tapped hole
Panel hinge position (hatching area) bottom view
HL
100 150 200
100 150 200
90
86
HL 154
Operating knob
Front panel t2
Mounting plate (max. t3.2)
Drilling plan
3P
4P
HL
HL
103.5
Panel cutout (Front view)
4P 3P HL
5
132 134
R1 155
8 61
134
155 148
CL
15 Conductor
CL
overlap max.
16
Pad lock Connector plug
45
ø8.5 15
15
61
52
106
102
30 30 30 Stud can be turned 45°or 90°
M4X0.7 Mounting screw
30 60
5.5
164.5
28(max.)
CL
30 30 30 30
ø18
M4X0.7 Tapped hole
45 90
Panel cutout dimensions shown give an allowance of 1.5mm around the handle escutcheon.
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
1
Miniature circuit breakers
Din-Safe single pole width residual current circuit breaker (RCBO)
Standards AS/NZS 61009 Approval N17482 One module wide (18 mm) Short circuit, overcurrent and earth leakage protection Short circuit protection 10 kA Sensitivity 10 and 30 mA Din rail mount Suits CD chassis Type "A" residual current device (AC/DC)
Amp rating (A)
6 10 16 20 25 32 40 6 10 16 20 25 32 40
Modules Voltage (18mm) (AC)
1
240
1
240
1
240
1
240
1
240
1
240
1
240
1
240
1
240
1
240
1
240
1
240
1
240
1
240
Short circuit (kA)
10 10 10 10 10 10 10 10 10 10 10 10 10 10
Trip Sensitivity (mA)
30 30 30 30 30 30 30 10 10 10 10 10 10 10
Cat. No 1) 2)
DSRCBH0630A DSRCBH1030A DSRCBH1630A DSRCBH2030A DSRCBH2530A DSRCBH3230A DSRCBH4030A i DSRCBH0610A DSRCBH1010A DSRCBH1610A DSRCBH2010A i DSRCBH2510A i DSRCBH3210A i DSRCBH4010A
Application The Din-Safe single pole width residual current circuit breaker will fit the standard Din-T chassis for use in NHP panelboards. The design makes it possible to provide an MCB complete with earth leakage protection in an 18 mm wide module, which allows a greater number of devices to be fitted into a distribution board.
Connection diagram
Note: 1) Neutral not switched. 2) Will not accept side mounting accessories. i Available on indent only.
Operation This unit combines the overload and short circuit protection of an MCB with earth leakage protection of an RCD. The unit occupies one, sub- circuit (one pole) of the distribution board and provides single phase protection against overload, short circuit and earth leakage current.
The MCB element provides thermal and magnetic tripping protection which is rated to 10 kA prospective fault current.
The RCD element of the device provides core-balance detection of the difference between the active and neutral currents and amplification to provide high sensitivity. The rated residual operating current (In) is 10 mA or 30 mA.
The green/yellow earth reference cable, in case of loss of supply neutral, ensures the device will continue to provide earth leakage protection and will operate normally upon detection of an earth leakage current.
Dimensions (mm)
Note: A 1.2 m long pigtail lead is included as standard.
Note: Nuisance tripping may be experienced in VFD and motor starting applications refer NHP.
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Din-T MCBs + RCDs Technical data
Tripping curves according to EN 60898
The following tables show the average tripping curves of the Terasaki Din-T MCBs based on the thermal and magnetic characteristics. Curve C
3
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RCDs classification according to EN 61008/61009
RCDs may be classified according to:
The behaviour in the presence of DC current
(types for general use).
Type AC
Type A
The time-delay (in the presence of residual current)
RCDs without time delay: type for general use
RCDs with time delay: type S for selectivity
Type AC
1) 2)
The type AC RCDs are designed to release with sinusoidal residual currents which occur suddenly or slowly rise in magnitude.
Residual current 0.5 x In 1 x In 2 x In 5 x In
Tripping time t = t = <300 ms t = <150 ms t = 40 ms
Type A
3) 4)
Certain devices during faults can be the source of non-
sinusoidal earth leakage currents (DC components) due to the
electronic components e.g. diodes, thyristors etc. Type A RCDs are designed to ensure that under these conditions
3
the residual current devices operate on sinusoidal residual
current and also with pulsating direct current(*) which occur
suddenly or slowly rise in magnitude.
(*) Pulsating direct current: current of pulsating wave form which assumes, in each period of the rated power frequency, the value 0 or a value not exceeding 0.006 A DC during one single interval of time, expressed in angular measure of at least 150º.
Residual current Tripping time
1. For sinusoidal residual current 0.5 x In 1 x In 2 x In 5 x In
2. For residual pulsating direct current At point of wave 0° 0.35 x In 1.4 x In 2.8 x In 7 x In At point of wave 90° 0.25 x In 1.4 x In 2.8 x In 7 x In
t = t = <300 ms t = <150 ms t = 40 ms
t = t = <300 ms t = <150 ms t = 40 ms
t = t = <300 ms t = <150 ms t = 40 ms
At point of wave 135° 0.11 x In 1.4 x In 2.8 x In 7 x In
t = t = <300 ms t = <150 ms t = 40 ms
Tripping curve type AC 1) Standard in Australia 2) Type A acceptable in Australia
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Tripping curve type A 3) Standard in New Zealand 4) DSRCBH is type A.
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Din-T MCBs + RCDs Technical data
Nuisance tripping
All DinSafe RCDs have a high level of immunity to transient currents, against current impulses of 8/20 µs according to EN 61008/61009 and VDE 0664.T1. Type A, AC...................................250 A 8/20 µs Type S.......................................3000 A 8/20 µs
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RCDs have a high level of immunity against alternating currents of high frequency according to EN 61008/61009.
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Din-T MCBs + RCDs Technical data
Use of an RCBO (DSRCBH)
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Din-T MCBs + RCDs Technical data
Product related information
Influence of temperature on RCBOs (DinSafe DSRCB)
The thermal calibration of the RCBO was carried out at an
ambient temperature of 30 °C. Ambient temperatures different
from 30 °C influence the bimetal and this results in earlier or
3
later thermal tripping.
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Din-T MCBs + RCDs Technical data
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Tripping current as a function of the frequency
All RCDs are designed to work at frequencies of 50-60 Hz, therefore to work at different values, we must consider the variation of the tripping sensitivity according to the tables below. It should be taken into consideration that there is a no tripping risk when pushing the test-button, due to the fact that such action is made by means of an internal resistor with a fixed value.
RCBO DSRCBH 3) Type AC 1) 30 mA
10 Hz 0.62
30 Hz 0.65
50 Hz 0.80
100 Hz 0.91
200 Hz 1.24
300 Hz 1.55
400 Hz 1.88
3
100 mA
0.74
0.71
0.80
0.95
1.16
1.38
1.59
300 mA
0.80
0.74
0.80
0.97
1.19
1.44
1.64
500 mA
1.10
0.81
0.80
0.89
1.18
1.38
1.68
Type A 2)
30 mA
8.17
3.13
0.75
1.70
3.10
3.52
3.67
100 mA
6.81
2.71
0.75
1.43
2.35
2.58
2.71
300 mA
6.20
2.16
0.75
0.49
0.87
0.74
0.95
500 mA
4.34
1.53
0.75
0.39
0.59
0.62
0.64
Notes:
1) The standard NHP/Terasaki type is the "type AC" in Australia, Type "A" in New Zealand. 2) The standard NHP/Terasaki DSRCBH single pole RCBO is "type A" in Australia and New Zealand. 3) The numbers in the table above are multipliers, e.g. A "DSRCD" at 50 hz has an 0.8 multiplier.
Therefore a 30 mA, "type AC" RCD will trip at (0.8 x 30 mA) 24 mA.
Power losses
The power losses are calculated by means of measuring the voltage drop between the incoming and the outgoing terminal of the device at rated current. Power loss per pole:
RCBO-Single pole DSRCBH
In (A)
6
10
13
16
20
25
32
40
50
63
Z (mOhm)
45.8
16.4
12.5
10.6
7.3
5.4
3.2
2.6
1.9
1.4
Pw (W)
1.65
1.7
2.1
2.7
2.9
3.3
3.4
4.2
4.8
5.6
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Din-T MCBs + RCDs Technical data
RCBO (DSRCB) let-through energy I2t
The benefit of an RCBO in short-circuit conditions, is its ability to reduce the value of the let-through energy that the short-circuit would be generating.
Din-T single pole width RCD (DSRCBH)
Curve C
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RCCB - Din-Safe safety switch (DSRCD)
RCBO - Din-Safe (DSRCBH)
Dimensions in mm
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Din-T MCBs + RCDs Technical data
Overview Din-Safe RCDs
RCBO
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Device type definition
Rating/description Standards
Cat. No.
Magnetic tripping characteristics
Residual tripping characteristic 1)
Tripping time at In Instantaneous
ms
Selective
ms
Rated current
A
Rated residual current In
mA
Calibration temperature
°C
Number of poles versus modules
Rated voltage Un
2 P AC
V
3 P AC
V
4 P AC
V
Frequency
Hz
Maximum service voltage Ubmax
V
Minimum service voltage Ubmin
V
Power supply
Selectivity class
Rated making and breaking capacity (Im)
A
Residual making and breaking capacity (Im)
A
Conditional short-circuit capacity (Inc)
A
Conditional residual short-circuit capacity (Ic)
A
Short-circuit capacity (Icn)
A
Grid distance (safety distance between two devices) mm
Isolator application
Insulation degree
Insulation voltage
V (DC)
Shock voltage (1.2/50 ms) kV
Insulation resistance
(mOhm)
Dielectric strength
V
Shock resistance (in x, y, z direction)(IEC 60077/16.3)
Vibration resistance (in x, y, z direction; IEC 60068-2-6)
Endurance
electrical at Un, In
mechanical at Un, In
Protection degree (outside/inside electrical enclosure)
Self extinguish degree (according to UL 94)
Tropicalisation (according to IEC 60068-2, DIN 40046) °C/RH
Pollution degree (acc. IEC 60947-1)
Operating temperature
°C
Storage temperature
°C
Terminals capacity Rigid cable min/max (Top)
mm2
Flexible cable min*/max (Top)
mm2
Rigid cable min/max (bottom)
mm2
Flexible cable min*/max (bottom) mm2
(*Flexible cable 0.75/1/1.5 mm2 with cable lug)
DSRCBH IEC 61009-1
C A <300 6, 10, 16, 20, 25, 32, 40 10, 30 30 1 240 (1 P+N) 50/60 255 100 Bottom 3 10xIn 10000 10000 yes 500 2) 6 2) 1000 2) 2500 2) 40 g, 18 shocks 5 ms 2 g, 30 min, 0...80 Hz 10000 20000 IP 20 / IP 40 V2 +55/95 % 3 -5..+60 -25..+70 1/25 1/16 1/35 1/25
Torque
Top/Bottom
Nm
Add-on devices (side add-on) Auxiliary contacts
UVT
Shunt trip
Motor operator
Panelboard switch
Busbars systems
Pin
Fork
Accessories
3 Bottom Bottom yes
Dimensions, weights,
# Poles
1+N
packaging
(HxDxW) 86x68xW
mm
18
Weight/unit
g
350
Package/unit
1
Note:
1) Refer catalogue section for types.
2) Making sure that N-L and both flying leads are disconnected.
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
1 Miniature circuit breakers
Din-T15 series 15 kA, 20 kA, 25 kA MCBs
Standards AS/NZS 3947-2 Current range 6-63 Amp 1, 2, 3 and 4 pole Sealable and lockable handle Modular design Mounts on CD chassis (250 A and 355 A) Industrial applications
1 pole 1 module 3) In (A) Icu (kA)
C - Curve 5 - 10 In
6
25
DTCB15106C
10
25
DTCB15110C
13
25
i DTCB15113C
16
25
DTCB15116C
20
25
DTCB15120C
25
25
DTCB15125C
32
20
DTCB15132C
40
20
DTCB15140C
50
15
DTCB15150C
63
15
DTCB15163C
3 pole 3 modules 3)
6
25
10
25
13
25
16
25
20
25
25
25
32
20
40
20
50
15
63
15
DTCB15306C DTCB15310C i DTCB15313C DTCB15316C DTCB15320C DTCB15325C DTCB15332C DTCB15340C DTCB15350C DTCB15363C
2 pole 2 modules 3)
In (A) Icu (kA)
C - Curve 5 - 10 In
6
25
i DTCB15206C
10
25
i DTCB15210C
13
25
i DTCB15213C
16
25
i DTCB15216C
20
25
i DTCB15220C
25
25
i DTCB15225C
32
20
i DTCB15232C
40
20
i DTCB15240C
50
15
i DTCB15250C
63
15
i DTCB15263C
4 pole 4 modules 2) 3)
6
25
10
25
13
25
16
25
20
25
25
25
32
20
40
20
50
15
63
15
i DTCB15406C i DTCB15410C i DTCB15413C i DTCB15416C i DTCB15420C i DTCB15425C i DTCB15432C i DTCB15440C i DTCB15450C i DTCB15463C
DTCB15 1 pole
In (A)
1 P 2 P 3 P 4 P
6 - 63
240 V AC 240/415 V AC 240/415 V AC 240/415 V AC
Shock resistance (in x, y, z direction) 20 g with shock duration of 10 ms (minimum 18 shocks) 40 g with shock duration of 5 ms (minimum 18 shocks)
Vibration resistance (in x, y, z direction) 3 g in frequency range 10 to 55 Hz (operating time at least 30 mins) according to IEC 60068-2-6
Storage temperature from -55 °C to +55 °C according to VDE 0664 parts 1 and 2
Operating temperature from -25 °C to +55 °C according to VDE 0664 Parts 1 and 2.
Use at 400 Hz At 400 Hz the magnetic tripping current is approximately 50 % higher than at AC 50/60 Hz
DTCB15 2 pole
DTCB15 3 pole
Notes: 1) 2 P MCB connected in series. The LINE-side is the OFF or bottom of the MCB and connects to CD chassis tee-offs.
2) All poles include overcurrent and short circuit protection. 3) Refer Section 3 for kA ratings at 240/415 V. The above ratings are at 415 V AC. i Available on indent only.
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Din-T MCBs Technical data
Innovators in Protection Technology
Characteristics according to EN 60947-2
Miniature Circuit Breakers are intended for the protection of the lines against both overloads and short-circuits in industrial wiring installations where normal operation is done by instructed people
Tripping characteristic curves
Rated ultimate short-circuit breaking capacity (Icu) Is the value of the short-circuit that the MCB is capable of withstanding in the following test of sequence of operations: O-t-CO.
After the test the MCB is capable, without maintenance, to withstand a dielectric strength test at a test voltage of 1000 V.
3
Moreover the MCB shall be capable of tripping when loaded with
2.5 In within the time corresponding to 2 In but greater than 0.1 s.
Rated service short-circuit breaking capacity (Ics) Is the value of the short-circuit that the MCB is capable of withstanding in the following test of sequence of operations: O-t-CO-t-CO.
After the test the MCB is capable, without maintenance, to withstand a dielectric strength test at a test voltage of twice its rated insulation voltage with a minimum of 1000 V. A verification of the overload releases on In and moreover the MCB shall trip within 1 h when current is 1.45 In (for In<63 A) and 2 h (for In>63 A).
Magnetic release An electromagnet with plunger ensures instantaneous tripping in the event of short-circuit. The standard leaves the calibration of magnetic release to the manufacturers discretion. NHP offers instantaneous tripping ranges: · release between 5 and 10 In · release between 10 and 20 In
Thermal release The release is initiated by a bimetal strip in the event of overload. The standard defines the range of release for two special overload values. Reference ambient temperature is 40 °C.
O - Represents an opening operation C - Represents a closing operation followed by an
automatic opening. t - Represents the time interval between two successive
short-circuit operations: 3 minutes.
Category A: Without a short-time withstand current rating.
Utilization category Application with respect to selectivity
A
Circuit breakers not specifically intended for
selectivity under short-circuit conditions with respect
to other short-circuit protective devices in series on
the load side, i.e. without an intentional short-time
delay provided for selectivity under short-circuit
conditions, and therefore without a short-time
withstand current rating according to 4.3.5.4
Test current 1.05 x In
1.30 x In
Tripping time
t 1 h (In 63 A) t 2 h (In > 63 A)
t < 1 h (In 63 A) t < 2 h (In > 63 A)
B
Circuit breakers specifically intended for selectivity
under short-circuit conditions with respect to other
short-circuit protective devices in series on the
load side, i.e. without an intentional short-time
delay (which may be adjustable), provided for
selectivity under short-circuit conditions. Such
circuit-breakers have a short-time withstand
current rating according to 4.3.5.4
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Innovators in Protection Technology
Din-T MCBs Technical data
Tripping curves according to EN 60898
The following tables show the average tripping curves of the Terasaki Din-T MCBs based on the thermal and magnetic characteristics. Curve C
3
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Din-T MCBs Technical data
Definitions related to circuit breakers
MCB = Miniature Circuit Breaker
Innovators in Protection Technology
Short-circuit (making and breaking) capacity Alternating component of the prospective current, expressed by its RMS value, which the circuit breaker is designed to make, to carry for its opening time and to break under specified conditions.
Ultimate or rated short-circuit breaking capacity (Icn - EN 60898) A breaking capacity for which the prescribed conditions, according to a specified test sequence, do not include the capability of the MCB to carry 0.96 times its rated current for the conventional time.
Prospective current
The current that would flow in the circuit, if each main current path of the MCB were replaced by a
3
conductor of negligible impedance.
Conventional non-tripping current (Int) A specified value of current which the circuit breaker is capable of carrying for a specified time without tripping.
Open position The position in which the predetermined clearance between open contacts in the main circuit of the MCB is secured.
Ultimate short-circuit breaking capacity (Icu - EN 60947-2) A breaking capacity for which the prescribed conditions, according to a specified test sequence, do not include the capability of the MCB to carry its rated current for the conventional time.
Service short-circuit breaking capacity (Ics - EN 60898) A breaking capacity for which the prescribed conditions, according to a specified test sequence, include the capability of the MCB to carry 0.96 times its rated current for the conventional time.
Closed position The position in which the predetermined continuity of the main circuit of the MCB is secured.
Maximum prospective peak current (Ip) The prospective peak current when the initiation of the current takes place at the instant which leads to the highest possible value.
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Din-T MCBs Technical data
Influence of ambient air temperature on the rated current
The maximum value of the current which can flow through an MCB depends on the nominal current of the MCB, the conductor cross-section and the ambient air temperature.
The values shown in the table below are for devices in free air.
3 For devices installed with other modular devices in the same switchboard, a correction factor (K) shall be applied relative to the mounting situation of the MCB, the ambient temperature and the number of main circuits in the installation.
The thermal calibration of the MCBs was carried out at an ambient temperature of 30 °C. Ambient temperatures different from 30 °C influence the bimetal and this results in earlier or later thermal tripping.
No of devices
K 1)
2 or 3
0.9
4 or 5
0.8
6 or 9
0.7
> 10
0.6
Calculation example
Within a distribution board consisting of eight 2 Pole, 16 A, `C' curve type MCBs, with an operating ambient temperature of 45 °C, which is the highest temperature the MCB can operate at without unwanted tripping?
Calculation
The correction factor K = 0.7, for use in an eight circuit installation: 16 A x 0.7 = 11.2 A
As the MCB is working at 45 °C it shall be given another factor (90 % = 0.9): In at 45 °C = In at 30 °C x 0.9 = 11.2 A x 0.9 = 10.1 A.
Note: 1) Applicable for MCBs working at maximum rated currents.
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Din-T MCBs Technical data
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Effects of frequency on the tripping characteristic
All the MCBs are designed to work at frequencies of 50-60 Hz, therefore to work at different values, consideration must be given to the variation of the tripping characteristics. The thermal tripping does not change with variation of the frequency but the magnetic tripping values can be up to 50 % higher than the ones at 50-60 Hz.
Limitation curves
Let-through energy I2t
The limitation capacity of an MCB in short-circuit conditions, is
its capacity to reduce the value of the let-through energy that
the short-circuit would be generating.
Peak current Ip Is the value of the maximum peak of the short-circuit current
3
limited by the MCB.
Tripping current variation
60 Hz 1
100 Hz 1.1
200 Hz 1.2
300 Hz 1.4
400 Hz 1.5
Power losses
The power losses are calculated by measuring the voltage drop between the incoming and the outgoing terminals of the device at rated current.
Power loss per pole
In Voltage drop Energy loss
(A)
(V)
(W)
0.5
2.230
1.115
1
1.270
1.272
2
0.620
1.240
3
0.520
1.557
4
0.370
1.488
6
0.260
1.570
8
0.160
1.242
10
0.160
1.560
13
0.155
2.011
16
0.162
2.586
20
0.138
2.760
25
0.128
3.188
32
0.096
3.072
40
0.100
4.000
50
0.090
4.500
63
0.082
5.160
Resistance (mOhm) 4458.00 1272.00 310.00 173.00
93.00 43.60 19.40 15.60 11.90 10.10 6.90 5.10 3.00 2.50 1.80 1.30
See following pages
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Din-T MCBs Technical data
Din-T 15 15 kA C curve
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Din-T MCBs Technical data
Use of standard MCB for DC use
For MCBs designed to be used in alternating current but used in installations in direct current, the following should be taken into consideration:
For protection against overloads it is necessary to connect
3
the two poles to the MCB. In these conditions the tripping characteristic of the MCB in direct current is similar to
alternating current.
For protection against short-circuits it is necessary to connect the two poles to the MCB. In these conditions the tripping characteristic of the MCB in direct current is 40% higher than the one in alternating current.
Use in DC selection table
Series Din-T 15
Rated current (A)
6....25 A
48 V 1 pole Icu (kA)
10
Installation of Din-T DC MCBs in direct current
110 V 2 poles in series Icu (kA)
10
250 V 1 pole Icu (kA)
-
440 V 2 poles in series Icu (kA)
-
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Din-T MCBs Technical data
Series
Din-T15 AS/NZS 3947-2
Standards (Aust / NZ / International) Tripping characteristics Nominal current Calibration temperature Number of poles (# mod) Neutral pole protected
IEC 60947-2
C
A
0.5-63
°C
40
1/2/3/4
-
Nominal voltage Un Frequency
AC 1 P 3 P/4 P
DC 1 P 1) 2 P (in series) 1)
V
240/415
V
415
V DC
48
V DC
110
Hz
50/60
Hz DC: magn.trip +40%
Maximum service voltage Ubmax between two wires
Minimum service voltage Ubmin
Selectivity class (IEC 60898)
Isolator application
IEC 60947-2
Hz 400: magn.trip +50%
V 250/440; 53/120
V
12; 12
3
yes
Rated insulation voltage Pollution degree 2
V
500
Pollution degree 3 Impulse withstand test voltage Insulation resistance Dielectric rigidity
V kV mOhm kV
440 6 10,000 2.5
Vibration resistance (in x, y, z direction) (IEC 77/16.3)
3 g
Endurance
Electrical at Un, In
4000
mechanical
Utilisation category (IEC 60947-2)
Protection degree (outside / inside, in enclosure with door)
Self-extinguish degree (according to UL94)
Tropicalisation (according to IEC 60068-2 / DIN 40046) °C/RH
Operating temperature
°C
Storage temperature
°C
Terminal capacity Rigid cable min/max (top)
mm2
Flexible cable min*/max (top)
mm2
Rigid cable min/max (bottom)
mm2
Flexible cable min*/max (bottom)
mm2
(* Flexible cable 0.75/1/1.5 mm2 with cable lug)
20,000 A
IP 20/IP 40 V2
+55 °C/95 % RH -25/+55 -55/+55 1/35
0.75/25 1/35
0.75/25
Torque
Nm
4.5
Add-on devices (side add-on)
Busbar systems Accessories
Auxiliary contacts UVT Shunt trip Motor operator Panelboard switch Pin (top/bottom) Fork (top/bottom)
yes yes yes yes yes yes/yes -/yes yes
Dimensions, weights, packaging (HxDxW) 86x68xW Weight/mod. Package
mm/mod.
18
g
120
mod.
12
IEC 60898
Short-circuit capacity AC Icn
Ics (service)
1 P 2 P 3 P/4 P
(kA)
230/400 V 230/400 V 230/400 V
AS/NZS 3947-2 -
Icu (ultimate)
1 P
127 V
50
240 V 415 V
50/25/20/15 2) -
IEC 60947-2
2 P
127 V
-
240 V
50/50/40/30 2)
415 V
50/25/20/15 2)
3 P, 4 P
240 V 415 V 440 V
50/50/40/30 2) 50/25/20/15 2) 50/20/15/10 2)
Ics (service)
75 % Icu
NEMA AB1 (120/240V)
-
Short-circuit capacity DC
(kA)
Icu (ultimate)
1 P
60 V
25
IEC 60947-2
220 V
-
2 P
125 V
30
Ics (service)
440 V
100 % Icu
Notes Refer pages 3 - 23, 24 for information on SAFE-T MCBs. 1) Preferred values of rated control supply voltage (IEC 60947 - 2): 24 V, 48 V, 110 V, 125 V, 250 V
2) 0.5-4 A/6-25 A/32-40 A/50-63 A 3) 10 (125 V DC)
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3
4) 10 (250 V DC) 5) On request.
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1 Miniature circuit breakers Din-T10 series 10 kA MCB
Standard AS/NZS 4898 1) Approval No. N17481 Short circuit breaking capacity - 10000 Amps Current range 0.5 - 63 Amps 1, 2, 3 and 4 pole Sealable and lockable handle Modular design Available in curve type B, C and D Mounts on CD chassis (250 A and 355 A)
1 pole 1 module
DTCB10 1 pole
In (A)
0.5 1 2 3 4 6 10 13 16 20 25 32 40 50 63
C Curve 5-10 In DTCB10105C DTCB10101C DTCB10102C DTCB10103C DTCB10104C DTCB10106C DTCB10110C DTCB10113C DTCB10116C DTCB10120C DTCB10125C DTCB10132C DTCB10140C DTCB10150C DTCB10163C
Short circuit capacity 10 kA
In (A)
0.5 - 63
1 P
240 V AC
2 P
240/415 V AC
3 P
240/415 V AC
4 P
240/415 V AC
Use at DC
Short circuit Max voltage
1 P 25 kA 48 V DC
2 P 2) 30 kA 110 V DC
2 pole 2 modules 0.5 1 2 4 6 10 13 16 20 25 32 40 50 63
DTCB10205C DTCB10201C DTCB10202C DTCB10204C DTCB10206C DTCB10210C DTCB10213C DTCB10216C DTCB10220C DTCB10225C DTCB10232C DTCB10240C DTCB10250C DTCB10263C
Notes: 1) A range of UL standard MCBs is available on indent. (ref DTCBUL1O_ _ _ C). 2) 2 pole MCB connected in series. The line side is the "OFF" (bottom) side of the MCB, and connects to CD chassis tee-offs.
i Available on indent only.
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Din-T MCBs Technical data
Characteristics according to BS EN 60898
Miniature Circuit Breakers are intended for the protection of wiring installations against both overloads and short-circuits in domestic or commercial wiring installations where operation is possible by uninstructed people
Rated short-circuit breaking capacity (Icn) Is the value of the short-circuit that the MCB is capable of withstanding in the following test of sequence of operations: O-t-CO.
3 Tripping characteristic curves
After the test the MCB is capable, without maintenance, to withstand a dielectric strength test at a test voltage of 900 V. Moreover, the MCB shall be capable of tripping when loaded with 2.8 In within the time corresponding to 2.55 In but greater than 0.1s.
Service short-circuit breaking capacity (Ics) Is the value of the short-circuit that the MCB is capable of withstanding in the following test of sequence of operations: O-t-CO-t-CO.
After the test the MCB is capable, without maintenance, to withstand a dielectric strength test at a test voltage of 1500 V. Moreover, the MCB shall not trip at a current of 0.96 In. The MCB shall trip within 1h when current is 1.6 In.
Magnetic release
An electromagnet with plunger ensures instantaneous tripping in the event of short-circuit. The NHP Din-T range has 3 different types, following the current for instantaneous release: types B, C and D curve.
Icn Test (A) current
Tripping time
Applications
B 3 x In 5 x In
0.1<t<45 s (In32 A) 0.1<t<90 s (In>32 A)
t<0.1 s
Only for resistive loads eg: · electrical heating · water heater · stoves.
C 5 x In 0.1<t<15 s (In32 A) Usual loads such as:
10 x In
0.1<t<30 s (In>32 A)
· lighting · socket outlets
t<0.1 s
· small motors
D 10 x In 0.1<t<4 s(**) (In32 A) Control and protection of
20 x In 0.1<t<8 s (In>32 A) circuits having important
transient inrush currents
t<0.1 s
(large motors)
Thermal release
The release is initiated by a bimetal strip in the event of overload. The standard defines the range of releases for specific overload values. Reference ambient temperature is 30 °C.
O - Represents an opening operation
C - Represents a closing operation followed by an automatic opening.
t - Represents the time interval between two successive short-circuit operations: 3 minutes.
The relation between the rated short-circuit capacity (Icn) and the rated service short-circuit breaking capacity (Ics) shall be as follows:
Icn (A)
6000 > 6000 10000 > 10000
Ics (A) 6000
0.75 Icn min. 6000
0.75 Icn min. 7500
In both sequences all MCBs are tested for emission of ionized gases during short-circuit (grid distance), in a safety distance between two MCBs of 35 mm when devices are installed in two different rows in the enclosure. This performance allows the use of any NHP/Terasaki enclosure.
Test current 1.13 x In
1.45 x In
2.55 x In
Tripping time
t 1 h (In 63 A) t 2 h (In > 63 A)
t < 1 h (In 63 A) t < 2 h (In > 63 A)
1 s < t < 60 s (In 32 A) 1 s < t < 120 s (In >32 A)
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Innovators in Protection Technology
Din-T MCBs Technical data
Tripping curves according to EN 60898
The following tables show the average tripping curves of the Terasaki Din-T MCBs based on the thermal and magnetic characteristics. Curve C
3
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Din-T MCBs Technical data
Din-T 10 10 kA C curve
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3
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Innovators in Protection Technology
Din-T MCBs Technical data
Influence of ambient air temperature on the rated current
The maximum value of the current which can flow through an MCB depends on the nominal current of the MCB, the conductor cross-section and the ambient air temperature.
The values shown in the table below are for devices in free air.
3 For devices installed with other modular devices in the same switchboard, a correction factor (K) shall be applied relative to the mounting situation of the MCB, the ambient temperature and the number of main circuits in the installation.
The thermal calibration of the MCBs was carried out at an ambient temperature of 30 °C. Ambient temperatures different from 30 °C influence the bimetal and this results in earlier or later thermal tripping.
No of devices
K 1)
2 or 3
0.9
4 or 5
0.8
6 or 9
0.7
> 10
0.6
Calculation example
Within a distribution board consisting of eight 2 Pole, 16 A, `C' curve type MCBs, with an operating ambient temperature of 45 °C, which is the highest temperature the MCB can operate at without unwanted tripping?
Calculation
The correction factor K = 0.7, for use in an eight circuit installation: 16 A x 0.7 = 11.2 A
As the MCB is working at 45 °C it shall be given another factor (90 % = 0.9): In at 45 °C = In at 30 °C x 0.9 = 11.2 A x 0.9 = 10.1 A.
Note: 1) Applicable for MCBs working at maximum rated currents.
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Din-T MCBs Technical data
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Effects of frequency on the tripping characteristic
All the MCBs are designed to work at frequencies of 50-60 Hz, therefore to work at different values, consideration must be given to the variation of the tripping characteristics. The thermal tripping does not change with variation of the frequency but the magnetic tripping values can be up to 50 % higher than the ones at 50-60 Hz.
Limitation curves
Let-through energy I2t
The limitation capacity of an MCB in short-circuit conditions, is
its capacity to reduce the value of the let-through energy that
the short-circuit would be generating.
Peak current Ip Is the value of the maximum peak of the short-circuit current
3
limited by the MCB.
Tripping current variation
60 Hz 1
100 Hz 1.1
200 Hz 1.2
300 Hz 1.4
400 Hz 1.5
Power losses
The power losses are calculated by measuring the voltage drop between the incoming and the outgoing terminals of the device at rated current.
Power loss per pole
In Voltage drop Energy loss
(A)
(V)
(W)
0.5
2.230
1.115
1
1.270
1.272
2
0.620
1.240
3
0.520
1.557
4
0.370
1.488
6
0.260
1.570
8
0.160
1.242
10
0.160
1.560
13
0.155
2.011
16
0.162
2.586
20
0.138
2.760
25
0.128
3.188
32
0.096
3.072
40
0.100
4.000
50
0.090
4.500
63
0.082
5.160
80
0.075
6.000
100
0.075
7.500
125
0.076
9.500
Resistance (mOhm) 4458.00 1272.00 310.00 173.00
93.00 43.60 19.40 15.60 11.90 10.10 6.90 5.10 3.00 2.50 1.80 1.30 0.90 0.75 0.60
See following pages
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Din-T MCBs Technical data
Use of standard MCB for DC use
For MCBs designed to be used in alternating current but used in installations in direct current, the following should be taken into consideration:
For protection against overloads it is necessary to connect
3
the two poles to the MCB. In these conditions the tripping characteristic of the MCB in direct current is similar to
alternating current.
Use in DC selection table
For protection against short-circuits it is necessary to connect the two poles to the MCB. In these conditions the tripping characteristic of the MCB in direct current is 40% higher than the one in alternating current.
Use of special MCB Din-T DC for DC use.
(UC = Universal current)
For MCBs designed to work in both alternating and direct current, it is necessary to respect the polarity of the terminals since the device is equipped with a permanent magnet.
Series Din-T 10
Rated current (A)
0.5....63 A
48 V 1 pole Icu (kA)
25
110 V 2 poles in series Icu (kA)
30
250 V 1 pole Icu (kA)
-
440 V 2 poles in series Icu (kA)
-
Installation of Din-T DC MCBs in direct current
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Notes
Din-T MCBs Technical data
Series
Din-T10 AS/NZS 4898
Standards (Aust / NZ / International)
IEC 60898
Tripping characteristics
B, C, D
Nominal current
A B(6-63), C/D(0.5-63)
Calibration temperature
°C
30
Number of poles (# mod) Neutral pole protected
1/2/3/4 yes
Nominal voltage Un AC 1 P
V
240/415
Frequency
3 P/4 P DC 1 P 1)
2 P (in series) 1)
V
415
V DC
48
V DC
110
Hz
50/60
Hz DC: magn.trip +40%
Hz 400: magn.trip +50%
Maximum service voltage Ubmax between two wires
V 250/440; 53/120
Minimum service voltage Ubmin
Selectivity class (IEC 60898)
Isolator application
IEC 60947-2
V
12; 12
3
yes
Rated insulation voltage Pollution degree 2
V
500
Pollution degree 3
V
440
Impulse withstand test voltage
kV
6
Insulation resistance
mOhm
10,000
Dielectric rigidity
kV
2.5
Vibration resistance (in x, y, z direction) (IEC 77/16.3)
3 g
Endurance
Electrical at Un, In
10,000
mechanical
20,000
Utilisation category (IEC 60947-2)
A
Protection degree (outside / inside, in enclosure with door)
Self-extinguish degree (according to UL94)
Tropicalisation (according to IEC 60068-2 / DIN 40046) °C/RH
Operating temperature
°C
Storage temperature
°C
IP 20/IP 40 V2
+55 °C/95 % RH -25/+55 -55/+55
Terminal capacity Rigid cable min/max (top)
mm2
1/35
Flexible cable min*/max (top) Rigid cable min/max (bottom)
mm2
0.75/25
mm2
1/35
Flexible cable min*/max (bottom)
mm2
0.75/25
(* Flexible cable 0.75/1/1.5 mm2 with cable lug)
Torque
Nm
4.5
Add-on devices Auxiliary contacts
yes
(side add-on) UVT
yes
Shunt trip
yes
Motor operator
yes
Panelboard switch
yes
Busbar systems Pin (top/bottom)
yes/yes
Fork (top/bottom)
-/yes
Accessories
yes
Dimensions, weights, packaging (HxDxW) 86x68xW
mm/mod.
18
Weight/mod.
g
120
Package
mod.
12
Short-circuit capacity AC
(kA)
AS/NZS 4898
IEC 60898
Icn Ics (service)
1 P 2 P 3 P/4 P
230/400 V 230/400 V 230/400 V
10 10 10 75 % Icn
Icu (ultimate)
1 P
127 V
30
240 V
15
IEC 60947-2
415 V
4
2 P
127 V
40
240 V
30
415 V
15
3 P, 4 P
240 V
30
415 V
15
440 V
10
Ics (service)
50 % Icu
NEMA AB1 (120/240V)
30
Short-circuit capacity DC
(kA)
Icu (ultimate)
1 P
60 V
25
IEC 60947-2
220 V
-
2 P
125 V
30
Ics (service)
440 V
100 % Icu
Refer pages 3 - 23, 24 for information on SAFE-T MCBs. 1) Preferred values of rated control supply voltage (IEC 60947 - 2): 24 V, 48 V, 110 V, 125 V, 250 V
2) 0.5-4 A/6-25 A/32-40 A/50-63 A 3) 10 (125 V DC)
Innovators in Protection Technology
3
4) 10 (250 V DC) 5) On request.
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Innovators in Protection Technology
Din-T MCBs + RCDs Technical data
Miniature circuit breakers - Din-T 10
Dimensions in mm.
3
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual J & P Richardson Industries Pty Ltd
1.2. CONTROL DEVICES CARLO GAVAZZI DPB-01-C-M48W Phase Failure Relay MULTITRODE MTR 24VDC Sump Pump Level Relay SPRECHER & SCHUH CS 7C-40E24V Pumps Stop Relay SPRECHER & SCHUH CS 7-PV-22 Pumps Stop Relay Aux Contact SPRECHER & SCHUH CS 7C-22E24V 24VDC Relay IDEC RH2B-ULD-D24VDC + SH2B-05 Run Relay + Base SPRECHER & SCHUH CA7-9C-01 24VDC Contactor COSMOTEC KTS01141 - Thermostat
C63100-WB065_Manual_DRAFT.doc Revision 0
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Date: February 18, 2014
Page 47 of 1068
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Monitoring Relays True RMS 3-Phase, 3-Phase+N, Multi-function Types DPB01, PPB01
DPB01
PPB01
· TRMS 3-phase over and under voltage, phase sequence and phase loss monitoring relays
· Detect when all 3 phases are present and have the correct phase sequence (except for N versions)
· Available versions (W4) supplied between phase and neutral
· Detect if all the 3-phase-phase or phase-neutral voltages are within the set limits
· Upper and lower limits separately adjustable · Measure on own power supply · Selection of measuring range by DIP-switches · Adjustable voltage on relative scale · Adjustable delay function (0.1 to 30 s) · Output: 8 A SPDT relay N.E. · For mounting on DIN-rail in accordance with
DIN/EN 50 022 (DPB01) or plug-in module (PPB01) · 22.5 mm Euronorm housing (DPB01)
or 36 mm plug-in module (PPB01) · LED indication for relay, alarm and power supply ON
Product Description
Ordering Key
3-phase or 3-phase+neutral line voltage monitoring relay for phase sequence, phase loss, over and under voltage (separately adjustable set
points) with built-in time delay function. Supply ranges from 208 to 480 VAC covered by two multivoltage relays.
Housing Function Type Item number Output Power supply
Type Selection
Mounting Phase sequence Output detection
Supply: 208 to 240 VAC
Supply: 380 to 415 VAC
DIN-rail yes Plug-in yes Plug-in yes DIN-rail no Plug-in no Plug-in no
SPDT SPDT SPDT SPDT SPDT SPDT
DPB 01 C M23 PPB 01 C M23
DPB 01 C M23 N PPB 01 C M23 N
DPB 01 C M48 W4 PPB 01 C M48 W4 PPB 01 C M48 DPB 01 C M48 N W4 PPB 01 C M48 N W4 PPB 01 C M48 N
DPB 01 C M23
Supply: 380 to 480 VAC DPB 01 C M48 DPB 01 C M48 N
Input Specifications
Input
L1, L2, L3, N
DPB01: Terminals L1, L2, L3, N
PPB01: Terminals 5, 6, 7, 11
Measure on own supply
Note: Connect the neutral only
if it is intrinsically at the star
centre
Measuring ranges 208 to 240 VAC 380 to 415 VAC
380 to 480 VAC
177 to 275 VL-L AC M23 versions 323 to 475 VL-L AC PPB01CM48 PPB01CM48N D/P PB01CM48W4 D/P PB01CM48NW4 323 to 550 VL-L AC DPB01CM48 DPB01CM48N
Ranges
Upper level
+2 to +22%
of the nominal voltage
Lower level
-22 to -2%
of the nominal voltage
Note: The input voltage
must not exceed the maximum
rated voltage or drop below
the minumum rated voltage
reported above.
Hysteresis
Set points from 2 to 5%
1%
Set points from 5 to 22%
2%
Specifications are subject to change without notice (10.04.07)
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DPB01, PPB01
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Output Specifications
Output Rated insulation voltage
SPDT relay 250 VAC
Contact ratings (AgSnO2)
Resistive loads
AC 1
DC 12
Small inductive loads AC 15
DC 13
µ 8 A @ 250 VAC 5 A @ 24 VDC 2.5 A @ 250 VAC 2.5 A @ 24 VDC
Mechanical life
30 x 106 operations
Electrical life
105 operations (at 8 A, 250 V, cos = 1)
Operating frequency
7200 operations/h
Dielectric strength
Dielectric voltage
2 kVAC (rms)
Rated impulse withstand volt. 4 kV (1.2/50 µs)
Supply Specifications
Power supply
Rated operational voltage
through terminals:
L1, L2, L3, N (DPB01)
5, 6, 7, 11
(PPB01)
Overvoltage cat. III (IEC 60664, IEC 60038)
D/P PB01CM23, D/P PB01CM23N
208 to 240 VL-L AC ±15% 45 to 65 Hz
D/P PB01CM48W4,
380 to 415 VL-L AC ±15%
D/P PB01CM48NW4,
(220 to 240 VL-N AC ±15%)
PPB01CM48, PPB01CM48N 45 to 65 Hz
DPB01CM48, DPB01CM48N
Rated operational power DPB01CM23x, PPB01CM23x DPB01CM48x, PPB01CM48x
DPB01CM48xW4 DPB01CM48xW4
380 to 480 VL-L AC ±15% (220 to 277 VL-N AC ±15%) 45 to 65 Hz
13 VA @ 230 VAC, 50 Hz 13 VA @ 400 VAC, 50 Hz Supplied by L1 and L2
13 VA @ 400 VAC, 50 Hz Supplied by L1 and N
General Specifications
Power ON delay
Reaction time Incorrect phase sequence or total phase loss Voltage level
Alarm ON delay Alarm OFF delay
Accuracy Temperature drift Delay ON alarm Repeatability
Indication for Power supply ON Alarm ON
Output relay ON
Environment Degree of protection Pollution degree Operating temperature @ Max. voltage, 50 Hz @ Max. voltage, 60 Hz Storage temperature
Housing Dimensions
DPB01 PPB01
Weight
Screw terminals Tightening torque
Approvals
CE Marking
EMC Immunity Emissions
1 s ± 0.5 s or 6 s ± 0.5 s
< 200 ms (input signal variation from -20% to +20% or from +20% to -20% of set value) < 200 ms (delay < 0.1 s) < 200 ms (delay < 0.1 s) (15 min warm-up time) ± 1000 ppm/°C ± 10% on set value ± 50 ms ± 0.5% on full-scale
LED, green LED, red (flashing 2 Hz during delay time) LED, yellow
IP 20 3 (DPB01), 2 (PPB01)
-20 to 60°C, R.H. < 95% -20 to 50°C, R.H. < 95% -30 to 80°C, R.H. < 95%
22.5 x 80 x 99.5 mm 36 x 80 x 94 mm Approx. 120 g
Max. 0.5 Nm according to IEC 60947 UL, CSA (except for W4 versions) Yes Electromagnetic Compatibility According to EN 61000-6-2 According to EN 61000-6-3
Mode of Operation
Connected to the 3 phases (and neutral) DPB01 and PPB01 operate when all 3 phases are present at the same time, the phase sequence is correct (not N versions) and the phasephase (or phase-neutral) voltage levels are within set limits.
If one or more phase-phase or phase-neutral voltages exceeds the upper set level or drops below the lower set level, the red LED starts
flashing 2 Hz and the output relay releases after the set time period. In any case if phase-neutral measurement is selected both phasephase and phase-neutral voltages are monitored. If the phase sequence is wrong or one phase is lost, the output relay releases immediately. Only 200 ms delay occurs. The failure is indicated by the red LED flashing 5 Hz during the alarm condition.
Example 1 (mains network monitoring)
The relay monitors over and
under voltage, phase loss
and
correct
phase
sequence.
In case of N versions, the
relay monitors over and
under voltage.
Example 2 (load monitoring)
The relay releases in case of interruption of one or more phases, when one or more voltages drop below the lower set level or exceed the upper set level.
2
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual DPB01, PPB01
Function/Range/Level and Time Delay Setting
Adjust the input range setting the DIP switches 3 and 4 as shown below.
Select the desired function setting the DIP switches 1 and 2 as shown below.
To access the DIP swiches open the grey plastic cover as shown below
Selection of level and time delay:
Upper knob: Setting of lower level on relative scale.
Centre knob: Setting of upper level on relative scale.
Lower knob: Setting of delay on alarm time on absolute scale (0.1 to 30 s).
Power ON delay ON: 6 s ± 0.5 s OFF: 1 s ± 0.5 s
Monitored voltage ON: Phase-Neutral OFF: Phase-Phase
Measuring range
SW3
ON
SW4
ON
M23 Ph-Ph 208 VAC Voltage
M48 Ph-Ph 380 VAC Voltage
M48 Ph-N 220 VAC Voltage
ON
OFF
OFF
ON
220 VAC 230 VAC
400 VAC 415 VAC
230 VAC 240 VAC
OFF
OFF
240 VAC
480 VAC DPB01CM48, DPB01CM48N
only
277 VAC DPB01CM48, DPB01CM48N
only
Operation Diagrams
Specifications are subject to change without notice (10.04.07)
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DPB01, PPB01
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Operation Diagrams (cont.) (*)
(*) N versions don't detect incorrect phase sequence. Wiring Diagrams
DPB01
4
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PPB01
Specifications are subject to change without notice (10.04.07)
Active: 18/04/2016
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual DPB01, PPB01
Note
When DPB01 or PPB01 is used with phase indicator lamps (see examples in the following diagrams), the lamp H1 or H2 might be dimly lit when there is a phase loss in L1 or L2. This might happen if the lamps used are the typical low power indicator lamps, and there are no other loads present.
This fact can be avoided by using W4 models. Note that the neutral must be always connected to the device.
DPB01
PPB01
Dimensions
DIN-rail
22.5 99.5
Plug-in
36
28.5
94 90
28.5
80 83.5 63 80 63
Specifications are subject to change without notice (10.04.07)
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
38 Series - Relay interface modules 0.1 - 2 - 3 - 5 - 6 - 8 A
Common features
· Instant ejection of relay by plastic retaining clip · Integral coil indication and protection circuit · 35 mm rail (EN 60715) mounting
6.2 mm wide
· EMR - DC, AC or AC/DC coil versions · SSR - DC or AC/DC input versions · Screw and Screwless terminal options
EMR Electromechanical Relays
38.51/38.61
SSR Solid State Relays
38.81/38.91
6.2 mm wide
· Special coil / input leakage current suppression types
· EMR - AC or AC/DC coil versions · SSR - AC or AC/DC input versions · Screw and Screwless terminal options
· 1 CO - 6 A 250VAC
· Single solid state output: Options 0.1A 48VDC, 2A 24VDC, 2A 240VAC
· Silent, high speed switching · Long electrical life
Page 1
38.51.3... - 38.61.3...
Page 2
38.81.3... - 38.91.3...
· 1 CO - 6 A 250VAC
6.2 mm wide
· Timed Interface module · 4 functions & 4 time scales 0.1s ... 6h · EMR - AC/DC (12 or 24V) supply versions · SSR - AC/DC (24V) supply · Screw terminals
38.21
· Single solid state output: Options 0.1A 48VDC, 2A 24VDC, 2A 240VAC
· Silent, high speed switching · Long electrical life
Page 1
Page 2
38.21...9024-8240
14 mm wide
· 2 pole 8 A or 1 pole 16 A · EMR - DC or AC/DC coil versions · SSR - DC input versions · Screw and Screwless terminal options
· 1 CO - 6 A 250VAC
· Single solid state output: Options 2A 24VDC, 2A 240VAC
· Silent, high speed switching · Long electrical life
Page 3
38.01/38.52/38.11/38.62
38.31/38.41
Page 3
Q-Pulse Id: TMS1594
· 1 CO - 16 A 250VAC · 2 CO - 8 A 250VAC
Active: 18/04/2016
· Single solid state output: Options 5A 24VDC, 3A 240VAC
· Silent, high speed switching · Long electrical life
Page 4
Page 5
Page 53 of 1068
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
38 Series - Relay interface modules - 1 Pole 6 A EMR
Features
1 Pole - 6 A electromechanical relay interface modules, 6.2 mm wide.
Ideal interface for PLC and electronic systems
· Sensitive DC coil or AC/DC coil versions · Integral coil indication and protection circuit · Instant ejection of relay using plastic
retaining clip · UL Listing (certain relay/socket combinations) · 35 mm rail (EN 60715) mounting
38.51/61
38.51 / 38.51.3 Screw terminal
38.61 / 38.61.3 Screwless terminal
· 1 pole electromechanical relay · Screw terminal and screwless terminal · 35 mm rail (EN 60715) mounting
38.51.3 / 38.61.3
· Leakage current suppression · 1 pole electromechanical relay · Screw terminal and screwless terminal · 35 mm rail (EN 60715) mounting
34.51
PROTECTION AND
INDICATION CIRCUIT
* Special version for max ambient temperature +70°C.
For outline drawing see page 12 Contact specification
93.01/51
Contact configuration
1 CO (SPDT)
Rated current/Maximum peak current
A
6/10
Rated voltage/Maximum switching voltage V AC
250/400
Rated load AC1
VA
1,500
Rated load AC15 (230 V AC)
VA
300
Single phase motor rating (230 V AC) kW
0.185
Breaking capacity DC1: 30/110/220 V A
6/0.2/0.12
Minimum switching load
mW (V/mA)
500 (12/10)
Standard contact material
AgNi
Coil specification
Nominal voltage (UN)
V AC/DC 12 - 24 - 48 - 60 - (110...125) - (220...240)
V AC
(230...240)*
V DC
6 - 12 - 24 - 48 - 60 (non polarized)
Rated power AC/DC
VA (50 Hz)/W
See page 9
Operating range
AC/DC AC
(0.8...1.1)UN (184...264)V
Holding voltage Must drop-out voltage Technical data
DC AC/DC AC/DC
(0.8...1.2)UN 0.6 UN / 0.6 UN 0.1 UN / 0.05 UN
Mechanical life AC/DC
cycles
10 · 106
Electrical life at rated load AC1
cycles
60 · 103
Operate/release time
ms
5/6
Insulation between coil and contacts (1.2/50 µs) kV
6 (8 mm)
Dielectric strength between open contacts V AC
1,000
Ambient temperature range (UN 60 V/>60V) °C Protection category
40...+70/40...+55 IP 20
Approvals relay (according to type)
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Active: 18/04/2016
34.51
LEAKAGE CURRENT SUPPRESSION CIRCUIT
93.01.3/51.3
1 CO (SPDT) 6/10
250/400 1,500 300 0.185
6/0.2/0.12 500 (12/10)
AgNi
(110...125)
--
--
(230...240)
--
--
1/1
0.5/--
(94...138)V
--
--
(184...264)V
--
0.6 UN / 0.6 UN
44 V
72 V
10 · 106 60 · 103
5/6 6 (8 mm)
1,000 --/40...+55
IP 20
1 Page 54 of 1068
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
38 Series - Relay interface modules - Ordering information
Ordering information
Electromechanical relay - 1 or 2 Pole
Example: 38 series screw terminal relay interface module, 1 CO (SPDT), sensitive 12 V DC coil.
A
B
C
D
3 8.5 1.7.0 1 2 .0 0 5 0
Series
Type 0 = Electromechanical 16 A relay,
with screw terminal 1 = Electromechanical 16 A relay,
with screwless terminal 2 = Timer multifunction (AI, DI, GI, SW),
with screw terminal 5 = Electromechanical relay,
with screw terminal 6 = Electromechanical relay,
with screwless terminal
No. of poles 1 = 1 pole, 6 or 16 A 2 = 2 pole, 8 A
Coil version 0 = AC (50/60 Hz)/ DC 3 = Leakage current suppression for
(110...125)V AC/DC - (230...240)V AC 7 = Sensitive DC, (6, 12, 24, 48, 60)V only 8 = AC (50/60 Hz)
Coil voltage See coil specifications
D: Special versions 0 = Standard
C: Options 5 = Standard DC 6 = Standard AC/DC
B: Contact circuit 0 = CO (nPDT)
A: Contact material 0 = AgNi Standard 4 = AgSnO2 5 = AgNi + Au (5 µm)
Selecting features and options: only combinations in the same row are possible.
Type
Coil version A
B
C
D
38.01/11 7
0 - 4
0
5
0
38.01/11 0
0 - 4
0
6
0
38.51/61 7
0-4-5 0
5
0
38.51/61 0 - 3 - 8 0 - 4 - 5 0
6
0
38.52/62 7
0 - 5
0
5
0
38.52/62 0
0 - 5
0
6
0
38.21 0
0
0
6
0
6 Q-Pulse Id: TMS1594
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
38 Series - Relay interface modules - Ordering information
Ordering information
Solid state relay - Single output - 6.2 & 14 mm wide
Example: 38 series screw terminal SSR relay interface module, 6.2 mm wide, 2 A output, 24 V DC input.
3 8.8 1.7.0 2 4 .9 0 2 4
Series
Type 21 = Timer SSR 6.2mm wide,
with screw terminal 31 = SSR 14mm wide,
with screw terminal 41 = SSR 14mm wide,
with screwless terminal 81 = SSR 6.2mm wide,
with screw terminal 91 = SSR 6.2mm wide,
with screwless terminal
Input version 0 = AC/DC for 24V Timer SSR and (110...125)V and
(220...240)V SSR only 3 = Leakage current suppression for
(110...125)V AC/DC and (230...240)V AC SSR only 7 = DC, (6, 24, 60)V SSR only
Input voltage See input specifications
Output version 9024 = 2 A - 24 V DC (38.81 & 38.91) 9024 = 5 A - 24 V DC (38.31 & 38.41) 7048 = 0.1 A - 48 V DC (38.81 & 38.91) 8240 = 2 A - 240 V AC (38.81 & 38.91) 8240 = 3 A - 240 V AC (38.31 & 38.41)
Selecting features and options: only combinations in the same row are possible.
Type
Input version Output version
38.81/91 7
9024 - 7048 - 8240
38.81/91 0 - 3
9024 - 7048 - 8240
38.31/41 7
9024 - 8240
38.21 0
9024 - 8240
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38 Series - Relay interface modules - Technical data
Technical data - 1 & 2 Pole Electromechanical Relays
Insulation
Insulation according to EN 61810-1 insulation rated voltage
rated impulse withstand voltage
pollution degree
overvoltage category
Insulation between coil and contacts (1.2/50 µs)
Dielectric strength between open contacts
Conducted disturbance immunity
Burst (5...50)ns, 5 kHz, on A1 - A2
Surge (1.2/50 µs) on A1 - A2 (differential mode)
Other data
Bounce time: NO/NC
Vibration resistance (10...55)Hz: NO/NC
Power lost to the environment
without contact current
with rated current
Terminals
Wire strip length
Screw torque
Max. wire size
Wire strip length Screw torque
Max. wire size
V kV
kV V AC
ms g
W W
mm Nm
mm2 AWG
mm Nm
mm2 AWG
250
400
4
4
3
2
III
III
6 (8 mm)
1,000
EN 61000-4-4
level 4 (4 kV)
EN 61000-4-5
level 3 (2 kV)
1 Pole 6 A
1 Pole 16 A - 2 Pole 8 A
1/6
2/5
10/5
15/2
0.2 (12 V) - 0.9 (240 V)
0.5 (24 V) - 0.9 (240 V)
0.5 (12 V) - 1.5 (240 V)
1.3 (24 V) - 1.7 (240 V)
38.21 / 38.51
38.61
10
10
0.5
--
solid cable stranded cable solid cable stranded cable
1x2.5/2x1.5 1x2.5/2x1.5 1x2.5
1x2.5
1x14/2x16 1x14/2x16 1x14
1x14
38.01 / 38.52
38.11 / 38.62
10
10
0.5
--
solid cable stranded cable solid cable stranded cable
1x2.5/2x1.5 1x2.5/2x1.5 1x2.5
1x2.5
1x14/2x16 1x14/2x16 1x14
1x14
Contact specification - 1 & 2 Pole Electromagnetic Relays
F 38 - Electrical life (AC) v contact current, 1 Pole 6 A
H 38 - Maximum DC1 breaking capacity, 1 Pole 6 A
Resistive load - cos = 1 Inductive load - cos = 0.4
DC breaking current (A)
Cycles
F 38 - Electrical life (AC) v contact current, 1 Pole 16 A and 2 Pole 8 A
DC voltage (V) H 38 - Maximum DC1 breaking capacity, 1 Pole 16 A and 2 Pole 8 A
Resistive load - cos = 1 Inductive load - cos = 0.4
38.01/11 limit current 38.52/62 limit current
2 contacts in series
DC breaking current (A)
Cycles
8 Q-Pulse Id: TMS1594
single contact
DC voltage (V)
· When switching a resistive load (DC1) having voltage and current values under the curve, an electrical life of 60·103 (1 Pole) or 80·103 ( 2 Pole) can be expected.
· In the case of DC13 loads, the connection of a diode in parallel with the load will permit a similar electrical life as for a DC1 load. Note: the release time for the load will be increased.
Active: 18/04/2016
Page 57 of 1068
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
38 Series - Relay interface modules - Technical data
Coil specifications - 1 Pole 6 A Electromechnical Relay
Coil data sensitive DC, 1 Pole
Nominal Coil
Operating range
voltage code
UN
Umin
Umax
V
V
V
6
7.006
4.8
7.2
12
7.012
9.6
14.4
24
7.024
19.2
28.8
48
7.048
38.4
57.6
60
7.060
48
72
Rated coil Power
consumption consumption
I at UN mA
P at UN W
35
0.2
15.2
0.2
10.4
0.3
6.3
0.3
7
0.4
Coil data AC/DC, 1 Pole
Nominal Coil
Operating range Rated coil Power
voltage code
consumption consumption
UN
Umin
Umax
I at UN P at UN
V
V
V
mA
VA/W
12 0.012 24 0.024
9.6 19.2
13.2
16
26.4
12
0.2/0.2 0.3/0.2
48 0.048
38.4
52.8
6.9 0.3/0.3
60 0.060
48
66
110...125 0.125
88
138
7
0.5/0.5
5(*) 0.6/0.6(*)
220...240 0.240
176
264
4(*) 1/0.9(*)
(*) Rated coil consumption and power consumption values relate to UN = 125 and 240 V.
Coil data AC, 1 Pole (indicated for max ambient temperature +70°C)
Nominal voltage
UN V (230...240) AC
Coil code
8.240
Operating range
Umin V
184
Umax V
264
Rated coil Power
consumption consumption
I at UN mA
P at UN VA/W
3
0.7/0.3
Coil data, leakage current suppression types, 1 Pole
Nominal voltage
UN V (110...125) AC/DC (230...240) AC
Coil code
3.125 3.240
Operating range
Umin V 94
184
Umax V
138 264
Rated coil Power
consumption consumption
I at UN mA
P at UN VA/W
8(*)
1/1(*)
7(*) 1.7/0.5(*)
(*) Rated coil consumption and power consumption values relate to UN = 125 and 240 V.
The 38 Series interface modules (supply version 3) have built-in leakage current suppression to address industry concerns of the contacts not dropping-out when there is residual current in the circuit; at (110...125)V AC and (230...240)V AC.
This problem can occur, for example, when connecting the interface modules to PLC,s with triac outputs or when connecting via relatively long cables.
Coil specifications - 1 Pole 16 A and 2 Pole 8 A Electromechanical Relay
Coil data sensitive DC, 1 Pole 16 A and 2 Pole 8 A
Coil data AC/DC, 1 Pole 16 A and 2 Pole 8 A
Nominal voltage
UN V 12 24 60
Coil code
7.012 7.024 7.060
Operating range
Umin V 9.6
19.2 48
Umax V
14.4 28.8 72
Rated coil Power
consumption consumption
I at UN mA
P at UN W
41
0.5
19.5
0.5
8
0.5
Nominal voltage
UN V
24 60 110...125 220...240
Coil code
0.024 0.060 0.125 0.240
Operating range
Umin V 19.2 48 88
184
Umax V
26.4 66 138 264
Rated coil Power
consumption consumption
I at UN mA
P at UN VA/W
20
0.5/0.5
7.1 0.5/0.5
4.6 0.6/0.6
3.8 0.9/0.9
Coil specification - 1 & 2 Pole Electromagnetic Relays
R 38 - DC coil operating range v ambient temperature 1 Pole and 2 Pole
1 2 3
4
1 - Max. permitted coil voltage at nominal load (DC coil). 2 - Max. permitted coil voltage at nominal load (AC/DC coils U 60 V). 3 - Max. permitted coil voltage at nominal load (AC/DC coils U > 60 V). 4 - Min pick-up voltage with coil at ambient temperature.
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
38 Series - Relay interface modules - Technical data
Technical data - Solid State Relays
Other data Power lost to the environment
Terminals Wire strip length
Screw torque Max. wire size
without output current with rated current
Wire strip length Screw torque
Max. wire size
W W
mm Nm
mm2 AWG
mm Nm
mm2 AWG
38.81/38.91 0.25 (24 V DC) 0.4 38.81 10 0.5 solid cable 1x2.5 / 2x1.5 1x14 / 2x16 38.31 10 0.5 solid cable 1x2.5 / 2x1.5 1x14 / 2x16
stranded cable 1x2.5 / 2x1.5 1x14 / 2x16
stranded cable 1x2.5 / 2x1.5 1x14 / 2x16
38.31/38.41
0.5
2.2 (DC output) / 3 (AC output)
38.91
10
--
solid cable
stranded cable
1x2.5
1x2.5
1x14
1x14
38.41
10
--
solid cable
stranded cable
1x2.5
1x2.5
1x14
1x14
Input specifications - Solid State Relays type 38.81 and 38.91 - 6.2 mm wide
Input data DC
Nominal voltage
UN V 6 24 60
Supply code
7.006 7.024 7.060
Operating range
Umin V 5
16.8 35.6
Umax V 7.2 30 72
Release Rated coil Power
voltage consumption consumption
U
I at UN
P
V
mA
W
2.4
7
0.2
10
10.5
0.3
20
6.5
0.4
Input data - Leakage current suppression types
Nominal Supply Operating range Release Rated coil Power
voltage
code
voltage consumption consumption
UN
Umin Umax
U I at UN P at UN
V
V
V
mA
W
110...125 AC/DC 3.125 94 138 44 8(*) 1/1(*)
230...240 AC 3.240 184 264 72 6.5(*) 1.6/0.6(*)
(*) Rated coil consumption and power consumption values relate to UN = 125 and 240 V.
Input data AC/DC
Nominal Supply Operating range Release Rated coil Power
voltage code
voltage consumption consumption
UN V
110...125 0.125
Umin V
88
Umax V
138
U
I at UN
P
V
mA VA/W
22
5.5* 0.7/0.7
220...240 0.240 184
264
44
3.5* 1/0.9
(*) Rated coil consumption and power consumption values relate to UN = 125 and 240 V.
The 38 Series interface modules (supply version 3) have built-in leakage current suppression to address industry concerns of the contacts not dropping-out when there is residual current in the circuit; at (110...125)V AC and (230...240)V AC.
This problem can occur, for example, when connecting the interface modules to PLC,s with triac outputs or when connecting via relatively long cables.
Input specification - Solid State Relay types 38.31 and 38.41 - 14 mm wide
Input data DC
Nominal voltage
UN V 24
Supply code
7.024
Operating range
Umin V
16.8
Umax V
30
Release Rated coil Power
voltage consumption consumption
U
I at UN
P
V
mA
W
5
12
0.3
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
38 Series - Timed interface modules
Additional technical data - Timed Interface Module
EMC specifications
Type of test
Reference standard
Electrostatic discharge
contact discharge
EN 61000-4-2
air discharge
EN 61000-4-2
Radio-frequency electromagnetic field (80 ÷ 1000 MHz)
EN 61000-4-3
Fast transients (burst) (5-50 ns, 5 kHz) on Supply terminals
EN 61000-4-4
Surges (1.2/50 µs) on Supply terminals common mode
EN 61000-4-5
differential mode
EN 61000-4-5
Radio-frequency common mode (0.15 ÷ 80 MHz) on Supply terminals EN 61000-4-6
Radiated and conducted emission
EN 55022
Other data
EMR
Power lost to the environment
without contact current W 0.1
with rated current
W 0.6
Terminals
38.21
Wire strip length
mm 10
Screw torque
Nm 0.5
Max. wire size
solid cable
mm2 1x2.5 / 2x1.5
AWG 1x14 / 2x16
4 kV 8 kV 10 V/m 4 kV 4 kV 4 kV 10 V class B SSR 0.1 0.5
stranded cable 1x2.5 / 2x1.5 1x14 / 2x16
Times scales
1234 1234 1234 1234
Functions
Wiring diagram
(0.1...3)s
(3...60)s
(1...20)min
(0.3...6)h
LED U = Supply voltage
Supply voltage OFF ON ON
NO contact/output Open
Open (time in progress) Closed
= Output contact
(AI) ON delay. Apply power to timer. Output contacts transfer after preset time has elapsed. Reset occurs when power is removed.
(DI) ON pulse. Apply power to timer. Output contacts transfer immediately. After the preset time has elapsed, contacts reset.
1234 1234
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1234
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(GI) Fixed pulse (0.5s) delayed. Apply power to timer. Output contacts transfer after preset time has elapsed. Reset occurs after a fixed time of 0.5s.
(SW) Symmetrical recycling: ON start. Apply power to timer. Output contacts transfer immediately and cycle between ON and OFF for as long as power is applied. The ratio is 1:1 (time on = time off).
11 Page 60 of 1068
38.21 38.51 / 38.51.3 38.81 / 38.81.3 Screw terminal
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
38 Series - Relay interface modules - Dimensional data
Outline drawings
38.01 38.31 38.52 Screw terminal
38.61 / 38.61.3 38.91 / 38.91.3 Screwless terminal
38.11 38.41 38.62 Screwless terminal
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
MTR/MTRA Installation & Troubleshooting
1 Introduction
The MultiTrode level control relay is a solid-state electronic module in a hi-impact plastic case with a DIN rail attachment on the back, making a snap-on-snap-off installation. Any number of relays can be easily added to the DIN metal rail then wired together to form a complex pumping system that other wise may have to be controlled and operated by a programmed PLC.
The relay is normally matched with the MultiTrode probe which works in conjunction with the relay and uses the conductivity of the liquid to complete an electrical circuit.
2 Electrical Overview
There are 10 screw terminals on the unit. Facing the relay as shown, we look at the bottom terminals (left to right):
· Lo (Charge mode). This is the point when the probe is dry
the relay will turn on.
· Lo (Discharge mode). This is the point when the probe in the
tank is dry the relay will turn off.
· Hi (Charge mode). This is the point when the probe in the
tank is wet a relay will turn off
· Hi (Discharge mode). This is the point when the probe in the
tank is wet a relay will turn on.
· C - is common earth. All earth bonding must be terminated
here for correct operation.
· " L " is "live" (240V AC)
· " N " is "neutral" (240V AC)
If the tank is plastic, or if you are conducting tests in a plastic bucket, or the vessel has no earth point inside, you must install an earth rod within the tank, vessel or bucket and make sure that it is bonded back to C on the relay unit.
3 DIP Switches
3.1 DIP Switches
(See Wiring Diagram for full program functions.)
3.1.1 DIP 1 & 2 DIP 1 and 2 control the Sensitivity, in other words the cleaner the liquid the higher the sensitivity setting must be. Concentrated acids, minerals are by their own chemical composition highly conductive, so a low level of sensitivity is required, purified water is almost an insulator against electrical current flow so a higher sensitivity inside the relay is required.
3.1.2 DIP 3, 4 & 5 DIP switches 3, 4 and 5, control delay on activation. For example, in discharge mode with DIP switches 3, 4 and 5 set to 10 seconds, when the Hi point becomes wet it will activate the motor and it will take 10 seconds of continual coverage of the probe sensor to make the relay close and start the pump. This is invaluable when the probe is in a turbulent part of a well where fluid is splashing around touching the sensors momentarily, and false activation cannot be tolerated.
3.1.3 DIP 6 DIP switch 6 controls the charge/discharge function. Set "ON" for charge, and "OFF" for discharge
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
MTR/MTRA Installation & Troubleshooting
3.2 Relay Contacts & their Applications
3.2.1 Contacts 15, 16 & 18 Contacts 15, 16, and 18 are used for electronic or visual notification of a change in state at the pump itself. Contacts 15, 16, and 18 are used for more advanced applications because they are a changeover relay, their state may be the same as contacts 25, 28 or the opposite. Both sets of contactors are triggered simultaneously. An example is when in discharge mode, (see Figure 1). You have a gravity flow coming in so the fluid reaches the lower sensor PB1, contacts 15 and 18 are open (15 being common to both contact 16 and 18) contacts 25 and 28 are also normally open but contacts 15 16 in this current situation are closed, whether PB1 is wet or dry is of no concern all will stay the same. The level now rises to PB2 and both relays change state, contacts 25 and 28 close to turn on the pump, contacts 15 and 16 are open, with 15 and 18 closed. In advanced applications this state change may be fed into a logic device to indicate the pump is running or the pump has stopped and perhaps light an LED or incandescent light source for visual confirmation that a change has occurred in the relay.
3.2.2 Contacts 25 & 28 Contacts 25 and 28 are used to control pump states. Contacts 25 and 28 are mostly used for turning on motors via a starting relay or solenoid, so, these sets of contacts react to the rising or falling levels of the fluid inside the tank, they will operate to turn on a pump in discharge mode when the top sensor is wet and in charge mode turn on the pump when the bottom sensor is dry.
4 Practical Overview
4.1 Discharge Mode DIP switch 6 set to "OFF"
Figure 1 Discharge Mode
Figure 1 shows two probes, (PB1 connected to Lo and PB2 connected to Hi). The pit is mostly underground and there is a gravity-fed inlet at the top left-hand side. The pit is empty with PB1 completely dry. Dipswitch 6 is set to "OFF."
The relay operation depends on the electrical conductivity of liquid in the pit, i.e. no liquid = no current flow. The level starts to rise and covers PB1.
This is a discharge operation so we do not want the relay to close and start a pump until the well is full so as the water rises it reaches PB2, the relay closes and the pump starts. The level now drops below PB2 but the pump still continues to run, the level continues to drop below PB1 the relay opens the pump stops.
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
MTR/MTRA Installation & Troubleshooting
4.2 Charge Mode DIP switch 6 set to "On"
Figure 2 Charge Mode
Note: "C" is connected to common bonded earth. The unit will not operate correctly if not earthed. Let's look at the same relay but in a tank that is charging (DIP 6 is now on). See Figure 3, where liquid is being pumped into a tank, and discharging through a gravity feed, the tank is on steel stands "x" metres above the ground. With the tank full, PB1 and PB2 will be wet, the relay is off, and the pump has stopped. Water is slowly fed out from the bottom, and now as PB2 (HI) becomes dry nothing happens; the water now drops to below PB1 (Lo), and the pumps restarts to fill the tank. The pump will continue to fill the tank until PB2 (HI), becomes wet again.
4.3 MTRA Relay with Alarm (Discharge Applications Only)
Figure 3 - MTRA Operation
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
MTR/MTRA Installation & Troubleshooting
The MTRA relay works in the same way as the MTR relay except the MTRA has a separate alarm output, and does not have a charge mode. The planned application is to close a contact to illuminate a warning alarm light. . Various other applications have included introducing a third probe to latch another relay.
In Figure 2 we see three probes in a pit that is plastic, note the steel rod in the tank. (In a plastic vessel a steel rod must be used to create an earth return in the liquid so probes can function.) PB1, PB2, and PB3 are dry, and the relay power LED is on. When water enters the pit and wets PB1, nothing happens, water now reaches PB2 causing contacts 13 and 14 to close, the pump LED to light, and the water to drop.
If, for example, the pump has its inlet partially blocked, the level continues to rise and wets PB3. This closes a separate relay that can activate a red flashing light, an audible fog horn or send a 5 volt pulse into another device with the common cause to warn human beings that a spill is due to occur. If the pumps become unclogged and PB3 becomes dry the alarm opens again and breaks the circuit that stops the light from flashing or the foghorn from sounding.
5 Most Common Installation Problems
The relay requires a path between the probes to earth through the liquid. If you are testing in a plastic bucket, have installed the probe in a plastic tank or have no good earthing in the vessel you will need to install a separate earth and make sure all earth bonding comes back to the C terminal. Most problems like these are traced back to a lack of or poor earthing, or open circuits in the probe wiring.
Now is the time to check the relay by using "the bridge testing line technique" remember you must simulate a fluid flow to correctly ascertain a good relay or a bad one. (All DIPswitch settings from 1 to 6 should be off.)
Cut two pieces of insulated flexible copper wire one black one red 250 mm long, strip both ends back 10 mm on both cables, and join one black end and one red end. Insert the joined ends into C on the relay box, observing all safe electrical practises. You should have one black wire and one red wire free.
Set your relay for discharge mode (DIP switch 6 is off) with no sensors connected to the unit, connect the red wire to Lo nothing should happen (if it does return the relay for replacement or repair*). Now connect the black wire to the Hi terminal the relay activated LED should light instantly (if it does not, the relay should be returned for repair*).
6 Troubleshooting
I have checked all the DIPswitches and settings but in discharge mode as soon as the bottom sensor gets wet the pump turns on then turns off almost straight away.
The installation went fine but now and again the pump will not turn on even though I am sure the probe is wet.
All wiring is complete and all DIPswitches have been checked but the pump will not turn on at all.
· This is the most common problem encountered with relay set up
and commissioning, the probe in the bottom of the tank is wired into the Hi terminal instead of the Lo terminal.
· Check the sensitivity level set on the relay, some times the level is
set for foul water but due to changes in the flow the water becomes grey or clear, try changing the setting from 20K to 80K and monitor the results carefully.
· If you have completed the test schedule for the relay and it passed
then check the wiring to the sensors for this is now where the problem lies or in the earthing arrangements. If possible check the resistance between the sensor cable and the steel sensor on the probe to prove a solid connection.
* Please contact your distributor or agent before returning any product for repair or warranty claim.
MultiTrode Pty Ltd--Australia Ph: +61 7 3340 7000 Fx: +61 7 3340 7077
E-mail: sales@multitrode.com.au
Sydney--Australia Ph: +61 2 9533 7735 Fx: +61 2 9533 7790 Visit www.multitrode.com.au for the latest information
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Page 4 of 4 Page 65 of 1068
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Technical Information
CA7 3-Pole Contactors
Electrical Data
CA7-9 CA7-12 CA7-16 CA7-23 CA7-30 CA7-37 CA7-43 CA7-60 CA7-72 CA7-85
Rated Insulation Voltage Ui
IEC, AS,BS,SEV, VDE 0660
[V]
690V
UL; CSA
[V]
600V
Rated Impulse Voltage Uimp
[kV]
Rated Voltage Ue-Main Contacts
AC 50/60Hz
[V]
DC
[V]
Operating Frequency for AC Loads [Hz]
8kV
115, 200, 208, 230, 240, 380, 400, 415, 460, 500, 575, 690V 24, 48, 110, 115, 220, 230, 300, 440V 50...60Hz
Switching Motor Loads
Standard IEC Ratings
AC-2, AC-3, AC-4
230V
[A] 12
15
20
DOL Reversing
240V
[A] 12
15
20
50Hz/60° C
400V
[A] 9
12
16
415V
[A] 9
12
16
500V
[A] 7
10
14
690V
[A] 5
7
9
230V [kW] 3
4
5.5
240V [kW] 3
4
5.5
400V [kW] 4
5.5
7.5
415V [kW] 4
5.5
7.5
500V [kW] 4
5.5
7.5
690V [kW] 4
5.5
7.5
UL/CSA/IEC
DOL Reversing
115V
[A] 9.8
9.8
16
60Hz/60° C
1Ø 230V
[A] 10
12
17
115V [HP] 1/2
1/2
1
230V [HP] 1 1/2
2
3
200V
[A] 7.8
11
17.5
3Ø 230V
[A] 6.8
9.6
15.2
460V
[A] 7.6
11
14
575V
[A] 9
11
17
200V [HP] 2
3
5
230V [HP] 2
3
5
460V [HP] 5
7-1/2
10
575V [HP] 7-1/2 10
15
AC2 [ops/hr] 450 450
450
Maximum Operating Rate
AC3 [ops/hr] 700
700
700
(at max. amps)
AC4 [ops/hr] 200 150
120
26.5
35
38
44
62
26.5
35
38
44
62
23
30
37
43
60
23
30
37
43
60
20
25
30
38
55
12
18
21
25
34
7.5
10
11
13
18.5
7.5
10
11
13
18.5
11
15
18.5
22
32
11
15
20
22
32
13
15
20
25
37
10
15
18.5
22
32
24 17 2 3 17.5 22 21 17 5 7-1/2 15 15 400 600 80
24
34
34
56
28
28
40
50
2
3
3
5
5
5
7-1/2 10
25.3 32.2 32.2 48.3
28
28
42
54
27
34
40
52
27
32
32
52
7-1/2 10
10
15
10
10
15
20
20
25
30
40
25
30
30
50
400 400 400 300 600 600 600 500
80
70
70
70
72
85
72
85
72
85
72
85
67
80
42
49
22
25
22
25
40
45
40
45
45
55
40
45
56
80
68
68
5
7-1/2
15
15
62.1
78.2
68
80
65
77
62
62
20
25
25
30
50
60
60
60
250
200
500
500
60
50
Contactors
A
CA7
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A39
Page 66 of 1068
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Technical Information
CA7 3-Pole Contactors
A Electrical Data
Switching Motor Loads (continued)
CA7-9 CA7-12 CA7-16 CA7-23 CA7-30 CA7-37 CA7-43 CA7-60 CA7-72 CA7-85
Contactors
CA7
AC-4
230V
200,000 Op. Cycles
240V
50Hz
400V
415V
500V
690V
230V
240V
400V
415V
500V
690V
60Hz
1Ø 115V
230V
115V
230V
200V
3Ø 230V
460V
575V
200V
230V
460V
575V
Maximum Operating Rate
[
Wye-Delta (Star Delta)
230V
50 Hz
240V
400V
415V
500V
690V
200V
60 Hz
230V
460V
575V
AC Elevator Control Ratings
UL / CSA
Max FLC
500,000 operations
200V
230V
460V
575V
200V
230V
460V
575V
[A] 4.3 [A] 4.3 [A] 4.3 [A] 4.3 [A] 4.3 [A] 4.3 [kW] 0.75 [kW] 0.75 [kW] 1.8 [kW] 1.8 [kW] 2.2 [kW] 3 [A] 4.3 [A] 4.3 [HP] 1/8 [HP] 1/3 [A] 4.3 [A] 4.3 [A] 4.3 [A] 4.3 [HP] 3/4 [HP] 1 [HP] 2 [HP] 3
250 [kW] 5.5 [kW] 5.5 [kW] 7.5 [kW] 7.5 [kW] 7.5 [kW] 7.5 [HP] 5 [HP] 5 [HP] 10 [HP] 10
[A] 8.0 [A] 7.8 [A] 6.8 [A] 7.6 [A] 6.1 [HP] 2 [HP] 2 [HP] 5 [HP] 5
6.6 6.6 6.6 6.6 6.6 6.6 1.5 1.5 3 3 3.7 5.5 6.6 6.6 1/4 1/2 6.6 6.6 6.6 6.6 1 1-1/2 3 5 250 7.5 7.5 10 11 11 10 5 7-1/2 15 15
11.0 11.0 9.6 11.0 9.0
3 3 7-1/2 7-1/2
9 9 9 9 9 9 2.2 2.2 4 4 5.5 7.5 9 9 1/3 1 9 9 9 9 2 2 5 7-1/2 220 10 10 13 15 15 13 7-1/2 10 20 20
16.0 11.0 15.2 14.0 11.0
3 5 10 1 0
10
12
14
16.5 25.5
31
38
10
12
14
16.5 25.5
31
38
10
12
14
16.5 25.5
31
38
10
12
14
16.5 25.5
31
38
10
12
14
16.5 25.5
31
38
10
12
14
16.5 25.5
31
38
2.2
3
3.7
4
6.3
7.5
11
2.2
3
4
4
7.5
7.5
11
4
5.5
6.3
7.5
13
15
20
4
5.5
6.3
7.5
13
17
20
5.5
7.5
7.5
10
15
20
25
7.5
10
11
15
22
25
32
10
12
14
16.5 25.5
31
38
10
12
14
16.5 25.5
31
38
1/2
1/2
3/4
1
2
2
3
1-1/2
2
2
2
3
5
5
10
12
14
16.5 25.5
31
38
10
12
14
16.5 25.5
31
38
10
12
14
16.5 25.5
31
38
10
12
14
16.5 25.5
31
38
2
3
3
3
7-1/2 7-1/2
10
3
3
3
5
7-1/2
10
10
5
7-1/2 10
10
15
20
25
7-1/2
10
10
10
20
25
30
200
200
200
200
120
120
120
13
17
20
22
32
37
45
13
18.5
20
22
32
40
50
20
25
32
40
55
63
80
22
25
37
40
55
63
80
22
25
32
45
63
80
90
18.5
25
32
40
55
63
80
7-1/2
10
15
20
30
40
50
10
15
20
25
40
50
60
25
30
40
50
75
100
125
25
30
40
50
75
100
125
21.0
27.0 31.0 37.0 43.0 54.0 62.0
17.5
25.3 25.3 32.2 32.2 48.3 62.1
15.2
22.0 28.0 28.0 42.0 54.0 68.0
21.0
27.0 27.0 34.0 40.0 52.0 65.0
17.0
22.0 27.0 32.0 41.0 52.0 62.0
5
7-1/2 7-1/2 10
10
15
20
5
7-1/2 10
10
15
20
25
15
20
20
25
30
40
50
15
20
25
30
40
50
60
A40
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Technical Information
CA7 3-Pole Contactors
Electrical Data
AC-1 Load, 30 Switching
Ith
Ambient Temperature 40º C 230V
240V
400V
415V
500V
690V
Ambient Temperature 60º C
Ith
230V
240V
400V
415V
500V
690V
Maximum Operating Rate
[
Continuous Current (UL/CSA)
General Purpose Rating (40°) Open
Enclosed
Maximum Operating Rate
[
Lighting Loads
Elec.Dischrg.Lamps-AC-5a, single compensated
Open Enclosed
Max. capacitance at prospective 10kA
short circuit current available at 20kA
the contactor
50kA
Incandescent Lamps - AC -5b
Electrical endurance ~ 100,000 operations
Switching power transformers AC-6a
50Hz
Inrush
= n
Rated transformer current
n=30
230 VAC 240 VAC 400 VAC 415 VAC 500 VAC 690 VAC
n=20
230 VAC 240 VAC 400 VAC 415 VAC 500 VAC 690 VAC
n=15
230 VAC 240 VAC 400 VAC 415 VAC 500 VAC 690 VAC
CA7-9 CA7-12 CA7-16 CA7-23 CA7-30 CA7-37 CA7-43 CA7-60 CA7-72 CA7-85
[A] 32
32
32
32
65
65
85
100
100
100
[kW] 13
13
13
13
26
26
34
40
40
40
[kW] 13
13
13
13
27
27
35
42
42
42
[kW] 22
22
22
22
45
45
59
69
69
69
[kW] 23
23
23
23
47
47
61
72
72
72
[kW] 28
28
28
28
56
56
74
87
87
87
[kW] 38
38
38
38
78
78
102 120
120
120
[A] 32
32
32
32
65
65
80
100
100
100
[kW] 13
13
13
13
26
26
32
40
40
40
[kW] 13
13
13
13
27
27
33
42
42
42
[kW] 22
22
22
22
45
45
55
69
69
69
[kW] 23
23
23
23
47
47
57
72
72
72
[kW] 28
28
28
28
56
56
69
87
87
87
[kW] 38
38
38
38
78
78
95
120
120
120
1,000 1,000 1,000 1,000 1,000 1,000 300
600
600
600
[A] 25
25
30
30
45
55
60
90
90
100
[A] 25
25
30
30
55
60
75
90
90
100
1,400 1,400 1,200 1,200 1,200 1,000 1000 700
700
600
[A] 22.5 [A] 22.5
[f] 1,000 [f] 500 [f] 200
25 25
1,000 500 200
28 28
1,000 500 200
29 29
1,000 500 200
40.5 37
2,700 1,350 540
45 41
2,700 1,350 540
77 57
3,200 1,600 640
81 57
4,000 2,000 800
85 81
4,000 2,000 800
90 90
4,700 2,350 940
[A] 12
16
18
22
30
37
43
60
70
76
[A] 10.9 10.9 10.9 10.9
20
20
23
40.8 40.8 40.8
[kVA] 4.3
4.3
4.3
4.3
8
8
9.2
16
16
16
[kVA] 4.5
4.5
4.5
4.5
8.3
8.3
10
17
17
17
[kVA] 7.5
7.5
7.5
7.5
14
14
16
28
28
28
[kVA] 7.8
7.8
7.8
7.8
14
14
17`
29
29
29
[kVA] 9.4
9.4
9.4
9.4
17
17
20
35
35
35
[kVA] 13
13
13
13
24
24
27
49
49
49
[A] 16.3 16.3 16.3 16.3
30
30
34.5 61.3 61.3 61.3
[kVA] 6.5
6.5
6.5
6.5
12
12
13.7 24.4 24.4 24.4
[kVA] 6.8
6.8
6.8
6.8 12.5 12.5 14.3 25.5 25.5 25.5
[kVA] 11.3 11.3 11.3 11.3 20.8 20.8 23.9 42.5 42.5 42.5
[kVA] 11.7 11.7 11.7 11.7 21.6 21.6 24.8 44.1 44.1 44.1
[kVA] 14.1 14.1 14.1 14.1
26
26
29.9 53.1 53.1 53.1
[kVA] 19.5 19.5 19.5 19.5 35.9 35.9 41.2 73.3 73.3 73.3
[A] 22
22
22
22
40
40
46
82
82
82
[kVA] 2.3
2.3
2.3
2.3
4.3
4.3
5.0
8.8
8.8
8.8
[kVA] 2.4
2.4
2.4
2.4
4.5
4.5
5.2
9.2
9.2
9.2
[kVA] 4.1
4.1
4.1
4.1
7.5
7.5
8.6 15.3 15.3 15.3
[kVA] 4.2
4.2
4.2
4.2
7.8
7.8
8.9 15.9 15.9 15.9
[kVA] 5.1
5.1
5.1
5.1
9.4
9.4 10.8 19.1 19.1 19.1
[kVA] 7.0
7.0
7.0
7.0 12.9 12.9 14.9 26.4 26.4 26.4
Contactors
A
CA7
CA7 ratings for lighting loads are provided for technical reference. For cUL rated and labeled devices, see CAL7 contactors listed in this section.
Q-Pulse Id: TMS1594
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Technical Information
CA7 3-Pole Contactors
A Electrical Data
CA7-9 CA7-12 CA7-16 CA7-23 CA7-30 CA7-37 CA7-43 CA7-60 CA7-72 CA7-85
Contactors
Switching power transformers AC-6a
60Hz
Inrush
= n
Rated transformer current
[A]
10.9 10.9 10.9 10.9
20
20
23
40.8 40.8 40.8
n=30
CA7
200 VAC [kVA] 3.8
3.8
3.8
3.8
6.9
6.9
8.0 14.1 14.1 14.1
208 VAC [kVA] 3.9
3.9
3.9
3.9
7.2
7.2
8.3 14.7 14.7 14.7
240 VAC [kVA] 4.5
4.5
4.5
4.5
8.3
8.3
9.6
17
17
17
480 VAC [kVA] 9.1
9.1
9.1
9.1 16.6 16.6 19.1 33.9 33.9 33.9
600 VAC [kVA] 11.3 11.3 11.3 11.3 20.8 20.8 23.9 42.4 42.4 42.4
660 VAC [kVA] 12.5 12.5 12.5 12.5 22.9 22.9 26.3 46.6 46.6 46.6
[A]
16.3 16.3 16.3 16.3
30
30
34.5 61.3 61.3 61.3
n=20
200 VAC [kVA] 5.6
5.6
5.6
5.6 10.4 10.4
12
21.2 21.2 21.2
208 VAC [kVA] 5.9
5.9
5.9
5.9 10.8 10.8 12.4 22.1 22.1 22.1
240 VAC [kVA] 6.8
6.8
6.8
6.8 12.5 12.5 14.3 25.5 25.5 25.5
480 VAC [kVA] 13.6 13.6 13.6 13.6 24.9 24.9 28.7
51
51
51
600 VAC [kVA] 16.9 16.9 16.9 16.9 31.2 31.2 35.9 63.7 63.7 63.7
660 VAC [kVA] 18.6 18.6 18.6 18.6 34.3 34.3 39.4 70.1 70.1 70.1
[A]
22
22
22
22
40
40
46
82
82
82
n=15
200 VAC [kVA] 7.5
7.5
7.5
7.5 13.9 13.9 15.9 28.4 28.4 28.4
208 VAC [kVA] 7.8
7.8
7.8
7.8 14.4 14.4 16.6 29.5 29.5 29.5
240 VAC [kVA]
9
9
9
9
16.6 16.6 19.1 34.1 34.1 34.1
480 VAC [kVA] 18.1 18.1 18.1 18.1 33.3 33.3 38.2 68.2 68.2 68.2
600 VAC [kVA] 22.6 22.6 22.6 22.6 41.6 41.6 47.8 85.2 85.2 85.2
660 VAC [kVA] 24.9 24.9 24.9 24.9 45.7 45.7 52.6 93.7 93.7 93.7
DC-1 Switching - 60°C
24VDC [A]
25
25
32
32
45
45
50
70
80
80
48VDC [A]
20
20
20
20
25
25
30
40
40
40
1 Pole
60VDC [A]
20
20
20
20
25
25
30
40
40
40
110VDC [A]
6
6
6
6
8
8
9
11
11
11
220VDC [A]
1.5
1.5
1.5
1.5
1.5
1.5
1.5
2
2
2
440VDC [A]
0.4
0.4
0.4
0.4
0.4
0.4
0.5
0.5
0.5
0.5
24VDC [A]
25
25
32
32
45
45
50
70
80
80
48VDC [A]
25
25
32
32
45
45
50
70
80
80
2 Poles in Series
60VDC [A]
25
25
32
32
45
45
50
70
80
80
110VDC [A]
25
25
32
32
45
45
50
70
80
80
220VDC [A]
8
8
8
8
10
10
10
15
15
15
440VDC [A]
1
1
1
1
1
1
1
1.5
1.5
1.5
24VDC [A]
25
25
32
32
45
45
63
90
90
100
48VDC [A]
25
25
32
32
45
45
63
90
90
100
3 Poles in Series
60VDC [A]
25
25
32
32
45
45
63
90
90
100
110VDC [A]
25
25
32
32
45
45
63
90
90
100
220VDC [A]
25
25
32
32
45
45
50
70
80
80
440VDC [A]
3
3
3
3
3.5
3.5
4
5
5
5
DC-2, 3, 5 Switching - 60°C
Starting, reverse current braking, reversing, DC-5, 60ºC
24VDC
[A]
25
25
32
32
45
45
63
90
90
100
48VDC [A]
25
25
32
32
45
45
50
70
70
80
60VDC [A]
25
25
32
32
45
45
50
70
70
80
Shunt Wound
110VDC [A]
20
20
25
25
30
30
35
70
70
80
3 Poles in Series
220VDC [A]
6
6
6
10
15
15
20
25
25
30
Series-wound Motors
440VDC [A]
0.6
0.6
0.6
0.6
0.6
0.6
0.6
0.6
0.6
0.6
3 Poles in Series
24VDC [A]
25
25
32
32
45
45
63
90
90
100
48VDC [A]
25
25
32
32
45
45
50
70
70
80
60VDC [A]
25
25
32
32
45
45
50
70
70
80
110VDC [A]
20
20
25
25
30
30
35
70
70
80
220VDC [A]
6
6
6
10
15
15
20
25
25
30
440VDC [A]
0.6
0.6
0.6
0.6
0.6
0.6
0.6
0.6
0.6
0.6
A42
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Technical Information
CA7 3-Pole Contactors
Electrical Data
Capacitor Ratings Capacitor Switching AC-6b-50 Hz Single Capacitor - 40°C
Single Capacitor - 60°C
Capacitor Bank - 40°C
Capacitor Bank - 60°C
Capacitor Switching - 60Hz Single Capacitor - 40°C Capacitor Bank - 40°C
230 V 240 V 400 V 415 V 500 V 690 V 230 V 240 V 400 V 415 V 500 V 690 V 230 V 240 V 400 V 415 V 500 V 690 V 230 V 240 V 400 V 415 V 500 V 690 V
200 V 230 V 460 V 600 V 200 V 230 V 460 V 600 V
A
CA7-9 CA7-12 CA7-16 CA7-23 CA7-30 CA7-37 CA7-43 CA7-60 CA7-72 CA7-85
Contactors
[kVar]
8
8
8.5
9
14
14
24
28
28
28
[kVar]
8
8
8.5
9
14
14
25
29
29
29
[kVar]
8
8
10
12.5
20
24
35
48
48
48
[kVar]
8
8
10
12.5
20
25
35
50
50
50
[kVar]
8
[kVar]
8
8 8
10 10
12.5 12.5
20 20
25 25
35 35
50 50
55 55
60 60
CA7
[kVar]
8
8
8.5
9
12.5 12.5
18
28
28
28
[kVar]
8
8
8.5
9
12.5 12.5
18
29
29
29
[kVar]
8
8
10
12.5
20
21.5
30
42
48
48
[kVar]
8
8
10
12.5
20
22
30
42
50
50
[kVar]
8
8
10
12.5
20
25
30
42
50
55
[kVar]
8
8
10
12.5
20
25
30
42
50
55
[kVar]
5
5
8
9
12.5
14
20
28
28
28
[kVar]
5
5
8
9
12.5
14
20
29
29
29
[kVar]
5
5
8
10
15
20
25
40
48
48
[kVar]
5
5
8
10
15
20
25
40
50
50
[kVar]
5
5
8
10
15
20
25
40
50
50
[kVar]
5
5
8
10
15
20
25
40
50
50
[kVar]
5
5
8
9
12.5 12.5
18
28
28
28
[kVar]
5
5
8
9
12.5 12.5
18
29
29
29
[kVar]
5
5
8
10
15
20
25
40
48
48
[kVar]
5
5
8
10
15
20
25
40
50
50
[kVar]
5
5
8
10
15
20
25
40
50
50
[kVar]
5
5
8
10
15
20
25
40
50
50
[kVar]
5
5
8
[kVar]
5
5
8
[kVar]
5
5
8
[kVar]
5
5
8
[kVar]
5
5
8
[kVar]
5
5
8
[kVar]
5
5
8
[kVar]
5
5
8
9
12.5
14
20
28
28
28
9
12.5
14
20
29
29
29
10
15
20
25
40
50
50
10
15
20
25
40
50
60
9
12.5 12.5
18
28
28
28
9
12.5 12.5
18
29
29
29
10
15
20
25
40
50
50
10
15
20
25
40
50
50
CA7 capacitor ratings are provided for technical reference. For cUL rated and labeled devices, see CAQ7 contactors listed in this section.
CA7-9...CA7-30 = L min. 30 µH; CA7-37...CA7-85 = L min. 6 µH
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Technical Information
CA7 3-Pole Contactors
A Electrical Data
Contactors
Resistance and Watt Loss Ie AC3 Resistance per power pole
Watt Loss - 3 power poles
Coil and 3 power poles
AC
DC
Coil only
AC
DC
CA7 Short-Circuit Coordination
Max. Fuse or circuit breaker ratings
DIN Fuses -gG, gL
Available Fault Current
Type "1" (690V)
Type "2" (690V)
BS 88 Fuses
Available Fault Current
Type "1" (690V)
Type "2" (690V)
Class K1, RK1 Fuses
Available Fault Current
Type "2" (600V)
cUL Short-Circuit Ratings
Class K1, RK1, K5, and RK5 Fuses
Available Fault Current
cUL Max. Rating (600V) Type 1
Class CC & CSA HRCI Fuses
Available Fault Current
cUL Max. Rating (600V) Type 2
Class J CSA & HRCI-J Fuses
Available Fault Current
cUL Max. Rating (600V) Type 2
Inverse-Time Circuit Breaker
Available Fault Current
cUL Max. Rating 480V Type 1
cUL Max. Rating 600V Type 1
Short Time Current Withstand Ratings
Icw 60° C
10 s
Off Time Between Operations
CA7-9 CA7-12 CA7-16 CA7-23 CA7-30 CA7-37 CA7-43 CA7-60 CA7-72 CA7-85
[m] 2.7
2.7
2.7
[W] 0.66 1.2
2.1
[W] 3.3
3.8
4.7
[W] 6.7
7.2
8.1
[W] 2.6
2.6
2.6
[W] 6.0
6.0
6.0
2.0
2.0
2.0
1.5
0.9
0.9
0.9
3.2
5.4
8.2
8.3
9.7
14.0 19.5
6.2
8.4 11.2 11.5
11
13.8 17.5
12.4
14.6 17.4 18.4
11
13.8 17.5
3.0
3.0
3.0
3.2
4.5
4.5
4.5
9.2
9.2
9.2 10.0 4.9
4.9
4.9
[A] 100 KA [A] 50 [A] 25
100 KA 50 35
100 KA 50 35
[A] 80 KA [A] 25 [A] 25
80 KA 32 32
80 KA 35 35
[A] 100 KA 100 KA 100 KA
[A] 15
20
20
100 KA 80 40
100 KA 125 80
100 KA 125 80
100 KA 160 100
100 KA 250 160
100 KA 250 160
100 KA 250 160
80 KA 50 50
80 KA 63 63
80 KA 80 80
80 KA 100 100
80 KA 100 100
80 KA 125 125
80 KA 160 160
100 KA 100 KA 100 KA 100 KA 100 KA 100 KA 100 KA
30
40
50
50
80
100
100
[A] 5 KA 5 KA
5 KA
[A] 35
40
70
[A] 100 KA 100 KA 100 KA
[A] 15
20
30
[A] 100 KA 100 KA 100 KA
[A] 15
20
30
[A] 5 KA 5 KA
5 KA
[A] 30
30
50
[A] ~
~
~
5 KA
5 KA 5 KA 5 KA 5 KA 5 KA 5 KA
90
110
125
150
200
250
300
100 KA
~
~
~
~
~
~
30
~
~
~
~
~
~
100 KA 100 KA 100 KA 100 KA 100 KA 100 KA 100 KA
30
50
50
70
80
100
150
5 KA
5 KA 5 KA 5 KA 5 KA 10 KA 10 KA
50
125
125
125
250
250
250
~
125
125
125
250
250
250
[A] 170 170
170
[Min.] 20
20
20
215
300
304
375
700
700
700
20
20
20
20
20
20
20
When used as a Branch Circuit Protection device, NEC 430-152 defines the maximum rating of an Inverse-time circuit breaker to be sized at 250% of the motor nameplate FLA for most applications.
UL Listed Combination. (UL File E41850) Per UL508A, NEC409 abd CSA 22.2 No.14 for contactor and fuses or circuit breaker only.
Per IEC 60947-1 for contactor and fuses only.
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Technical Information
CA7 Contactors & Overload Relay
Electrical Data
Short Circuit Coordination le AC3
Type 2 Coordination Combinations (contactor, overload and fuses) -- Per UL 508 and IEC 60947-4-1
Contactor
CA7-9
CA7-12... CA7-16... CA7-23... CA7-30... CA7-37... CA7-43... CA7-60... CA7-72... CA7-85...
Overload Relay
CEP7-M/A/B32-0.32... CEP7-M/A/B32-1.0... CEP7-M/A/B32-2.9... CEP7-M/A/B32-5... CEP7-M/A/B32-12... CEP7-M/A/B32-12... CEP7-M/A/B32-32... CEP7-M/A/B32-32... CEP7-M/A/B37-37... CEP7-M/A/B37-37... CEP7-M/A/B45-45... CEP7-M/A/B85-85... CEP7-M/A/B85-85... CEP7-M/A/B85-85...
Withstand Rating
100kA 100kA 100kA 100kA 100kA 100kA 100kA 100kA 100kA 100kA 100kA 100kA 100kA 100kA
Maximum Voltage
600V 600V 600V 600V 600V 600V 600V 600V 600V 600V 600V 600V 600V 600V
Max. Amp Rating (UL Class CC or J Fuses)
1 2 6 10 15 20 20 30 40 50 50 80 100 100
UL Listed Combinations (contactor, overload and circuit breaker) Per UL 508
Contactor CA7-9...12
CA7-12 CA7-16...23
CA7-23 CA7-30...37
CA7-37 CA7-43
CA7-60
CA7-72
CA7-85
Overload Relay
CEP7-M/A32-2.9...12 CT7-24-0.16...10 CT7-24-16
CEP7-M/A32-2.9...32 CT7-24-0.16...16 CT7-24-24
CEP7-M/A37-12...37 CT7-24-16...CT7-45-30
CT7-45-45 CEP7-M/A45...45 CT7-45-30...45 CEP7-M/A85...85 CT7-75-30...60 CEP7-M/A85...85 CT7-75-30...75 CEP7-M/A85...85 CT7-75-30...CT7-100-90
Withstand Rating 5kA
5kA
5kA 5kA 5kA 10kA 10kA
Maximum Voltage
480V
480V
600V 600V 600V 600V 600V
Max. Amp Rating (UL Listed Circuit Breaker)
30
50
125 125 250 250 250
CEP7 First Generation Scheduled for
Obsolesence 2006
Contactors
A
CA7
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Technical Information
CA7 Contactors & Overload Relay
A Short Circuit Ratings
Standard Fault Short Circuit Ratings per UL508 and CSA 22.2 No.14
Contactors
CEP7 Second Generation Cat. No.
Max. avail- Conditional able fault S.C. current, current (kA) Iq (kA)
S.C.P.D.
ED1AB, EEAB ED1BB, EEBB
1
Suitable for use with fuses only
ED1CB, ED1DB,
CA7
ED1EB, EECB,
CEP7 EEDB, EEEB, EEED,
5
EEFD, EEPB, EERB,
EESB, EETD
600
Not restricted
to
EEEE, EEFE, EEGE, EEUE
10
IEC Short Circuit Ratings per EN60947-4-1
CEP7 Second Generation Cat. No.
ED1AB, EEAB ED1BB, EEAB
CondiProspective tional S.C. current, S.C.
Ir (kA) current, Iq (kA)
1
ED1CB, ED1DB,
EECB, EEDB,
1
CEP7
EEPB, EERB ED1EB, EEEB,
100
EEED, EEFD, EEEE, EEFE,
3
EESB, EETD
EEGE, EEUE
5
Max. voltage (V)
690
S.C.P.D.
Suitable for use with fuses only
Not restricted to
High Fault Short Circuit Ratings per UL508 and CSA 22.2 No.14
CEP7 Second Generation Cat. No.
ED1AB, EEAB ED1BB, EEBB
ED1CB, ED1DB, ED1EB, EEEB, EECB, EEDB CEP7
EEED, EEFD
EEEE, EEFE EEGE
Contactor Cat. No.
CA7-09
CA7-09 CA7-12 CA7-16 CA7-23 CA7-30 CA7-37 CA7-43 CA7-60 CA7-72 CA7-85
Max. starter FLC (A)
Max. available fault current (kA)
0.5
1
09
12
16
23 30
100
37
43
60
72
85
Max. voltage
(V)
600
UL Class J and CSA HRCI-J fuse (A) 3 6 20 20 30 30 50 50 70 80 100 150
IEC Type 1 and Type II Fuse Coordination with CA7 Series contactors per EN60947-4-1
CEP7 Second Generation Cat. No. ED1AB, EEAB ED1BB, EEBB ED1CB, ED1DB, EECB, EEDB
ED1EB, EEEB CEP7
EEED, EEFD
EEEE, EEFE
EEGE
Contactor Cat. No.
CA7-09
CA7-09 CA7-12 CA7-16 CA7-23 CA7-09 CA7-12 CA7-16 CA7-23 CA7-30 CA7-37 CA7-43 CA7-60 CA7-72 CA7-85 CA7-60 CA7-72 CA7-85
Max. starter FLC (A) 0.5 1 09 12 16 23 09 12 16 23 30 37 43 60 72 85 60 72 85
Prospective S.C. current,
Ir (kA) 1
1
3
3
3
5
Conditional S.C. current,
Iq (kA)
100
Max. voltage (V)
600
Type I with Class J fuse
(A) 3 6 20 20 30 30 20 20 30 30 50 50 70 80 100 150 80 100 150
Type II with Class J fuse
(A) 3 6 15 20 30 30 15 20 30 30 50 50 70 80 100 150 80 100 150
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Technical Information
CA7 3-Pole Contactors
Electro-Mechanical Data
Service Life
Mechanical
AC
DC
Electrical AC-3 (400V)
AC
Shipping Weights
AC - CA7
AC -CAU7
DC - CA7
DC - CAU7
Terminations - Power Description
CA7-9 CA7-12 CA7-16 CA7-23 CA7-30 CA7-37 CA7-43 CA7-60 CA7-72 CA7-85
[Mil.] 13
13
13
13
13
13
12
10
10
10
[Mil.] 13
13
13
13
13
13
13
10
10
10
[Mil.] 1.3
1.3
1.3
1.3
1.3
1.3
1.0
1.0
1.0
1.0
[kg] 0.39
0.39
0.39
0.39
0.48
0.49
0.51 1.45 1.45 1.45
[Lbs.] 0.86
0.86
0.86
0.86
1.06
1.08
1.12 3.20 3.20 3.20
[kg] 0.85
0.85
0.85
0.85
1.08
1.08
1.15 3.14 3.14 3.14
[Lbs.] 1.89
1.89
1.89
1.89
2.39
2.39
2.54 6.92 6.92 6.92
[kg] 0.60
0.60
0.60
0.73
0.85
0.85
1.00 1.47 1.47 1.47
[Lbs.] 1.32
1.32
1.32
1.61
1.87
1.87
2.20 3.24 3.24 3.24
[kg] 1.27
1.27
1.27
1.53
1.81
1.81
2.13 3.22 3.22 3.22
[Lbs.] 2.81
2.81
2.81
3.39
4.00
4.00
4.70 7.10 7.10 7.10
Contactors
A
CA7
Torque Requirement
Terminations - Control Description
1 Wire 2 Wires
1 Wire 2 Wires
1 Wire 2 Wires
One saddleclamp per pole: cross, slotted or Pozidrive No. 2/blade
No. 3 screw
[mm2] 1...4
1...4
1...4
1...4
[mm2] 1...4
1...4
1...4
1...4
Dual connection; one saddleclamp and one box lug per pole; cross, slotted or Pozidrive No. 2/blade No.
4 screw
2.5...10 2.5...10 2.5...16 2.5...10 2.5...10 2.5...10
Dual connection; two box lugs per pole Allen Head: 4mm, 5/32
2.5...35 2.5...35 2.5...35 2.5...25 2.5...25 2.5...25
[mm2] 1.5...6 1.5...6 [mm2] 1.5...6 1.5...6
1.5...6 1.5...6
1.5...6 1.5...6
2.5...16 2.5...16
2.5...16 2.5...16
2.5...25 2.5...50 2.5...50 2.5...50 2.5...16 2.5...35 2.5...35 2.5...35
[AWG] 16...10 16...10 16...10 16...10 14...4
14..4
14...4 14...1 14...1 14...1
[AWG] 16...10 16...10 16...10 16...10 14...4
14..4
14...4 14...1 14...1 14...1
[Nm] 1.0...2.5 1.0...2.5 1.0...2.5 1.0...2.5 2.5...3.5 2.5...4 [Lb-in] 9...22 9...22 9...22 9...22 22...31 22...35
2.5...4 3.5...6 3.5...6 3.5...6 22...35 31...53 31...53 31...53
Coils Wires Control Modules Wires Torque Requirement
1 or 2 1or 2
Degree of Protection - contactor Protection Against Accidental Contact
[mm2] [AWG] [mm2] [AWG] [Nm] [Lb-in]
Environmental and General Specifications
Ambient Temperature Storage Operation Conditioned 15% current reduction after AC-1 at >60° C
Altitude at installed site Resistance to Corrosion/Humidity
Shock Resistance Vibration Resistance Pollution Degree Operating Position Standards Approvals
Combination Screw Head: Cross, Slotted, Pozidrive 1.5...6 16...12 1.5...6 16...12 1...2.5 9...13
IP 2LX per IEC 529 and DIN 40 050 (with wires installed) Safe from touch by fingers and back-of-hand per VDE 0106; Part 100
-55...+80° C (-67...176° F) - [CRI7E Electronic Interface -50...+80° C (-58...176° F)] -25...+60° C (-13...140° F) -25...+70° C (-13...158° F)
2000 meters above sea level per IEC 947-4 Damp-alternating climate: cyclic to IEC 68-2, 56 cycles Dry heat: IEC 68-2, +100°C (212° F), relative humidity <50%, 7 days. Damp tropical: IEC 68-2, +40°C (104°F), relative humidity <92%, 56 days. IEC 68-2: Half sinusoidal shock 11ms, 30g (in all three directions) IEC 68-2: Static > 2g, in normal position no malfunction <5g
3 Refer to Dimension Pages IEC947-1/4, EN 60947; UL 508; CSA 22.2, No. 14
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Technical Information
CA7 3-Pole Contactors
Contactors
A Lug Kit and Paralleling Link Specifications
CA7-PKN23 / KL23
CA7-P-K37
CA7-P-K43
CA7-P-K85
CA7-P-B23
CA7-P-B37
Approvals
UL Listed; CSA Certified; C
Conformity to Standards
UL508; CSA 22.2 No. 14; IEC 60947-4
Protection Against Accidental Contact
IP2LX Finger Protection
Terminations
CA7
Description Wire Size
Torque Requirement
1 Wire 1 Wire 1 Wire
Cross, slotted or Pozidrive screw
Allen Head; 5mm, 3/16
Allen Head; 7 mm, 15/32
[mm2] [mm2] [AWG] [Nm] [Lb-in]
4...16 4...25 10...4 2...3 18...27
4..16 4..25 10...4 2...3 18...27
6...35 6...50 8...2 3..6 27...54
10...70 10...95 8..2/0 8...12 72...108
35...70 35...95 0...2/0 6...12 54...108
35...70 35...95 0...2/0 6....12 54...108
Coil Data
Voltage Range
AC: 50Hz, 60Hz, 50/60 Hz DC Coil Consumption
Pickup [xUs] Dropout [xUs] Pickup [xUs] Dropout [xUs]
AC: 50Hz, 60Hz, 50/60 Hz
Pickup [VA/W]
Hold-in [VA/W]
True DC Coils (CA7C)
Pickup [W]
Hold-in [W]
Two Winding DC Coils
Pickup [W]
CA7Y & CA7D
Hold-in [W]
Operating Times
AC: 50Hz, 60Hz, 50/60 Hz
Pickup [ms]
Dropout [ms]
with RC Suppressor
Dropout [ms]
True DC Coils (CA7C)
Pickup [ms]
without Suppression
Dropout [ms]
with Integrated Suppression Dropout [ms]
with External Suppression Dropout [ms]
Two Winding DC Coils (CA7Y/D) Pickup [ms]
with Internal Suppression Dropout [ms]
CA7-9
70/50 8/2.6 6.5 6.5 120 1.1
15...30 10...60 10...60 40...70 7...15 14...20 70...95 17...26 9...20
CA7-12 CA7-16 CA7-23 CA7-30 CA7-37 CA7-43 CA7-60 CA7-72 CA7-85
0.85...1.1 0.3...0.6 0.8...1.1 (9V coils = 0.65...1.3; 24V coils = 0.7...1.25) 0.1...0.6
70/50 8/2.6 6.5 6.5 120 1.1
70/50 8/2.6 6.5 6.5 120 1.1
70/50 9/3 9.2 9.2 200 1.2
80/60 9/3 9.2 9.2 200 1.2
80/60 9/3 9.2 9.2 200 1.2
130/90 10/3.2 10.1 10.1 200
1.3
200/110 16/4.5
~ ~ 200 4.5
200/110 16/4.5
~ ~ 200 4.5
200/110 16/4.5
~ ~ 200 4.5
15...30 10...60 10...60 40...70 7...15 14...20 70...95 17...26 9...20
15...30 10...60 10...60 40...70 7...15 14...20 70...95 15...27 14...24
15...30 10...60 10...60 40...70 7...15 17...23 80...125 15...27 14...24
15...30 10...60 10...60 50...80 7...15 17...23 80...125 15...27 14...24
15...30 10...60 10...60 50...80 7...15 17...23 80...125 15...27 14...24
15...30 20...40 20...40 20...40
10...60 10...60 10...60 10...60
10...60 10...60 10...60 10...60
50...80
~
~
~
7...15
~
~
~
17...23
~
~
~
80...125 ~
~
~
15...27 20...40 20...40 20...40
14...24 20...35 20...35 20...35
220V.
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Technical Information
CA7 4-Pole Contactors
Electrical Data
Rated Insulation Voltage Ui IEC, AS, BS, SEV, VDE 0660 UL; CSA
Rated Impulse Voltage Uimp Rated Voltage Ue - Main Contacts
AC 50/60Hz DC Operating Frequency for AC Loads
Contactors
CA7-9-
CA7-12-
CA7-16-
CA7-23-
CA7-40-M22 CA7-40-M40 CA7-90-M22 CA7-90-M40
A
M40(31; 22) M40(31; 22) M40(31; 22) M40(31; 22)
690V 600V 8 kV
115, 200, 208, 230, 240, 380, 400, 415, 460, 500, 575, 690V 24, 48, 110, 115, 220, 230, 300, 440V 50...60Hz
CA7
Switching Motor Loads
Standard IEC Ratings
AC-2, AC-3, AC-4
230V
[A]
12
15
20
26.5
38
38
85
85
DOL & Reversing
240v
[A]
12
15
20
26.5
38
38
85
85
50Hz/60ºC
400V
[A]
9
12
16
23.
37
37
85
85
415V
[A]
9
12
16
23
37
37
85
85
500V
[A]
7
10
14
20
29
30
80
80
690V
[A]
5
7
9
12
9
21
22
49
230V
[kW]
3
4
5.5
7.5
11
11
25
25
240V
[kW]
3
4
5.5
7.5
11
11
25
25
400V
[kW]
4
5.5
7.5
11
18.5
18.5
45
45
415V
[kW]
4
5.5
7.5
11
18.5
18.5
45
45
500V
[kW]
4
5.5
7.5
13
18.5
20
55
55
690V
[kW]
4
5.5
7.5
10
7.5
18.5
18.5
45
UL/CSA/IEC
DOL & Reversing
115V
[A]
7.2
9.8
16
24
34
34
80
80
60Hz/60ºC
1Ø
230V
[A]
18
12
17
17
28
28
68
68
115V
[HP]
1/2
1/2
1
2
3
3
7-1/2
7-1/2
230V [HP] 1-1/2
2
3
3
5
5
15
15
200V
[A]
7.8
11
17.5
17.5
32.2
32.2
78.2
78.2
230V
[A]
6.8
9.6
15.2
22
28
28
80
80
460V
[A]
7.6
11
14
21
34
34
65
77
575V
[A]
9
11
17
17
17
32
22
52
200V [HP]
2
3
5
5
10
10
25
25
230V [HP]
2
3
5
7-1/2
10
10
30
30
460V [HP]
5
7-1/2
10
15
25
25
50
60
575V [HP] 7-1/2
10
15
15
15
30
20
50
Maximum Operating Rate AC2 [ops/hr] 450
450
450
400
400
400
200
200
(at max. amps)
AC3 [ops/hr] 700
700
700
600
600
600
500
500
AC4 [ops/hr] 200
150
120
80
70
70
50
50
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Technical Information
CA7 4-pole Contactors
Contactors
A
CA7
Electrical Data
AC-1 Load, 3Ø Switching Ambient Temperature 40ºC
Ambient Temperature 60º
Ith 230V 240V 400V 415V 500V 690V Ith 230V 240V 400V 415V 500V 690V
CA7-9M40(31; 22)
[A]
[kW]
32
[kW]
13
[kW]
13
[kW]
22
[kW]
23
[kW]
28
[kW]
38
[kW]
32
[kW]
13
[kW]
13
[kW]
22
[kW]
23
[kW]
28
[kW]
38
CA7-12M40(31; 22)
32 13 13 22 23 28 38 32 13 13 22 23 28 38
Max Operating Rate
[ops/hour]
1,000 1,000,
Continuous Current (UL/CSA)
General Purpose Rating (40º) Open
[A]
25
25
Enclosed [A]
25
25
Max. Operating Rate
[ops/hour] 1,400
1,400
Lighting Loads
Elec. Dischrg.Lamps-AC-5a, Open
[A] 22.5
25
single compensated
Enclosed [A] 22.5
25
Incandescent Lamps AC-5b,
Electrical endurance~100,000 operations
12
16
DC-1 Switching - 60ºC
24VDC [A]
25
25
48VDC [A]
20
20
1 Pole
60VDC [A]
20
20
110VDC [A]
6
6
220VDC [A] 1.5
1.5
440VDC [A] 0.4
0.4
24VDC [A]
25
25
48VDC [A]
25
25
2 Pole in Series
60VDC [A]
25
25
110VDC [A]
25
25
220VDC [A]
8
8
440VDC [A]
1
1
24VDC [A]
25
25
48VDC [A]
25
25
3 Poles in Series
60VDC [A]
25
25
110VDC [A]
25
25
220VDC [A]
25
25
440VDC [A]
3
3
24VDC [A]
25
25
48VDC [A]
25
25
4 Poles in Series
60VDC [A]
25
25
110VDC [A]
25
25
220VDC [A]
25
25
440VDC [A]
8
8
CA7-16M40(31; 22)
32 13 13 22 23 28 38 32 13 13 22 23 28 38 1,000,
30 30 1,200
28 28
18 32 20 20 6 1.5 0.4 32 32 32 32 8 1 32 32 32 32 32 3 32 32 32 32 32 8
CA7-23M40(31; 22)
32 13 13 22 23 28 38 32 13 13 22 23 28 38 1,000
30 30 1,200
29 29
22 32 20 20 6 1.5 0.4 32 32 32 32 8 1 32 32 32 32 32 3 32 32 32 32 32 8
CA7-40-M22 CA7-40-M40 CA7-90-M22 CA7-90-M40
75
75
130
130
30
30
52
52
31
31
54
54
52
52
90
90
54
54
93
93
65
65
113
113
90
90
155
155
60
60
110
110
24
24
44
44
25
25
46
46
42
42
76
76
43
43
79
79
52
52
95
95
72
72
131
131
300
300
600
600
60
60
125
130
60
60
125
130
1,000
1,000
600
600
65
65
115
115
54
54
95
95
18
25
60
75
45
45
80
80
25
25
40
40
25
30
40
40
10
10
11
11
1.5
1.5
1.8
1.8
0.4
0.4
0.5
0.5
45
45
80
80
45
45
80
80
45
45
80
80
45
45
80
80
10
10
15
15
1
1
1.5
1.5
~
48
~
100
~
48
~
100
~
48
~
100
~
48
~
100
~
48
~
80
~
3.5
~
5
~
60
~
110
~
60
~
110
~
60
~
110
~
60
~
110
~
60
~
100
~
10
~
15
CA7 ratings for lighting loads are provided for technical reference. For cUL rated and labeled devices, see CAL7 contactors listed in this section.
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Technical Information
CA7 4-pole Contactors
Electrical Data
Resistance and Watt Loss Ie AC3 Resistance per power pole Watt Loss - 4 power poles Coil and 4 power poles AC DC (true) DC (2 winding)
Short Circuit Coordination
DIN Fuses -gG, gL Available Fault Current Type "1" (690V) Type "2" (690V)
BS 88 Fuses Available Fault Current Type "1" (690V) Type "2" (690V)
Class K1, RK1 Fuses Available Fault Current Type "2" (600V)
cUL Short-Circuit Ratings Class K1, RK1, K5, and RK5 Fuses Available Fault Current cUL Max. Rating (600V) Type 1 Class CC & CSA HRCI Fuses Available Fault Current cUL Max. Rating (600V) Type 2 Class J CSA & HRCI-J Fuses Available Fault Current cUL Max. Rating (600V) Type 2 Inverse-Time Circuit Breaker Available Fault Current cUL Max. Rating 480V Type 1 cUL Max. Rating 600V Type 1
CA7-9-
CA7-12-
CA7-16-
CA7-23-
CA7-40-M22 CA7-40-M40 CA7-90-M22 CA7-90-M40
A
M40(31; 22) M40(31; 22) M40(31; 22) M40(31;22)
Contactors
[m]
2.7
2.7
2.7
2.0
2.0
[W] 2.8
2.8
2.8
2.0
11.3
[W] 13.7
13.7
13.7
10.8
26.1
[W] 17.6
17.6
17.6
17.4
32.6
[W]
~
~
~
~
~
1.5
0.8
0.7
8.4
13.5
11.8
37.4
36.0
56.3
43.9
~
~
~
32.5
52.8 CA7
[A] 100 KA
[A]
50
[A]
25
[A] 80 KA
[A]
25
[A]
25
[A] 100 KA
[A]
15
100 KA 50 35
80 KA 32 32
100 KA 20
100 KA 50 35
80 KA 35 35
100 KA 20
100 KA 80 40
80 KA 50 50
100 KA 30
50 KA 160 100
~ ~ ~
100 KA 70
[A] 5 KA
[A]
35
[A] 100 KA
[A]
15
[A] 100 KA
[A]
15
[A] 5 KA
[A]
30
[A]
~
5 KA 40
100 KA 20
100 KA 20
5 KA 30 ~
5 KA 70
100 KA 30
100 KA 30
5 KA 50 ~
5 KA 90
100 KA 30
100 KA 30
5 KA 50 ~
5 KA 125
~ ~
100 KA 70
5 KA 125 125
50 KA 160 100
~ ~ ~
100 KA 70
5 KA 125
~ ~
100 KA 70
5 KA 125 125
50 KA 250 160
~ ~ ~
100 KA 100
50 KA 250 160
~ ~ ~
100 KA 100
10 KA 300
~ ~
100 KA 150
10 KA 250 250
10 KA 300
~ ~
100 KA 150
10 KA 250 250
Short Time Current Withstand
Ratings
Icw 60° C
[A] 170
170
170
215
304
304
700
700
Off Time Between Operations
[Min.]
20
20
20
20
5
5
5
5
When used as a Branch Circuit Protection device, NEC 430-152 defines the maximum rating of an Inverse-time circuit breaker to be sized at 250% of the motor nameplate FLA for most applications.
UL Listed Combination. (UL File E41850) Per UL508A, NEC409 abd CSA 22.2 No.14 for contactor and fuses or circuit breaker only.
Per IEC 60947-1 for contactor and fuses only. UL Testing not complete a the time of printing this catalog.
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Technical Information
CA7 4-pole Contactors
Contactors
A Mechanical Data
Service Life Mechanical
Shipping Weights AC - CA7
CA7
DC - CA7
Terminations - Power Description
CA7-9-
M40(31; 22)
CA7-12-
M40(31; 22)
CA7-16-
M40(31; 22)
CA7-23-
M40(31; 22)
CA7-40-M22
CA7-40-M40
CA7-90M22
CA7-90M40
AC [Mil.] 13
13
13
13
10
DC [Mil.] 13
13
13
13
10
10
10
10
10
10
10
[kg] 0.39
0.39
0.39
0.39
0.51
[Lbs.] 0.86
0.86
0.86
0.86
1.12
[kg] 0.60
0.60
0.60
0.73
1.00
[Lbs.] 1.32
1.32
1.32
1.61
2.20
0.51
1.45
1.45
1.12
3.20
3.20
1.00
1.47
1.47
2.20
3.24
3.24
Torque Requirement
Terminations - Control Description
1 Wire [mm2] 2 Wires [mm2]
1 Wire [mm2] 2 Wires [mm2]
1 Wire [AWG] 2 Wires [AWG]
[Nm] [Lb-in]
One saddleclamp per pole: cross, slotted or Pozidrive No. 2/blade No. 3 screw
1...4 1...4
1.5...6 1.5...6
16...10 16...10
1.0...2.5 9...22
1...4 1...4
1.5...6 1.5...6
16...10 16...10
1.0...2.5 9...22
1...4 1...4
1.5...6 1.5...6
16...10 16...10
1.0...2.5 9...22
1...4 1...4
1.5...6 1.5...6
16...10 16...10
1.0...2.5 9...22
Dual connection; one saddleclamp and one box lug per pole; cross, slotted or Pozidrive No. 2/blade
No. 4 screw
2.5...10 2.5...10
2.5...10 2.5...10
2.5...16 2.5...16
2.5...16 2.5...16
14...6
14..6
14...6
14..6
2.5...4 22...35
2.5...4 22...35
Dual connection; two box lugs per pole Allen Head: 4mm, 5/32
2.5...16 2.5...10
2.5...25 2.5...16
14...4 14...4
2.5...4 22...35
2.5...35 2.5...25
2.5...50 2.5...35
14...1 14...1
3.5...6 31...53
Coils
1 or 2 [mm2]
Wires
[AWG]
Control Modules
1or 2 [mm2]
Wires
[AWG]
Torque Requirement
[Nm]
[Lb-in]
Degree of Protection - contactor
Protection Against Accidental Contact
Combination Screw Head: Cross, Slotted, Pozidrive 1.5...6 16...12 1.5...6 16...12 1...2.5 9...13
IP 2LX per IEC 529 and DIN 40 050 (with wires installed) Safe from touch by fingers and back-of-hand per VDE 0106; Part 100
Environmental and General Specifications
Ambient Temperature Storage Operation Conditioned 15% current reduction after AC-1 at >60° C
Altitude at installed site Resistance to Corrosion/Humidity
Shock Resistance Vibration Resistance Pollution Degree Operating Position Standards Approvals
-55...+80° C (-67...176° F) - [CRI7E Electronic Interface -50...+80° C (-58...176° F)] -25...+60° C (-13...140° F) -25...+70° C (-13...158° F)
2000 meters above sea level per IEC 947-4 Damp-alternating climate: cyclic to IEC 68-2, 56 cycles Dry heat: IEC 68-2, +100°C (212° F), relative humidity <50%, 7 days. Damp tropical: IEC 68-2, +40°C (104°F), relative humidity <92%, 56 days. IEC 68-2: Half sinusoidal shock 11ms, 30g (in all three directions) IEC 68-2: Static > 2g, in normal position no malfunction <5g
3 Refer to Dimension Pages IEC947-1/4, EN 60947; UL 508; CSA 22.2, No. 14
CE, UL, CSA
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Technical Information
CA7 Contactors
Coil Data (CA7 4-Pole)
CA7-9- CA7-12- CA7-16- CA7-23- CA7-40- CA7-40- CA7-90- CA7-90-
M40(31; 22) M40(31; 22) M40(31; 22) M40(31; 22) M22
M40
M22
M40
Voltage Range
AC: 50Hz, 60Hz, 50/60 Hz DC Coil Consumption
Pickup [xUs] Dropout [xUs] Pickup [xUs] Dropout [xUs]
0.85...1.1 0.3...0.6 0.8...1.1 (9V coils = 0.65...1.3; 24V coils = 0.7...1.25) 0.1...0.6
AC: 50Hz, 60Hz, 50/60 Hz
Pickup [VA/W] 70/50
70/50
70/50
70/50 130/90 130/90 400/240 400/240
Hold-in [VA/W] 8/2.6
8/2.6
8/2.6
9/3
12/3.6 12/3.6
24/9
24/9
True DC Coils (CA7C)
Pickup [W] 6.5
6.5
6.5
9.2
10.1
10.1
~
~
Hold-in [W] 6.5
6.5
6.5
9.2
10.1
10.1
~
~
Two Winding DC Coils
Pickup [W] ~
~
~
~
~
~
325
325
CA7Y & CA7D
Hold-in [W] ~
~
~
~
~
~
5.5
5.5
Operating Times
AC: 50Hz, 60Hz, 50/60 Hz
Pickup [ms] 15...30 15...30 15...30 15...30 15...30 15...30 20...30 20...30
Dropout [ms] 10...60 10...60 10...60 10...60 10...60 10...60 20...40 20...40
with RC Suppressor
Dropout [ms] 10...60 10...60 10...60 10...60 10...60 10...60 20...40 20...40
True DC Coils (CA7C)
Pickup [ms] 40...70 40...70 40...70 40...70 50...80 50...80
~
~
without Suppression
Dropout [ms] 7...15
7...15
7...15
7...15
7...15
7...15
~
~
with Integrated Suppression Dropout [ms] 14...20 14...20 14...20 17...23
~
~
~
~
with External Suppression Dropout [ms] 70...95 70...95 70...95 80...125
~
~
~
~
Two Winding DC Coils
Pickup [ms] ~
~
~
~
~
~
15...20 20...25
with Internal Suppression Dropout [ms] ~
~
~
~
~
~
20...25 20...25
Contactors
A
CA7
Technical Information Auxiliary Contact Data
Electrical Contact Ratings - NEMA Min. Contact Rating
Contact Ratings - IEC AC-15 (solenoids, contactors) rated voltage IEC 60947-5-1
40 ºC AC-12 (Control of resistive loads) IEC 60947-5-1
60 ºC
DC-12 Switching DC Loads L/R < 1 ms, Resistive Loads IEC 60947-5-1
DC-13 IEC 60947-5-1, Solenoids and contactors
Mounted Standard Auxiliary
24V 48V 120V 240V 400V 480V/500V 600V 690V
Ith 230V 400V 690V
Ith 230V 400V 690V 24V 48V 110V 220V 440V 24V 48V 110V 220V 440V
Built-in Auxiliary Contacts in Contactor CA7-9...CA7-23
A600, P600 17V, 10 mA
10 A 10 A 10 A 10 A 6 A 2.5 A 1 A 1 A 20 A 8 kW 14 kW 24 kW 20 A 8 kW 14 kW 24 kW 12 A 9 A 3.5 A 0.55 A 0.2 A 5 A 3 A 1.2 A 0.6 A 0.3 A
Front Mounted Auxiliary Contacts CA7-PV, CS7-PV, CZE/A7, CV7
Front Mounted Bifurcated Auxiliary Contacts
17V, 5 mA 6 A 6 A 6 A 5 A 3 A 1.6 A 1 A 1 A 10 A
A600, Q600
5V, 3 mA 3 A 3 A 3 A 3 A 2 A 1.2 A 0.7 A 0.7 A 10 A
6 A
6 A
12 A 9 A 3.5 A 0.55 A 0.2 A 5 A 3 A 1.2 A 0.6 A 0.15 A
6 A 3.2 A 0.45 A 0.18 A 0.1 A 2.5 A 1.5 A 0.6 A 0.3 A 0.15 A
Side Mounted Auxiliary Contacts
CA-PA, CM7 A600, Q600 17V, 10 mA
6 A 6 A 6 A 5 A 3 A 1.6 A 1 A 1 A 10 A
6 A
6 A 3.2 A 0.45 A 0.18 A 0.1 A 5 A 3 A 1.2 A 0.6 A 0.15 A
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Technical Information
CA7 Contactors
A Auxiliary Contacts
Contactors
CA7
Continuous Current Rating per UL/CSA
Rated Voltage
AC
[V]
Continuous Rating
40°C
[A]
Continuous Rating
DC
[A]
Short-Circuit Protection -gGFuse
Type 2 Coordination
[A]
Rated Impulse Voltage Uimp
[kV]
Insulation Voltage (between control and
load circuit) per DIN< VDE 0103, Part 101 [V]
(NAMUR recommendation)
Mechanically Linked Contacts (per IEC60947-5-1 Annex L (SUVA Third-party certified)
Built-in Auxiliary Contacts in Contactor CA7-9...CA7-23
600 max. 10 A general purpose Heavy pilot duty (A600)
5A, 600 max. Standard pilot duty (P600)
20
8
380
Mutually unrestricted between all NO and NC contacts
Terminals
Terminal Type
Maximum Wire Size per IEC 947-1
Flexible with Wire-End Fernule
1 conductor 2 conductor
Solid/Stranded- 1 conductor
Conductor
2 conductor
Recommended Tightening Torque
Max. Wire Size per UL/CSA
Recommended Tightening Torque
[mm2]
[mm2]
[mm2] [mm2] [Nm] [AWG] [lb-in]
2xA4
1...4
1...4
1.5...6 1.5...6 1...2.5 16...10 9...22
Front Mounted Auxiliary Contacts CA7-PV, CS7-PV, CZE/A7, CV7
Side Mounted Auxiliary Contacts CA-PA, CM7
600 max. 10 A general purpose Heavy pilot duty (A600)
2.5A, 600 max. Standard pilot duty (Q600)
10
8
600 max. 10 A general purpose Heavy pilot duty (A600)
2.5A, 600 max. Standard pilot duty (Q600)
10
6
440
440
Mutually unrestricted between all NO & Mutually unrestricted between all
NC contacts. CZE & CV7 not mechanically
NO and NC contacts
linked with contactor main contacts
2xA4
0.5...2.5
0.75...2.6
0.5...2.5 0.75...2.6
1...15 18...14 9...13
2xA4
0.5...2.5
0.75...2.6
0.5...2.5 0.75...2.6
1...15 18...14 9...13
Accessories
Latch Attachment Release, CV7-11 Coil Consumption
Contact Signal Duration Time Attachment Reset Time
at min. time setting at max. time setting Repeat Accuracy
[VA/W] [W]
[min/max]
[ms] [ms]
AC 45/40 DC 25W 0.03...15s
10 70 ±10%
Positively-Guided Contacts ( Mechanically-linked) SUVA Certified · Restricted guidance guarantees without
restrictions from contactor to auxiliary contact and auxiliary contact to contactor.
Contact Ratings (Per NEMA/UL A600 & Q600)
Standard A600 Q600
Circuit Voltage
120AC 240AC 480AC 600AC
125DC 250DC 301-600DC
Make (Amps/VA)
60A/7200VA 30A/7200VA 15A/7200VA 12A/7200VA
0.55A/69VA 0.27A/69VA 0.1A/69VA
Break (Amps/VA
6A/720VA 3A/720VA 1.5A/720VA 1.2A/720VA
0.55A/69VA 0.27A/69VA 0.1A/69VA
Continuous Amps 10
25
See Section G for additional details.
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Technical Information
CA7 Contactors - Contact Life
Contactors
Determining Contact Life
To determine the contactor's estimated electrical life, follow these guidelines: 1. Identify the appropriate Utilization Category from Table A. 2. On the following pages, choose the graph for the Utilization
Category selected.
3. Locate the Rated Operational Current (le) along the bottom of
A
the chart and follow the graph lines up to the intersection of the
appropriate contactor's life-load curve.
4. Read the estimated contact life along the vertical axis.
Table A IEC Special Utilization Categories, AC Ratings
Category Typical Applications
Rated Current
Conditions for testing electrical life
Make
Break
Conditions for testing making and
breaking capacity
Ops.
Make
Break
Ops.
I/Ie U/ue cos Ic/Ie Ur/Ue cos
I/Ie U/ue cos I/Ie U/ue cos
Non-inductive or slightly AC-1 inductive loads; resistance
furnaces
All values
1 1 0.95 1 1 0.95 6000 1.5 1.05 0.8 1.5 1.05 0.8 50
AC-2
Slip-ring motors: Starting, plugging
All values
2 1.05 0.65 2 1.05 0.65 6000 4 1.05 0.65 4 1.05 0.65 50
Slip-ring motors: AC-3 Starting, switching off
motors during running
Ie 17Amp
6
17Amp <Ie 100Amp 6
Ie> 100Amp
6
1 0.65 1 0.17 0.65
10 1.1 0.65 8 1.1 0.65
1 0.35 1 0.17 0.35 6000 10 1.1 0.35 8 1.1 0.35 50
1 0.35 1 0.17 0.35
8 1.1 0.35 6 1.1 0.35
AC-4
Squirrel-cage motors: Starting, plugging, inching
Ie 17Amp
6
17Amp <Ie 100Amp 6
Ie> 100Amp
6
1 0.65 6 1 0.35 6 1 0.35 6
1 0.65
12 1.1 0.65 10 1.1 0.65
1 0.35 6000 12 1.1 0.35 10 1.1 0.35 50
1 0.35
10 1.1 0.35 8 1.1 0.35
AC-5a
Switching of electric discharge lamp control
2 1.05 0.45 2 1.05 0.45 6000 3 1.05 0.45 3 1.05 0.45 50
CONTACTORS
AC-5b Switching of incandescent lamps
1 1.05
1 1.05
6000 1.5 1.05
1.5 1.05
50
AC-6a Switching of transformers
Rating derived from AC-3 rating (x 0.45)
CONTROL DEVICES
AC-6b Switching of capacity banks
AC-12
AC-13 AC-14 AC-15 AC-20 AC-21
AC-22
AC-23
Control of resistive loads and
solid state loads with isolation by All values
opto couplers
Control of solid state loads
with transformer isolation
Control of small electromagnetic loads
72 VA
Control of electromagnetic loads 72 VA
Connecting and disconnecting
under no load conditions
Switching or resistive loads, including moderate overloads
All values
Switching of mixed resistive &
inductive loads, including moder- All values
ate overloads
Switching of motor loads or other highly inductive loads
All values
Depends on circuit conditions of application
1 1 0.9 1 1 0.9 6050 2 1 0.65 1 1 0.65 6050 10 1.1 0.65 1.1 1.1 0.65 10 6 1 0.3 1 1 0.3 6050 6 1.1 0.7 6 1.1 0.7 10 10 1 0.3 1 1 0.3 6050 10 1.1 0.3 10 1.1 0.3 10
No testing required 1 1 0.95 1 1 0.95 10000 1.5 1.05 0.95 1.5 1.05 0.95 5
1 1 0.8 1 1 0.8 10000 3 1.05 0.65 3 1.05 0.65 5
1 1 0.65 1 1 0.65 10000 10 1.05 0.45 8 1.05 0.45 5
SWITCHES
CA7
Legend
Ue Rated operational voltage U Voltage before make Ur Recovery voltage Ie Rated operational current I Making current Ic Breaking current L Inductance of test circuit R Resistance of test circuit
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Utilization categories and test conditions for AC & DC. For contactors according to IEC 158-1, starters according to IEC 292-1 ... 4 and control switches according to IEC 337-1 and IEC 337-1A.
With a minimum value of 1000A for I or Ic. With a minimum value of 800A for Ic. With a minimum value of 1200A for I. Plugging is understood as stopping or reversing the motor rapidly by reversing
the motor primary connections while the motor is running. Inching [or jogging] is understood as energizing a motor once or repeatedly for short periods to obtain small movements of the driven mechanism.
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Technical Information
CA7 Contactors - Contact Life
Contactors
A Determining Contact Life To determine the contactor's estimated electrical life, follow these guidelines: 1. Identify the appropriate Utilization Category from Table A. 2. On the following pages, choose the graph for the Utilization Category selected.
3. Locate the Rated Operational Current (le) along the bottom of the chart and follow the graph lines up to the intersection of the ap-
propriate contactor's life-load curve.
4. Read the estimated contact life along the vertical axis.
CA7 Table A IEC Special Utilization Categories, DC Ratings
Category Typical Applications
Rated Current
Conditions for testing electrical life
Make
Break
Conditions for testing making and
breaking capacity
Ops.
Make
Break
Ops.
DC-1
DC-2 DC-3 DC-4 DC-5 DC-15
Non-inductive or slightly inductive loads, resistance furnaces Shunt-motors: Starting, switching off motors during running Shunt motors: Starting, plugging, inching Series-motors: Starting , switching off motors during running Series-motors: Starting, plugging, inching Electromagnets for contactors, valves, solenoid actuators
All Values
All Values All Values All Values All Values All Values
I/Ie U/ue cos Ic/Ie Ur/Ue cos
11 1
11
1
2.5 1 2
1 0.1 7.5
2.5 1 2 2.5 1
2
2.5 1 7.5 1 0.3 10
2.5 1 7.5 2.5 1 7.5 1 1 6xP 1 1 6xP
I/Ie U/ue cos I/Ie U/ue cos 1.5 1.1 1 1.5 1.1 1
4 1.1 2.5 4 1.1 2.5 4 1.1 2.5 4 1.1 2.5 4 1.1 15 4 1.1 15 4 1.1 15 4 1.1 15 1.1 1.1 6 x P 1.1 1.1 6 x P
Legend
Ue Rated operational voltage U Voltage before make Ur Recovery voltage Ie Rated operational current I Making current Ic Breaking current L Inductance of test circuit R Resistance of test circuit
Utilization categories and test conditions for AC & DC. For contactors according to IEC 158-1, starters according to IEC 292-1 ... 4 and control switches according to IEC 337-1 and IEC 337-1A.
Only according to VDE. P = Ue x Ie rated power [W]. The value "6 x P" has been derived from an empiric
relationship which covers most magnetic loads for DC up to an upper limit of P = 50W.
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Technical Information
CA7 Contactors - Contact Life
Predicting Electrical Life Sprecher + Schuh contactors are designed for superior
and size of contactor required. This assures reliable opera-
A
performance in a wide variety of applications, by giving
tion and high value the ability to very closely match the
consideration to the specific load, utilization category and contactor to the application.
required electrical life, you can purchase exactly the type
Contactors
Identify they appropriate utilization category. For this example, we will determine CA7 contact life for inching and plugging squirrel-cage motors.
Utilization Category
AC-1
AC-2 AC-3 AC-4
Resistance Furnaces
Slip-ring motors Squirrel-cage motors Squirrel-cage motors
AC-15
Electromagnets
CA7
Definition Non inductive or slightly inductive loads, Resistive Furnaces Starting and stopping of running motors Starting and stopping of running motors Starting, plugging, and inching (Plugging is understood as stopping or reversing the motor rapidly by reversing the motor primary connections while the motor is running. Inching [or jogging] is understood as energizing a motor once or repeatedly for short periods to obtain small movements of the driven mechanism.) Electromagnets for contactors, valves, solenoid actuators
Choose the graph for the utilization category selected. (a graph pertaining to most Utilization Categories can be found in each contactor section.)
Locate the Rated Operational Current (Ie) along the bottom of the chart and follow the graph lines up to the intersection of the appropriate contactor's life-load curve.
Contact Life (Millions of Operations)
CA7-30 CA7-37 CA7-43
10
CA7-23
CA7-16 CA7-12
1
CA7-9
Starting with inching and plugging; Ue = 230...460 VAC
CA7-60 CA7-72 CA7-85
0.1
Read the estimated contact life along
0.01
1
the vertical axis.
10
Rated operational current Ie AC-4 [A]
AC-4
100
A comprehensive list of Utilization Categories can be found in each contactor section, however, these are the primary categories used in most industrial motor applications.
The life-load curves shown here are based on Sprecher+Schuh tests according to the requirements defined in IEC 60947-4-1. Since contact life in a given application is dependent on environmental conditions and duty cycle, actual application contact life may vary from that indicated by the curves shown here.
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Technical Information
CA7 Contactors Life Load Curves
Contactors
A Life-Load Curves
· Locate the Rated Operational Current (le) along the bottom of the chart and follow the graph lines up to the intersection of the appropriate contactor's life-load curve.
· Read the estimated contact life
CA7 along the vertical axis.
AC-1
(to 690V)
AC-2
(to 460V)
AC-3
(to 460V)
NOTE: The life-load curves shown here are based on Sprecher+Schuh tests according to the requirements defined in IEC 60947-4-1. Since contact life in any given application is dependent on environmental conditions and duty cycle, actual application contact life may vary from that indicated by the curves shown here.
575V applications use 90% of curve value.
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Technical Information
CA7 Contactors Life Load Curves
Life-Load Curves
· Locate the Rated Operational Current (le) along the bottom of the chart and follow the graph lines up to the intersection of the appropriate contactor's life-load curve.
· Read the estimated contact life along the vertical axis.
AC-3
(to 575)
CA7-9
10
Starting and stopping of running squirrel-cage induction motors; Ue = 500...575V AC
CA7-12
CA7-16
CA7-23
CA7-30 CA7-37 CA7-43 CA7-60
CA7-72 CA7-85
AC-3
Contactors
A
CA7
1
Contact Life (Millions of Operations)
0.1 1
10
100
Rated operational current Ie AC-3 [A]
AC-4
(to 690V)
CA7-30 CA7-37 CA7-43
10
CA7-23
CA7-16
CA7-12
Starting with inching and plugging; Ue = 230...690 VAC
CA7-60 CA7-72 CA7-85
CA7-9
1
AC-4
Contact Life (Millions of Operations)
NOTE: The life-load curves shown here are based on Sprecher+Schuh tests according to the requirements defined in IEC 60947-4-1. Since contact life in any given application is dependent on environmental conditions and duty cycle, actual application contact life may vary from that indicated by the curves shown here.
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0.1 1
10
100
Rated operational current Ie AC-4 [A]
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Contactors
Contact Life (Millions of Operations)
Max. Starting / Loading time [s]
A Life-Load Curves
AC-3 (90%), AC-4 (10%) CA7
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Technical Information
CA7 Contactors Life Load Curves
CA7-12 CA7-16
10
Mixed operation of squirrel-cage motors; Ue = 230...460 VAC
AC-3 90% Starting and stopping of running motors
AC-4 10% Starting with inching or plugging
CA7-23
CA7-30
CA7-37
CA7-43
CA7-60
CA7-72 CA7-85
AC-3 (90%), AC-4 (10%)
CA7-9
1
0.1 1
10
100
Rated operational current Ie AC-3 / AC-4 [A]
Contact Life for Mixed Utilization Categories
Heavy Duty Starting and Regular Short-time Operation
AC-3 and AC-4
CA7-9/12/16
CA7-23 CA7-30/37 CA7-43
CA7-60/72/85
In many applications, the utilization category cannot be defined as
100
either purely AC-3 or AC-4. In those applications, the electrical life
of the contactor can be estimated with the following equation:
Lmixed = Lac3/ [1+Pac4 x (Lac3/Lac4-1)], where:
Lmixed Approximate contact life in operations for a mixed
10
AC-3/AC-4 utilization category application.
Lac3 Approximate contact life in operations for a pure AC-3 utilization category (from the AC-3 life-load curve).
Lac4 Approximate contact life in operations for a pure AC-4
utilization category (from the AC-4 life-load curve).
1
10
Pac4 Percentage of AC-4 operations
100
1000
Starting Current / Short-time current [A]
10000
575V applications use 85% of curve value.
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NOTE: The life-load curves shown here are based on Sprecher+Schuh tests according to the requirements defined in IEC 60947-4-1. Since contact life in any given application is dependent on environmental conditions and duty cycle, actual application contact life may vary from that indicated by the curves shown here.
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Technical Information
CA7 Contactors Operating Rates
Operating Rates
The estimated contact life shown in the life-load curves is based on the standard operating rates shown in Table B below. For applications requiring a higher operating frequency, the maximum operating power (Pn in kW or HP) for a given contactor must be reduced to maintain the same contact life.
To find a contactor's maximum operating power, for an operating rate greater than shown in Table B, follow these guidelines:
1. Identify the appropriate curve for the contactor and utilization category from Table B.
2. Locate the appropriate Maximum Operating Rate curve on the following pages.
3. Locate the intersection of the curve with the application's operating rate (ops/hr.) found on the vertical axis.
4. Read the percent of maximum operating power (Pn) of the con-
A
tactor from the horizontal axis.
Contactors
5. Multiply the % maximum power by the standard power rating.
Example: The contactor selected for an AC-4 utilization category
application is a CA7-16 (10HP at 460V), however, the application
requires an operating rate of 200 ops/hr., compared to the standard
operating rate of 120 ops/hr. as shown in Table B.
CA7
1. Locate the AC-4 Maximum Operating Rate curve on the following pages.
2. Locate the intersection of 200 ops/hr on the CA7-16 curve. The data shows that the maximum operating power of the CA7-16 contactor in this application is 60%.
3. Therefore, the maximum horsepower that can be switched by the CA7-16 contactor in this application is 6 HP (0.60 x 10HP).
Table B Standard Operating Rates by Contactor and Utilization Category
Contactor
CA-9 CA-12 CA-16 CA-23 CA-30 CA-37 CA-43 CA-60 CA-72 CA-85
AC-1 Max. ops/hr.
1000 1000 1000 1000 1000 1000 1000 800 800 600
AC-2 Max. ops/hr.
AC-3 Max. ops/hr.
AC-4 Max. ops/hr.
Operating Parameters and Start Time
40% Duty Cycle 250ms
250ms
500
700
200
500
700
150
500
700
120
400
600
80
400
600
80
400
600
70
400
600
70
300
500
70
250
500
60
200
500
50
AC-4 @ Ie for 200K ops.
Max. ops/hr.
250ms 400 300 240 160 160 140 140 140 120 140
Duty Cycle or Load Factor Defined as the "on" time for a given operating cycle per hour including the "start time." A 40% Duty Cycle is calculated in the following manner:
Contactor switches six (6) times per minute (tpm), 250ms start time; 40% duty cycle.
To determine the "on" time and "off" time: · Operations per hour = 360; [60 min x 6 tpm = 360] · One operating cycle = 10 sec; [60 min ÷ 6 tpm = 10 sec] · "On" time at 40% duty cycle = 4 sec; [10 sec x 0.4 (40%) = 4 sec] · 4 sec "on" time includes the start time of 250ms · "Off" time at 40% duty cycle = 6 sec; [10 sec 4 sec = 6 sec]
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Technical Information
CA7 Contactors Operating Rates
A Operating Rate Curves
Contactors
Max. Operating Rate [Ops/hr]
AC-1 CA7
3000 CA7-9/12/16/23
2500 CA7-30/37
2000 CA7-43
1500 CA7-60/72/85 1000
Non or slightly inductive loads, resistance furnaces; Ue = 230...690 VAC AC-1
500
0
0
10
20
30
40
50
60
70
80
90
100
P/Pn [%]
AC-2
10000
Slip-ring motors: starting, switching off; Ue = 230...460 VAC
AC-2
Max. Operating Rate [Ops/hr]
1000
CA7-9/CA7-12/CA7-16 CA7-23/CA7-30/CA7-37/CA7-43
CA7-60 CA7-72 CA7-85
100
0
10
20
30
40
50
60
70
80
90
100
P/Pn [%]
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Technical Information
CA7 Contactors Operating Rates
Operating Rate Curves
A
Contactors
AC-3
10000
Squirrel-cage motors: starting, switching off motors during running; Ue = 230...460 VAC Relative operating time 40%, Starting time tA= 0.25s
AC-3
CA7
Max. Operating Rate [Ops/hr]
1000
CA7-9/CA7-12/CA7-16 CA7-23/CA7-30/CA7-37/CA7-43 CA7-60/CA7-72/CA7-85
100
0
10
20
30
40
50
60
70
80
90
100
P/Pn [%]
AC-4
1000
100
Squirrel-cage motors: starting, plugging, inching; Ue = 230 ...460 VAC Starting Time tA = 0.25s
AC-4
CA7-9
CA7-12 CA7-16
CA7-23/30 CA7-37/43/60 CA7-72 CA7-85
Max. Operating Rate [Ops/hr]
10 0
10
20
30
40
50
60
70
P/Pn [%]
80
90
100
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Dimensions
CA7 Contactors
Contactors
A Series CA7, CAU7, CAQ7, CNX, CAN7 and CAL7 (Contactors, Reversing Contactors & Special Use Contactors)
· Dimensions are in millimeters (inches) · Dimensions not intended for
manufacturing purposes
CA7
AC Contactors
Catalog Number CA7-9...CA7-23; CAQ7-16; CAN7-12, CNX-205...208; CAN7-12, CA(V)L7-20 CA7-30...CA7-37; CNX-209; CAN7-30... CAN7-37
CA7-40
CA7-43, CNX-212
CA7-60...CA7-85 CNX-218
CA7-90
CA7-9C...CA7-16C, CAQ7-16C CNX-205C...206C; CAN7-12C
True DC Contactors
CA7-23C CNX-207C...208C
CA7-30C...CA7-37C; CAQ7-37C; CNX-209C; CAN7-30C...CAN7-37C
CA7-40C
CA7-43C, CNX-212C
a
45 (1-25/32)
45 (1-25/32)
59 (2-21/64)
54 (2-1/8)
72 (2-53/64)
95 (3-3/4)
45 (1-25/32)
45 (1-25/32)
45 (1-25/32)
59 (2-21/64)
54 (2-1/8)
b
80 (3-3/16)
81 (3-3/16)
81 (3-3/16)
81 (3-3/16)
122 (4-51/64)
81 (3-3/16)
81 (3-3/16)
81 (3-3/16)
81 (3-3/16)
81 (3-3/16)
81 (3-3/16)
c
80.5 (3-11/64)
97.5 (4)
100.5 (4-7/64)
100.5 (4-7/64)
117 (4-49/64)
117 (4-49/64)
106.5 (4-3/16)
123.5 (4-55/64)
141.5 (5-37/64)
144.5 (5-11/16)
144.5 (5-11/16)
c1
75.5 (3-3/32)
92.6 (3-49/64)
95.5 (3-49/64)
95.5 (3-49/64)
111.5 (4-35/64)
111.5 (4-35/64)
101.5 (4)
119 (4-43/64)
136.5 (5-3/8)
139.5 (5-1/2)
140 (5-33/64)
Reversing Contactors, Capacitor Contactors & Accessories (+...)
Contactors with...
auxiliary contact block-front mounting
2-, or 4-pole
(CAQ7) capacitor switching deck -front mounting
auxiliary contact block-side mounting
1-, or 2 pole
pneumatic timing module
electronic timing module
on coil terminal side
reversing contactor w-mech.interlock
on side of contactor
mechanical latch
interface module
on coil terminal side
surge suppressor
on coil terminal side
Dim. [mm] c/c1 + 39 c/c1 + 39 a + 9 c/c1 + 58 b + 24 a+9+a c/c1 + 61 b + 9 b + 3
Labeling with...
label sheet
+0
marking tag sheet with clear cover
+0
marking tag adapter for V7 Terminals +5.5
Dim. [inches] c/c1 +1-37/64 c/c1 +1-37/64 a + 23/64 c/c1 + 2-23/64 b + 15/16 a+ 23/64+a c/c1 +2-31/64 b + 23/64 b + 1/8
+0 +0 +7/32
c2
6 (1/4)
6.5 (17/64)
6.5 (17/64)
6.5 (17/64)
8.5 (21/64)
8.5 (21/64)
6 (1/4)
6 (1/4)
6.5 (17/64)
6.5 (17/64)
6.5 (17/64)
ød
2-4.5 (2-3/16)
2-4.5 (2-3/16)
2-4.5 (2-3/16)
2-4.5 (2-3/16)
4-5.4 (4-7/32)
4-5.4 (4-7/32)
2-4.5 (2-3/16)
2-4.5 (2-3/16)
2-4.5 (2-3/16)
2-4.5 (2-3/16)
2-4.5 (2-3/16)
d1
60 (2-23/64)
60 (2-23/64)
60 (2-23/64)
60 (2-23/64)
100 (3-15/16)
100 (3-15/16)
60 (2-23/64)
60 (2-23/64)
60 (2-23/64)
60 (2-23/64)
60 (2-23/64)
d2
35 (1-25/64)
35 (1-25/64)
45 (1-25/32)
45 (1-25/32)
55 (2-11/64)
55 (2-11/64)
35 (1-25/64)
35 (1-25/64)
35 (1-25/64)
45 (1-25/32)
45 (1-25/32)
Mounting Position
AC contactors
True DC contactors
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Dimensions
CA7 Contactors
Contactors
Series CA7 with Two Winding DC Coil
A
· Dimensions are in millimeters (inches) · Dimensions not intended for
manufacturing purposes
CA7
Catalog Number CA7-9Y...CA7-23Y
CA7-30Y, CA7-37Y
AC Contactors
CA7-43Y
CA7-60D...CA7-85D CAN7-72D, CNX-218D
CA7-90D
a
54 (2-9/64)
54 (2-9/64)
63 (2-31/64)
81 (3-3/16)
95 (3-3/4)
b
90 (3-35/64)
90 (3-35/64)
90 (3-35/64)
131 (5-5/32)
122 (4-51/64)
c
80.5 (3-11/64)
97.5 (4)
100.5 (4-7/64)
117 (4-49/64)
117 (4-49/64)
c1
75.5 (3-3/32)
92.6 (3-49/64)
95.6 (3-7/8)
111.5 (4-35/64)
111.5 (4-35/64)
c2
6 (1/4)
6.5 (17/64)
6.5 (17/64)
8.5 (21/64)
8.5 (21/64)
ød
2-4.5 (2-3/16)
2-4.5 (2-3/16)
2-4.5 (2-3/16)
4-5.4 (4-7/32)
4-5.4 (4-7/32)
d1
60 (2-23/64)
60 (2-23/64)
60 (2-23/64)
100 (3-15/16)
100 (3-15/16)
d2
35 (1-25/64)
35 (1-25/64)
45 (1-25/32)
55 (2-11/64)
55 (2-11/64)
Reversing Contactors, Capacitor Contactors & Accessories (+...)
auxiliary contact block-front mounting auxiliary contact block- left side mounting pneumatic timing module electronic timing module mechanical latch interface module Labeling with...
Contactors with... 2-, or 4-pole 1-, or 2 pole
on coil terminal side
on coil terminal side label sheet marking tag sheet with clear cover marking tag adapter for V7 Terminals
Dim. [mm] c/c1 + 39 a + 9 c/c1 + 58 b + 24 c/c1 + 61 b + 9
+0 +0 +5.5
Dim. [inches] c/c1 +1-37/64 a + 23/64 c/c1 + 2-23/64 b + 15/16 c/c1 +61 c/c1 + 2-31/64
+0 +0 +7/32
Mounting Position Two Winding DC contactors
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A CA7 Contactors with Terminal Lugs · Dimensions are in millimeters (inches) · Dimensions not intended for manufacturing purposes
Dimensions
CA7 Contactors
Contactors
CA7
CA7-P-KN23 / KL23
CA7-P-K37
Catalog Number
CA7-P-KN23 / KL23
CA7-P-K37 CA7-P-K43 CA7-P-K85
CA7-P-K43
With Contactor CA7-9...16
CA7-23 CA7-30 & 37
CA7-43 CA7-60...85
h1
61.6 (2-27/64)
61.6 (2-27/64)
67.6 (2-21/32)
69.0 (2-23/32)
79.7 (3-1/8)
AC Operated Contactor
h2
h3
78.6 (3-3/32)
~
78.6 (3-3/32)
~
84.6 (3-21/64)
71.5 (2-13/16)
85.0 (3-11/32)
74.5 (2-15/16)
104.7 (4-1/8)
86.7 (3-13/64)
h4
~
~
88.5 (3-31/64)
90.5 (3-9/16) 111.7 (4-3/8)
CA7-P-K85
h1
87.2 (3-7/16)
105.2 (4-9/64)
111.2 (4-3/8)
112.6 (4-7/16)
79.7 (3-1/8)
DC Operated Contactor
h2
h3
104.2 (4-3/32)
~
122.2 (4-13/16)
~
128.2 (5-3/64)
115.1 (4-17/32)
128.6 (5-1/16)
118.1 (4-21/32)
104.7 (4-1/8)
86.7 (3-13/64)
h4
~
~
132.1 (5-13/64) 134.1 (5-9/32) 111.7 (4-3/8)
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CA7 Contactors with Paralleling Links
· Dimensions are in millimeters (inches) · Dimensions not intended for manufacturing purposes
Dimensions
CA7 Contactors
A
CA7
Contactors
Catalog Number
CA7-P-B23
CA7-P-K37
CA7-P-B23
With Contactor CA7-9...16
CA7-23
CA7-30 & 37
h1
65.1 (2-9/16)
65.1 (2-9/16)
69.0 (2-23/32)
AC Operated Contactor
h2
h3
90.1 (3-9/16)
~
90.1 (3-9/16)
~
94.0 (3-45/64)
74.5 (2-15/16)
h4 ~
~ 99.5 (3-29/32)
CA7-P-B37
h1
90.7 (1/4)
108.7 (4-9/32)
112.6 (4-7/16)
DC Operated Contactor
h2
h3
104.2 (2-3/16)
~
133.7 (5-17/64)
137.6 (5-13/32)
~
118.1 (4-21/32)
h4 ~
~ 143.1 (5-5/8)
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Switches & Pilot Lights
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
RH Series
Relays & Sockets
RH Series Compact Power Relays
SPDT through 4PDT, 10A contacts Compact power type relays
The RH series are miniature power relays with a large capacity. The RH relays feature 10A contact capacity as large as the RR series but in a miniature package. The compact size saves space.
Display Lights
Relays & Sockets
Timers
Contact SPDT DPDT
3PDT
4PDT
Part Number Selection
Part Number
Model
Blade Terminal
PCB Terminal
Basic
RH1B-U
RH1V2-U
With Indicator
RH1B-UL
--
With Check Button
RH1B-UC
--
With Indicator and Check Button
RH1B-ULC --
Top Bracket Mounting
RH1B-UT
--
With Diode (DC coil only)
RH1B-UD
RH1V2-UD
With Indicator and Diode (DC coil only)
RH1B-ULD --
Basic
RH2B-U
RH2V2-U
With Indicator
RH2B-UL
RH2V2-UL
With Check Button
RH2B-UC
--
With Indicator and Check Button
RH2B-ULC --
Top Bracket Mounting
RH2B-UT
--
With Diode (DC coil only)
RH2B-UD
RH2V2-UD
With Indicator and Diode (DC coil only)
RH2B-ULD --
Basic
RH3B-U
RH3V2-U
With Indicator
RH3B-UL
RH3V2-UL
With Check Button
RH3B-UC
--
With Indicator and Check Button
RH3B-ULC --
Top Bracket Mounting
RH3B-UT
--
With Diode (DC coil only)
RH3B-D*
RH3V2-D*
With Indicator and Diode (DC coil only)
RH3B-LD* --
Basic
RH4B-U
RH4V2-U
With Indicator
RH4B-UL
RH4V2-UL
With Check Button
RH4B-UC
--
With Indicator and Check Button
RH4B-ULC --
Top Bracket Mounting
RH4B-UT
--
With Diode (DC coil only)
RH4B-UD
RH4V2-UD
With Indicator and Diode (DC coil only)
RH4B-LD* --
Coil Voltage Code (Standard Stock in bold)
AC6V, AC12V, AC24V, AC110V, AC120V, AC220V, AC240V DC6V, DC12V, DC24V, DC48V, DC110V
DC6V, DC12V, DC24V, DC48V, DC110V DC12V, DC24V, DC48V, DC110V
AC6V, AC12V, AC24V, AC110-120V, AC220-240V DC6V, DC12V, DC24V, DC48V, DC100-110V
DC6V, DC12V, DC24V, DC48V, DC100-110V
AC6V, AC12V, AC24V, AC110V, AC120V, AC220V, AC240V DC6V, DC12V, DC24V, DC48V, DC110V
DC6V, DC12V, DC24V, DC48V, DC110V
AC6V, AC12V, AC24V, AC110V, AC120V, AC220V, AC240V DC6V, DC12V, DC24V, DC48V, DC110V
DC6V, DC12V, DC24V, DC48V, DC110V
1. *Carries no UL recognition mark. 2. PCB terminal relays are designed to mount directly to a circuit board without any socket.
Ordering Information When ordering, specify the Part No. and coil voltage code:
(example) RH3B-U AC120V
Part No.
Coil Voltage Code
Terminal Blocks
Circuit Breakers
726
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Switches & Pilot Lights
Display Lights
Relays & Sockets
Relays & Sockets
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
RH Series
Sockets (for Blade Terminal Models)
Relays
Standard DIN Rail Mount 1 Finger-safe DIN Rail Mount 1
RH1B
SH1B-05
SH1B-O5C
RH2B
SH2B-05
SH2B-05C
RH3B
SH3B-05
SH3B-05C
RH4B
SH4B-05
SH4B-05C
Through Panel Mount SH1B-51 SH2B-51 SH3B-51 SH4B-51
PCB Mount SH1B-62 SH2B-62 SH3B-62 SH4B-62
Hold Down Springs & Clips
Appearance
Description Relay
Pullover Wire Spring
RH1B RH2B RH3B RH4B
For DIN Mount Socket SY2S-02F1 2 SY4S-02F1 2 SH3B-05F1 2
SH4B-02F1 2
For Through Panel & PCB Mount Socket
Min Order Qty
SY4S-51F1
10
Leaf Spring (side latch)
RH1B, RH2B, RH3B, RH4B SFA-202 3
SFA-302 3
20
Leaf Spring (top latch)
RH1B, RH2B, RH3B, RH4B SFA-101 3
SFA-301 3
1. DIN Rail mount socket comes with two horseshoe clips. Do not use unless you plan to insert pullover wire spring. Replacement horseshoe clip part number is Y778-011.
2. Must use horseshoe clip when mounting in DIN mount socket. Replacement horseshoe clip part number is Y778-011.
3. Two required per relay.
AC Coil Ratings
Rated Current (mA) ±15% at 20°C
Voltage
(V) SPDT
AC 50Hz DPDT 3PDT
4PDT
SPDT
AC 60Hz DPDT 3PDT
6
170 240 330 387 150 200 280
12
86 121 165 196 75 100 140
24
42 60.5 81
98
37
50
70
110
9.6
-- 18.1 21.6 8.4
-- 15.5
110-120
--
9.410.8
--
--
-- 8.0-9.2 --
120
8.6
-- 16.4 19.5 7.5
-- 14.2
220
4.7
--
8.8 10.7 4.1
--
7.7
220-240 -- 4.7-5.4 --
--
-- 4.0-4.6 --
240
4.9
--
8.2
9.8
4.3
--
7.1
4PDT 330 165 83 18.2 -- 16.5 9.1
8.3
Coil Resistance () ±10% at 20°C
SPDT DPDT 3PDT 4PDT
330 9.4 6.4 5.4 165 39.3 25.3 21.2 83 153 103 84.5 18.2 -- 2,200 1,800
--
--
--
--
16.5 -- 10,800 7,360
9.1
-- 10,800 7,360
-- 18,820 --
--
8.3
-- 12,100 9,120
Operation Characteristics (against rated values at 20ºC)
Max. Continuous Applied Voltage
Pickup Voltage
Dropout Voltage
110%
80% maximum
30% minimum
DC Coil Ratings
Voltage (V)
Rated Current (mA) ±15% at 20°C SPDT DPDT 3PDT 4PDT
Coil Resistance () ±10% at 20°C
SPDT DPDT 3PDT 4PDT
6
128 150 240
12
64
75 120
24
32 36.9 60
48
18 18.5 30
100-110 -- 8.2-9.0 --
110
8
-- 12.8
250 47
40
25
24
125 188 160 100 96
62 750 650 400 388
31 2,660 2,600 1,600 1,550
--
-- 12,250 --
--
15 13,800 -- 8,600 7,340
Operation Characteristics (against rated values at 20ºC)
Max. Continuous Applied Voltage
Pickup Voltage
Dropout Voltage
110%
80% maximum
10% minimum
Standard coil voltages are in BOLD.
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RH Series
Relays & Sockets
Contact Ratings
Maximum Contact Capacity
Model
Continuous Current
Allowable Contact Power
Resistive Load
Inductive Load
Rated Load
Voltage Res. Ind. (V) Load Load
SPDT
10A
1540VA 300W
990VA 210W
110 AC 10A 7A 220 AC 7A 4.5A 30 DC 10A 7A
DPDT
3PDT
10A
4PDT
1650VA 300W
1100VA 225W
110 AC 10A 7.5A 220 AC 7.5A 5A 30 DC 10A 7.5A
Note: Inductive load for the rated load -- cos ø = 0.3, L/R = 7 ms
TÜV Ratings
Voltage
RH1
RH2
RH3
RH4
240V AC
10A
10A
7.5A
7.5A
30V DC
10A
10A
10A
10A
AC: cos ø = 1.0, DC: L/R = 0 ms
UL Ratings
Voltage
Resistive
RH1 RH2
RH3
RH4
240V AC 10A 7.5A 7.5A
120V AC -- 10A 10A
30V DC 10A 10A --
28V DC -- -- 10A
General Use
RH1 RH2
RH3 RH4
7A 6.5A 5A
-- 7.5A 7.5A
7A -- --
-- ----
Horse Power Rating
RH1 RH2
RH3 RH4
1/3 HP 1/3 HP --
1/6 HP 1/6 HP --
--
----
--
----
CSA Ratings
Voltage
Resistive
General Use
Horse Power Rating
RH1 RH2 RH3 RH4 RH1 RH2 RH3 RH4 RH1, 2, 3
240V AC 10A 10A -- 7.5A 7A 7A 7A 5A 1/3 HP
120V AC 10A 10A 10A 10A 7.5A 7.5A -- 7.5A 1/6 HP
30V DC 10A 10A 10A 10A 7A 7.5A -- --
--
Socket Specifications
Sockets
DIN Rail Mount Sockets
SH1B-05
SH2B-05 SH3B-05 SH4B-05
Finger-safe DIN Rail Mount
Through Panel Mount Socket
PCB Mount Socket
SH1B-05C
SH2B-05C SH3B-05C SH4B-05C
SH1B-51 SH2B-51 SH3B-51 SH4B-51
SH1B-62
SH2B-62 SH3B-62 SH4B-62
Terminal
(Coil) M3 screws (contact) M3.5 screws with captive wire clamp
Electrical Rating 250V, 10A
M3.5 screws with captive wire clamp
300V, 10A
(coil) M3 screws (contact) M3.5 screws with captive wire clamp, fingersafe
250V, 10A
M3.5 screws with captive wire clamp, fingersafe
300V, 10A
Solder PCB mount PCB mount
300V, 10A 250V, 10A 300V, 10A
Wire Size Maximum up to 2#12AWG
Torque
5.5 - 9 in·lbs 9 - 11.5 in·lbs
Maximum up to 2#12AWG 9 - 11.5 in·lbs
Maximum up to 2#12AWG
5.5 - 9 in·lbs 9 - 11.5 in·lbs
Maximum up to 2#12AWG 9 - 11.5 in·lbs
--
--
--
--
--
--
Accessories
Description Appearance
Aluminum DIN Rail (1 meter length)
DIN Rail End Stop
Replacement Hold-Down Spring Anchor
Use with All DIN rail sockets
DIN rail
Part No. BNDN1000
BNL5
Remarks IDEC offers a low-profile DIN rail (BNDN1000). The BNDN1000 is designed to accommodate DIN mount sockets. Made of durable extruded aluminum, the BNDN1000 measures 0.413 (10.5mm) in height and 1.37 (35mm) in width (DIN standard). Standard length is 39" (1,000mm).
9.1 mm wide.
DIN mount sockets and hold down springs.
Y778-011
For use on DIN rail mount socket when using pullover wire hold down spring. 2 pieces included with each socket.
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
RH Series
Specifications
Contact Material
Contact Resistance 1
Minimum Applicable Load
Operate Time 2
SPDT DPDT
3PDT 4PDT
Release Time 2
SPDT DPDT
3PDT 4PDT
SPDT
Power Consumption (approx.)
DPDT 3PDT
4PDT
Insulation Resistance
Dielectric Strength 3 Operating Frequency
SPDT
DPDT 3PDT 4PDT
Vibration Resistance
Shock Resistance Mechanical Life
Electrical Life
Operating Temperature 4 Operating Humidity Weight (approx.)
DPDT
SPDT 3PDT 4PDT
SPDT
DPDT 3PDT 4PDT
Silver cadmium oxide 50m maximum 24V DC, 30 mA; 5V DC, 100 mA (reference value)
20ms maximum
25ms maximum
20ms maximum
25ms maximum
AC: 1.1VA (50Hz), 1VA (60Hz)
DC: 0.8W
AC: 1.4VA (50Hz), 1.2VA (60Hz) DC: 0.9W
AC: 2VA (50Hz), 1.7VA (60Hz)
DC: 1.5W
AC: 2.5VA (50Hz), 2VA (60Hz)
DC: 1.5W
100M minimum (500V DC megger)
Between live and dead parts:
2,000V AC, 1 minute
Between contact and coil:
2,000V AC, 1 minute
Between contacts of the same pole: 1,000V AC, 1 minute
Between live and dead parts:
2,000V AC, 1 minute
Between contact and coil:
2,000V AC, 1 minute
Between contacts of different poles: 2,000V AC, 1 minute
Between contacts of the same pole: 1,000V AC, 1 minute
Electrical: Mechanical:
1,800 operations/hour maximum 18,000 operations/hour maximum
Damage limits:
10 to 55Hz, amplitude 0.5 mm
Operating extremes: 10 to 55Hz, amplitude 0.5 mm
Damage limits: Operating extremes:
1,000m/s2 (100G) 200m/s2 (20G - SPDT, DPDT) 100m/s2 (10G - 3PDT, 4PDT)
50,000,000 operations minimum
500,000 operations minimum (120V AC, 10A)
200,000 operations minimum (120V AC, 10A)
25 to +50°C (no freezing)
25 to +40°C (no freezing)
45 to 85% RH (no condensation) SPDT: 24g, DPDT: 37g, 3PDT: 50g, 4PDT: 74g
Note: Above values are initial values. 1. Measured using 5V DC, 1A voltage drop method 2. Measured at the rated voltage (at 20°C), excluding contact bouncing
Release time of relays with diode: 40 ms maximum 3. Relays with indicator or diode: 1000V AC, 1 minute 4. For use under different temperature conditions, refer to Continuous Load Current vs. Operating Temperature Curve. The operating
temperature range of relays with indicator or diode is 25 to +40°C.
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RH Series
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Electrical Life Curves
AC Load
1000
(RH1)
500
120V AC resistive
Characteristics (Reference Data)
DC Load
1000
(RH1)
500
Life (× 10,000 operations)
Life (× 10,000 operations)
100 50
20 10
(RH2) 1000
240V AC inductive 120V AC inductive
240V AC resistive
1 2 3 4 5 6 7 8 9 10 Load Current (A)
120V AC resistive
500
30V DC resistive 100
50 100V DC resistive
30V DC inductive 20
100V DC inductive
10
1 2 3 4 5 6 7 8 9 10
Load Current (A)
(RH2) 1000
500
30V DC resistive
Display Lights
Life (× 10,000 operations)
Life (× 10,000 operations)
Relays & Sockets
Timers
Terminal Blocks
100
50 240V AC inductive
20
240V AC resistive 120V AC inductive
10
(RH3/RH4) 1000
500
1 2 3 4 5 6 7 8 9 10 Load Current (A)
120V AC resistive
Life (× 10,000 operations)
100 50
20
240V AC inductive
240V AC resistive
120V AC inductive
10
1 2 3 4 5 6 7 8 9 10
Load Current (A)
Maximum Switching Capacity
(RH1)
10.0
5.0
AC resistive AC inductive
Load Current (A)
DC resistive 1.0
0.5
DC inductive
100
50
100V DC resistive
100V DC inductive
20
30V DC inductive
10
(RH3/RH4) 1000
500
1 2 3 4 5 6 7 8 9 10 Load Current (A)
30V DC resistive
30V DC inductive
Life (× 10,000 operations)
100 50
20
100V DC resistive
100V DC inductive
10
1 2 3 4 5 6 7 8 9 10
Load Current (A)
(RH2/RH3/RH4)
10.0 5.0
1.0 0.5
AC resistive AC inductive
DC inductive
DC resistive
Load Current (A)
730
0.1
1
5
10
50 100 200 300
0.1 1
Load Voltage (V)
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50
100
200 300
Load Voltage (V)
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
RH Series
Continuous Load Current vs. Operating Temperature Curve (Basic Type, With Check Button, and Top Bracket Mounting Type)
Operating Temperature (oC) Operating Temperature (oC)
Operating Temperature (oC)
(RH1)
Note: The rated voltage is
100
applied to the coil.
90
80
DC Coil 70
60
50
AC Coil
40
30
20
10
0 1 2 3 4 5 6 7 8 9 10 Load Current (A)
(RH2)
Note: The rated voltage is
100
applied to the coil.
90
80
70
DC Coil
60
50
40
AC Coil
30
20
10
0 1 2 3 4 5 6 7 8 9 10 Load Current (A)
(RH3/RH4)
Note: The rated voltage is
100
applied to the coil.
90
80
70
60
50
AC/DC Coil
40
30
20
10
0 1 2 3 4 5 6 7 8 9 10 Load Current (A)
Internal Connection (View from Bottom) Basic Type
SPDT
DPDT
1
5
9
13
14
( )
( + )
1 5 9 13( )
4 8 12 ( + )14
3PDT
1 5 9
13 ()
2
4
6
8
10
12
( + )14
4PDT
1
2
5
6
9
10
13( )
3
4
7
8
11
12
( + )14
With Check Button
Front Pushbutton
Contacts can be operated by pressing the check button.
With Indicator (-L type)
SPDT
Below 100V AC/DC
1
5
9
13
14
( )
( + )
3PDT
1 5 9 13()
2
4
6
8
10
12
( + )14
100V AC/DC and over
1
5
9
13
14
( )
( + )
1 5 9 13( )
2
4
6
8
10
12
( + )14
4PDT
1
2
5
6
9
10
13( )
3
4
7
8
11
12
( + )14
1
2
5
6
9
10
13( )
3
4
7
8
11
12
( + )14
DPDT
Below 24V AC/DC
24V AC/DC and over
1 5 9
13( )
4 8 12
( + )14
1 5 9
13( )
4 8 12
( + )14
When the relay is energized, the indicator goes on. · Relay coils less than 100V
DC do not contain a protection diode (except DPDT). · Relay coils below 100V use LED indicator, coils above 100V use neon lamp indicator.
With Diode (-D type)
SPDT
DPDT
1
5
9
13
14
( )
( + )
1 5 9 13( )
4 8 12 ( + )14
3PDT
1 5 9
13()
2
4
6
8
10
12
( + )14
4PDT
1
2
5
6
9
10
13( )
3
4
7
8
11
12
( + )14
Contains a diode to absorb the back emf generated when the coil is de-energized. The release time is slightly longer. Available for DC coil only. · Diode Characteristics
Reverse withstand voltage: 1,000V Forward current: 1A
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With Indicator LED & Diode (-LD type)
SPDT
3PDT
Below 100V DC
1
5
9
13
14
( )
( + )
1 5 9 13( )
2
4
6
8
10
12
( + )14
100V DC and over
1 5 9 13() 14(+)
1 5 9 13( )
2
4
6
8
10
12
( + )14
4PDT
1
2
5
6
9
10
13( )
3
4
7
8
11
12
( + )14
1
2
5
6
9
10
13( )
3
4
7
8
11
12
( + )14
DPDT
1
Below
5
24V
9
AC/DC
13( )
1
24V
5
AC/DC
9
and over
13 ( )
4 8 12 ( + )14
Contains an LED indicator and a surge absorber, and has the same height as the basic type.
4 8 12
14 ( + )
RH1B-U/RH1B-UL/RH1B-UD/RH1B-ULD
Total length from panel surface including relay socket SH1B-05: 61.5 (63.5) max., SH1B-51: 39.6 (41.6) max.
Dimensions in the ( ) include a hold-down spring.
4.7
27.5
ø2.6 hole
1 5 9
13 14
0.5
5.4
14
35.6 max.
6.4
Dimensions (mm)
RH2B-U/RH2B-UL/RH2B-UD/RH2B-ULD
Total length from panel surface including relay socket SH2B-05: 61.5 (63.5) max., SH2B-51: 39.6 (41.6) max.
Dimensions in the ( ) include a hold-down spring.
4.7
27.5
ø2.6 hole
0.5
35.6 max.
6.4
1
4
5
8
9
12
13
14
21
RH3B-U/RH3B-UL/RH3B-D/RH3B-LD
Total length from panel surface including relay socket SH3B-05: 61.5 (63.5) max., SH3B-51: 39.6 (41.6) max.
Dimensions in the ( ) include a hold-down spring.
27.5
4.7
ø2.6 hole
0.5
1
2
4
5
6
8
9
10
11
13
14
35.6 max.
6.4
31
RH4B-U/RH4B-UL/RH4B-UD/RH4B-LD
Total length from panel surface including relay socket SH4B-05: 61.5 (63.5) max., SH4B-51: 39.6 (41.6) max.
Dimensions in the ( ) include a hold-down spring.
RH1B-UT
4.7
27.5 43.2 38
ø2.6 hole
0.5
35.6 max.
6.4
1
2
5
6
9
10
13
3
4
7
8
11
12
14
41
3.5 14.5
ø2.6 hole
0.5
2
5.4
35.6 max.
6.4
6.6
4.7
5.9
1 5 9
13 14
4.7
27.5
RH2B-UT
10
43.2 38
3.5 21.5
ø2.6 hole
0.5
4.7
2
35.6 max.
6.4
7.25
4.7
5.9
1
4
5
8
9
12
13
14
RH3B-UT
RH4B-UT
27.5
Timers
Terminal Blocks
10 10 10
4.7 10 10
Circuit Breakers 43.2 38
732
3.5
ø2.6 hole
0.5
21.5
2
31.5
35.6 max.
6.4
7.25
4.7
5.9
1
2
4
5
6
8
9
10
12
13
14
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4.7
2 ø2.6 hole
0.5
35.6 max.
6.4
42 max.
7.25
4.7
5.9
3.5
1
2
3
4
5
6
7
8
9
10
11
12
13
14
28 41.5
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
RH Series
RH1V2-U/RH1V2-UD
Dimensions con't (mm) RH2V2-U/RH2V2-UL/RH2V2-UD
27.5
27.5
0.5 35.6 max.
0.5
1 5 9 13 14
4.6
14
RH3V2-U/RH3V2-UL/RH3V2-D
1.5
2
2-ø2 holes
3-ø2.4 holes
7.15
6.6
4.4
12.5
4.7
0.5
0.5 2 0.5
35.6 max.
4.6
2 5
1
4
5
8
9
12
13
14
21
RH4V2-U/RH4V2-UL/RH4V2-UD
11-ø2.4 holes
10 10
4.7
14-ø2.4 holes
7.8
8-ø2.4 holes
10 14.2 30 10
13.15
4.7
2
2
13.15
13.15
27.5 7.8
7.25
35.6 max.
0.5
0.5 4.6
1
2
4
5
6
8
9
10 11
13
14
31
27.5 7.8
7.25
0.5 35.6 max.
0.5
4.6
1
2
3
4
5
6
7
8
9
10
11
12
13
14
41
Standard DIN Rail Mount Sockets SH1B-05
17
8
M3.5 Terminal
Screw
31.5
18
DIN Rail
(BNDN)
SH2B-05
Terminal Arrangement
2-ø4.2 Mounting Holes
(or M4 Tapped Holes)
5
1
22
8
M3.5 Terminal
Screw
4.2 47
4.2
47
67
67
16
M3 Terminal
5.5 min.
4.8 min.
14 13
Screw
4.4 max.
4 max.
9
(Top View)
16
14.5
ø3.6 min.
ø3.2 min.
26
2.5
20
25
30
7.9 max.
5.9 max.
2.5
(For terminals 1, 5, and 9)
(For terminals 13 and 14)
31.5
18
DIN Rail
(BNDN)
Terminal Arrangement
2-ø4.2 Mounting Holes (or M4 Tapped Holes)
85 41
14.5 25
26 4.4 max.
7.9 max.
5.5 min. ø3.6 min.
14 13 12 9
(Top View)
2.5
67
SH3B-05
32 8
36 40
4.2 47
M3.5 Terminal Screw
SH4B-05
31.5
18
DIN Rail
(BNDN)
Terminal Arrangement
2-ø4.2 Mounting Holes (or M4 Tapped Holes)
865 421
42 8
67
36
4.4 max.
5.5 min.
14
13
12 10 9
14.5
7.9 max.
(Top View)
46
25
ø3.6 min.
50
4.2 47
31.5
M3.5 Terminal
18
Screw
DIN Rail (BNDN)
Terminal Arrangement
2-ø4.2 Mounting Holes (or M4 Tapped Holes)
8 765 4 321
14.5 25
46 4.4 max.
5.5 min.
7.9 max.
ø3.6 min.
14
13
12 11 10 9
(Top View)
Relays & Sockets
Timers
Terminal Blocks
2.5
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
RH Series
Relays & Sockets
Dimensions con't (mm)
Finger-safe DIN Rail Mount Sockets SH1B-05C
SH2B-05C
17
7
M3.5 Terminal Screw
ø5
36
25
DIN Rail
(BNDN)
Terminal Arrangement
5
2-ø4.2 Mounting Holes
1
(or M4 Tapped Holes)
22 7 M3.5 Terminal Screw
ø5
69
16
M3 Terminal
Screw
14 13
9
16
Ring terminals
18.7
cannot be used.
(Top View)
1.7
26 30
20
29.5
SH3B-05C
32 7
M3.5 Terminal Screw
ø5
SH4B-05C
36
25
DIN Rail
(BNDN)
Terminal Arrangement
2-ø4.2 Mounting Holes (or M4 Tapped Holes)
865 421
42 7
ø5
4.2 49
69
69
36
14
13
12 10 9
Ring terminals
(Top View)
36
18.7
cannot be used.
40
29.5
46
1.7
50
1.7
4.2 49
4.2 49
36 25
18.7 29.5
DIN Rail (BNDN)
Terminal Arrangement
2-ø4.2 Mounting Holes (or M4 Tapped Holes)
85 41
26
Ring terminals cannot be used.
14 13 12 9
(Top View)
36 25
18.7 29.5
DIN Rail (BNDN)
Terminal Arrangement
2-ø4.2 Mounting Holes (or M4 Tapped Holes)
8 765 4 321
46
Ring terminals cannot be used.
14
13
12 11 10 9
(Top View)
Through Panel Mount Socket SH1B-51
SH2B-51
18
3.5 2.4 12.2
Panel Thickness:
1 to 2
Terminal Arrangement
3 11 18.7
1 5 9
13 14
(Bottom View)
5.4 min.
25.6
+0.2 0
[18
(N1)
+
12.4]
+ 0.5 0
N: No. of sockets mounted
10.4 min. when using hold-down springs
27
3.5 21.2
31 0.3
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+0.2 0
14 58 9 12
25.6
13 14
3
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N: No. of sockets mounted
11
5.4 min.
18.7
10.4 min. when using hold-down springs
SH3B-51
36 30.2
SH4B-51
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1 to 2
Terminal Arrangement
0.3 25.4
1 24 568 9 10 12
13 14
3
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11
18.7
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25.6
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3.5
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13
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11
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18.7 10.4 min. when using hold-down springs
Timers 31 0.3 25.4
Terminal Blocks 31
Circuit Breakers
734
Q-Pulse Id: TMS1594
www.idec.com
Active: 18/04/2016
Page 103 of 1068
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Small, compact Thermostat KTO 011 / KTS 011
Large setting range Small size Simple to mount High switching performance
Regulating and Monitoring
Thermostat KTO 011 (NC)
Thermostat KTS 011 (NO)
KTO 011: Thermostat (normally closed); contact breaker for regulating heaters.
KTS 011: Thermostat (normally open); contact maker for regulating of filter fans and heat exchangers or for switching signal devised when temperature limit has been exceeded.
|
Technical Data
Switch temperature difference Sensor element Contact type Contact resistance Service life Max. Switching capacity
EMC Connection Mounting
Casing Dimensions Weight Fitting position Operating/Storage temperature Protection type
7K (± 4K tolerance) thermostatic bimetal snap-action contact < 10mOhm > 100,000 cycles 250VAC, 10 (2) A 120VAC, 15 (2) A DC 30W acc. to EN 55014-1-2, EN 61000-3-2, EN 61000-3-3 2-pole terminal for 2.5mm², clamping torque 0.8Nm clip for 35mm DIN rail, EN50022 (or for exit filter EF 118 Series) plastic according to UL94 V-0, light grey 60 x 33 x 43mm approx. 40g variable -20 to +80 °C (-4 to +176 °F) / -45 to +80 °C (-49 to +176 °F) IP20
Thermostat Heater KTO 011 (NC)
Thermostat e.g. Fan KTS 011 (NO)
Thermostat KTS 011 (NO)
e.g. Signal device
Example of connection
Setting range 0 to +60°C
-10 to +50°C +20 to +80°C +32 to +140°F +14 to +122°F
0 to +60°C
26 Q-Pulse Id: TMS1594
Art. No. Contact Breaker (NC) 01140.0-00 01142.0-00 01159.0-00 01140.9-00 01142.9-00 01146.9-00
Example of connection
Art. No. Contact Maker (NO) 01141.0-00 01143.0-00 01158.0-00 01141.9-00 01143.9-00 01147.9-00
Approvals VDE VDE VDE
UL File No. E164102 UL File No. E164102 UL File No. E164102
Active: 18/04/2016
Page 104 of 1068
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual J & P Richardson Industries Pty Ltd
1.3. PUSHBUTTONS & SELECTOR SWITCHES KRAUS & NAIMER CA10-A221-FT2 'LOCAL REMOTE' Selector Switch SPRECHER & SCHUH D7P-MT44-PX01 Emergency Stop Pushbutton
C63100-WB065_Manual_DRAFT.doc Revision 0
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Date: February 18, 2014
Page 105 of 1068
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
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Page 109 of 1068
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
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Q-Pulse Id: TMS1594
Active: 18/04/2016
Page 110 of 1068
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual ]]
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Q-Pulse Id: TMS1594
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Page 111 of 1068
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Emergency stop operators
Components
1
2
3
Protection class IP 66 Individually packaged 3 part ordering 22.5 mm mounting
D7P-MT44
1 Mushroom operators Description 30 mm Red operator 40 mm Red operator 60 mm Red operator 40 mm Red operator
Operator head
Coupling plate Contact Blocks
Nonilluminated Plastic Cat. No.
Nonilluminated Metal Price $ Cat. No.
Illuminated Plastic Price $ Cat. No. 1) Price $
Illuminated Metal Cat. No. 1) Price $
D7P-MT34 67.00 D7M-MT34 74.50 -
-
D7P-MT44 70.50 D7M-MT44 75.00 D7P-LMT44 90.00 D7M-LMT44 95.50
D7P-MT64 79.00 D7M-MT64 82.50 D7P-LMT64 110.00 D7M-LMT64 118.00
2
D7P-MK44 113.00 D7M-MK44 124.00 -
-
D7ALP D7-X01
D7PX10
2 Coupling plates
Description Plastic coupling plate Metal coupling plate
Cat. No. D7-ALP D7-ALM
Price $ 4.50 6.50
3 Contact blocks Description
Operator Colour Contacts
Normally closed contact block
Red
1 N/C
Normally closed contact block with Red
1 N/C
spring clamp terminals
Normally closed late break
Brown N/C L.B.
Normally closed early break
Brown N/C E.B.
Normally closed low voltage
Blue
1 N/C
(Quadfurcated gold contacts)
Dual circuit 2 normally closed 2)
Red
2 N/C
"Auto break" safety contact block for Yellow 1 N/C
emergency stop operators 2)
safety
Panel Mount Cat. No.
D7-X01
D7-Q01
DIN/Base Mount Price $ Cat. No.
11.80 D7-BX01
16.80 D7-BQ01
D7-X01L D7-X01B D7-X01V
15.40 D7-BX01L 15.40 26.20 D7-BX01V
D7-X02D 27.40 D7-X01S 32.00 -
Price $ 13.20 18.00
16.80
27.40
2 + 3 Combined contact block and coupling plate
Description 1 N/O contact block + coupling plate 1 N/C contact block + coupling plate 1 N/O and 1 N/C contact block + coupling plate
Screw Cap Cat. No.
D7PX10 D7PX01 D7PX11
Metal Screw Cap Price $ Cat. No.
16.80 D7MX10 16.80 D7MX01 28.60 D7MX11
Price $ 19.60 19.60 32.00
Price Schedule `A2'
Notes: 1) For LED 2 lamps refer 2 - 32. 2) Dual circuit and `Auto Break' cannot be mounted in D7 low profile enclosures. For Accessories refer 2 - 33.
Q-Pulse Id: TMS1594For further information please coAnctatcivteS:a1le8s/0143/0201N6HP NHP or visit nhp.com.au
Page 112GSoT fno1t0i6nc8luded
2 - 5
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual J & P Richardson Industries Pty Ltd
1.4. POWER SUPPLIES, GPOs, PLUGS & SOCKETS CLIPSAL 2015 + 90B 15A Outlet + Shroud PROCONNECT 3PS6A3NE01 + 3PS6PC 63A 3Phase N&E Inlet + Cover WILCO WIBN27 27Pin Inlet Socket POWERBOX PB251-24CM-CC-T 24VDC 10A RTU Power Supply POWERBOX PBIH-2412J-CC Radio Power Supply Yuasa NP7.2-12 12V 7Ah Battery
C63100-WB065_Manual_DRAFT.doc Revision 0
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Active: 18/04/2016
Date: February 18, 2014
Page 113 of 1068
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
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Active: 18/04/2016
Page 114 of 1068
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
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Active: 18/04/2016
Page 115 of 1068
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
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Active: 18/04/2016
Page 116 of 1068
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
ISO Connect 3PS63 Series
Maximum cable sizes: Cable outside diameter: Stripping length: IP rating:
50 mm2 strandard 35 mm2 flexible
minimum 11 mm maximum 29 mm
sheathing 60 mm insulation 30 mm
socket outlet IP 66 outlet and inlet IP 66
Rated current:AC23 63 A/440 V AC (AS/NZ 3947-3 / IEC60947-3) 90 A maximum rated current (IEC60309-1)
Housing material:
polyamide 6
Contacts 1P+N+E 3P+E 3P+N+E
1P+N+E+2p 3P+E+2p 3P+N+E+2p
Voltage rating 220-240 V AC 380-440 V AC 380-440 V AC
220-240 V AC 380-440 V AC 380-440 V AC
Socket outlet Cat. No. 3PS6D1NE01 3PS6D30E01 3PS6D3NE01
3PS63D1NE01P 1) 3PS63D30E01P 1) 3PS63D3NE01P 1)
3PS63 Series accessories Description Angled wall box 30° M40X1.5 (without cable gland) Handle maximum outside cable diameter 29 mm Handle with 50 mm thread with cable gland 30° incline sleeve Appliance inlet plug cap Note: 1) Includes 2 x 16 A pilot pins.
Price Schedule `B4'
Q-Pulse Id: TMS1594
GST not included Active: 18/04/2016
Appliance inlet Cat. No. 3PS6A1NE01 3PS6A30E01 3PS6A3NE01 3PS63A1NE01P 1) 3PS63A30E01P 1) 3PS63A3NE01P 1)
Cat. No. 3PS6WAS 3PS6G 3PS6GFP 3PS6LB 3PS6PC
7 Page 118 of 1068
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
ISO Connect
Dimensions (mm)
Angled wall box with appliance inlet
Series
A
B
C
d
3PS16 114
108
82
6
3PS32 134
128
91
7
3PS63 169
156
106
8
3PS125 223
204
155
9
3PS200 266
216
155
9
E
E'
F
Kg Draw. No ISO
69
69
82
0.22
1 M20x1.5
78
88
101
0.36
1 M25x1.5
88
111
129
0.64
1 M40x1.5
139
154
170
-
2 M50x1.5
139
154
170
-
2 M63x1.5
1
2
Angled wall box with socket outlet
Series A
B
C
d
3PS16 141 126
82
6
3PS32 162 148
91
7
3PS63 202 180
106
8
3PS125 285 242
155
9
3PS200 308 248
155
9
3
E
E'
F
Y
Kg Draw. No
ISO
69
69
82
196 0.31
3
M20x1.5
78
88
101
226 0.50
3
M25x1.5
88
111 129 273 0.88
3
M40x1.5
139
154 170 354
-
4
M50x1.5
139
154 170 375
-
4
M63x1.5
4
10 Q-Pulse Id: TMS1594
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Page 119 of 1068
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
ISO Connect
Dimensions (mm)
Socket outlet
Series
A
B
C
D
d
E
G
H
Y
Z
Kg
3PS16
71
92
72
57
4.5
48
47
13
107
120 0.24
3PS32
77
106
82
67
4.5
55
51
17
116
135 0.38
3PS63
89
122
99
80
5.5
66
59
25
132
163 0.64
3PS125 120
140
129
100
6
81
68
24
152
218 1.50
3PS200 122
179
144
120
7
98
94
35
190
230 2.40
Socket outlet with handle
Series
A
B
3PS16
151
97
3PS32
172
107
3PS63
201
123
3PS125
261
145
3PS200
353
177
C
Diam. Kg
72
18
0.30
82
22
0.47
99
29
0.79
129
45
1.90
144
58
3.15
Appliance inlet with handle
Series
A
B
3PS16
100
71
3PS32
115
82
3PS63
133
96
3PS125
167
125
3PS200
260
143
C
Diam. Kg
30.5
18
0.22
34
22
0.33
40
29
0.56
48
45
1.20
54
58
2.60
Q-Pulse Id: TMS1594
Active: 18/04/2016
11 Page 120 of 1068
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
ISO Connect - Cross reference chart 3PS Series
NHP - 3PS16 3PS1D1NE01
3PS1D30E01 3PS1D3NE01 3PS16D1NE01P 3PS16D30E01P 3PS16D3NE01P NHP - 3PS32 3PS3D1NE01 3PS3D30E01 3PS3D3NE01 3PS32D1NE01P 3PS32D30E01P 3PS32D3NE01P NHP - 3PS63 3PS6D1NE01 3PS6D30E01 3PS6D3NE01 3PS63D1NE01P 3PS63D30E01P 3PS63D3NE01P NHP - 3PS125 3PS9D1NE01 3PS9D30E01 3PS9D3NE01 3PS9D1NE01P 3PS9D30E01P 3PS9D3NE01P NHP - 3PS200 3PS2D1NE01 3PS2D30E01 3PS2D3NE01 3PS2D1NE01P 3PS2D30E01P 3PS2D3NE01P
Socket outlet
Contacts 1P+N+E 3P+E 3P+N+E 1P+N+E+2P 3P+E+2P 3P+N+E+2P Contacts 1P+N+E 3P+E 3P+N+E 1P+N+E+2P 3P+E+2P 3P+N+E+2P Contacts 1P+N+E 3P+E 3P+N+E 1P+N+E+2P 3P+E+2P 3P+N+E+2P Contacts 1P+N+E 3P+E 3P+N+E 1P+N+E+2P 3P+E+2P 3P+N+E+2P Contacts 1P+N+E 3P+E 3P+N+E 1P+N+E+2P 3P+E+2P 3P+N+E+2P
Note: Not all units are interchangeable
Marechal - DS 1 3114015
3114013 3114017 3114015972 3114013972 3114017972 Marechal - DS 3 3134015 3134013 3134017 3134015972 3134013972 3134017972 Marechal - DS 6 3164015 3164013 3164017 3164015972 3164013972 3164017972 Marechal - DS 9 3194015 3194013 3194017 3194015972 3194013172 3194017972 Marechal - DS 2 3924015 3924013 3924017 3924015972 3924013972 3924017972
Eaton - CH 1 CH1D1NE01
CH1D30E01 CH1D3NE01 CH1D1NE01P CH1D30E01P CH1D3NE01P Eaton - CH 3 CH3D1NE01 CH3D30E01 CH3D3NE01 CH3D1NE01P CH3D30E01P CH3D3NE01P Eaton - CH 6 CH6D1NE01 CH6D30E01 CH6D3NE01 CH6D1NE01P CH6D30E01P CH6D3NE01P Eaton - CH 9 CH9D1NE01 CH9D30E01 CH9D3NE01 CH9D1NE01P CH9D30E01P CH9D3NE01P Eaton - CH 2 CH2D1NE01 CH2D30E01 CH2D3NE01 CH2D1NE01P CH2D30E01P CH2D3NE01P
12 Q-Pulse Id: TMS1594
Active: 18/04/2016
Page 121 of 1068
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
ISO Connect - Cross reference chart 3PS Series
NHP - 3PS16 3PS1A1NE01
3PS1A30E01 3PS1A3NE01 3PS16A1NE01P 3PS16A30E01P 3PS16A3NE01P NHP - 3PS32 3PS3A1NE01 3PS3A30E01 3PS3A3NE01 3PS32A1NE01P 3PS32A30E01P 3PS32A3NE01P NHP - 3PS63 3PS6A1NE01 3PS6A30E01 3PS6A3NE01 3PS63A1NE01P 3PS63A30E01P 3PS63A3NE01P NHP - 3PS125 3PS9A1NE01 3PS9A30E01 3PS9A3NE01 3PS9A1NE01P 3PS9A30E01P 3PS9A3NE01P NHP - 3PS200 3PS2A1NE01 3PS2A30E01 3PS2A3NE01 3PS2A1NE01P 3PS2A30E01P 3PS2A3NE01P
Appliance inlet
Contacts 1P+N+E 3P+E 3P+N+E 1P+N+E+2P 3P+E+2P 3P+N+E+2P Contacts 1P+N+E 3P+E 3P+N+E 1P+N+E+2P 3P+E+2P 3P+N+E+2P Contacts 1P+N+E 3P+E 3P+N+E 1P+N+E+2P 3P+E+2P 3P+N+E+2P Contacts 1P+N+E 3P+E 3P+N+E 1P+N+E+2P 3P+E+2P 3P+N+E+2P Contacts 1P+N+E 3P+E 3P+N+E 1P+N+E+2P 3P+E+2P 3P+N+E+2P
Note: Not all units are interchangeable
Marechal - DS 1 3118015
3118013 3118017 3118015972 3118013972 3118017972 Marechal - DS 3 3138015 3138013 3138017 3138015972 3138013972 3138017972 Marechal - DS 6 3168015 3168013 3168017 3168015972 3168013972 3168017972 Marechal - DS 9 3198015 3198013 3198017 3198015972 3198013172 3198017972 Marechal - DS 2 3928015 3928013 3928017 3928015972 3928013972 3928017972
Eaton - CH 1 CH1A1NE01
CH1A30E01 CH1A3NE01 CH1A1NE01P CH1A30E01P CH1A3NE01P Eaton - CH 3 CH3A1NE01 CH3A30E01 CH3A3NE01 CH3A1NE01P CH3A30E01P CH3A3NE01P Eaton - CH 6 CH6A1NE01 CH6A30E01 CH6A3NE01 CH6A1NE01P CH6A30E01P CH6A3NE01P Eaton - CH 9 CH9A1NE01 CH9A30E01 CH9A3NE01 CH9A1NE01P CH9A30E01P CH9A3NE01P Eaton - CH 2 CH2A1NE01 CH2A30E01 CH2A3NE01 CH2A1NE01P CH2A30E01P CH2A3NE01P
Q-Pulse Id: TMS1594
Active: 18/04/2016
13 Page 122 of 1068
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
PB251A Series
2 2 0 - 3 3 0 WAT T S D C U P S
Features
· Ultra-low noise output · Independent battery charging · DC OK & battery charger OK alarms & LEDs · Battery disconnected alarm · Battery Low Voltage Disconnect - LVD · Battery fuse fail LED · Over-temperature protection · Analogue meters on standard model · Optional : Liquid Crystal Display · Optional : Network Enabled · Models available Q1 2010
Specifications
INPUT Voltage: Line regulation: Current: Inrush current: Frequency: OUTPUT Voltage Current Load regulation Current limit type
Current limit type
Short circuit protection
190 to 264 vac, or 190 to 400VDC 0.2%typical 1.4A maximum 10A maximum 45 to 65 Hz
See table See table 0.5%typical load cct Constant current batt. cct Constant current Indefinite, auto-resetting
Over-voltage protection Ripple & noise ENVIRONMENTAL
17.5 to 20V latching (13.8Vdc output) 31.5 to 39V latching (27.6Vdc output) 100 MHz bandwidth 28mVp-p (13.8Vdc output) 55mVp-p (27.6Vdc output)
Operating temperature
0 to 70oC ambient with derating, 5...90% relative humidity (non-condensing)
Over-temperature protection Automatic & auto-resetting
Cooling requirement
Natural convection
Efficiency
80% minimum
STANDARDS & APPROVALS
Safety
Complies with AS/NZS 60950, class 1, NSW Office of Fair Trading Approval N20602
Selection Table
EMC
Isolation input - output input - ground output - ground
Emissions comply with AS/NZS CISPR11, Group 1, Class B. Complies with ACA EMC Scheme, Safety & EMC Regulatory Compliance Marked
4242VDC for 1 minute 2121VDC for 1 minute 707VDC for 1 minute
ALARMS & BATTERY FUNCTIONS
DC OK Battery OK
Green LED : ON=OK voltage free change over contacts (32V,1A) Alarms on loss of AC mains power or failure of off-line AC/DC converter / battery charger
Green LED : ON=OK voltage free change over contacts (32V,1A) Alarms on battery low voltage, failure of battery fuse or battery disconnected. Alarm cancelled when fuse or battery replaced, or AC input restored
Battery Low Voltage Disconnect Low voltage disconnect 10.5V for 12V
(LVD)
battery, 21V for 24V battery, adjustable
1.6 to 2.0V / cell all models
Charger over-load protection Auto-resetting electronic circuit breaker
Reverse polarity protection
Internal battery fuse
Battery to load voltage drop 0.2 to 0.35V typical model dependant
OPTIONS
Liquid Crystal Display Network Enabled
16 character 2 line display, add -LCD to rack mount model
Internal network card in conjunction with PB251A becomes a network enabled device combining the benefits of SNMP V1, XML and an embedded webpage. Add -N to all model
MECHANICAL
Chassis mount case size
264 L x 172 W x 67 H mm
CM case size with heatsink 264 L x 186 W x 67 H mm
Rack mount size
232 D x 19" W x 2RU H
Weight
1.9 kg
Weight with heatsink
2.1 kg
Weight (rack mounted version) 5.5 kg
MODEL NUMBER PB251A-12CM PB251A-24CM PB251A-12CM-H PB251A-24CM-H PB251A-12RML PB251A-24RML PB251A-12B PB251A-24B
VDC 13.8V 27.6V 3.8V 27.6V 13.8V 27.6V 13.8V 27.6V
OUTPUT ILOAD 16A 11 20A 12A 20A 12A 20A 12A
OUTPUT IBATT 2A 2A 2A 2A 4A 2A 20A 12A
OUTPUT
POWER
220W 300W 275W 330W 275W 330W 275W 330W
MECHANICAL chassis mount chassis mount chassis mount / heatsink chassis mount / heatsink rack mount / screw terminals rack mount / screw terminals rack mount / Hirose connector rack mount / Hirose connector
NOTE: Non standard battery charging current available on request. ie PB251-12CM-H-10 for
Q-Pulse Id: TMS1594
Active: 18/04/2016
Page 123 of 1068
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
PB251A Series
2 2 0 - 3 3 0 WAT T S D C U P S
Features 254.0
· Ultra-low noise output
P B 251A- **C M (-H) ME C HANIC AL OUT LINE
· Independent battery charging
HE AT S INK :P B 251A-**C M-H ONLY
130.0
80.0
· DC OK & battery charger OK alarms & LEDs · Battery disconnected alarm · Battery Low Voltage Disconnect - LVD · Battery fuse fail LED · Over-temperature protection · Analogue meters on standard model · Optional : Liquid Crystal Display
NOTE S : 1. Mounting C entres: S uitable for M4 Hardware
S tandard: 165 x 80 mm Alternate: 254 x 80 mm 2. M3 threaded holes on bottom of base. S tandard: 130 x 80 mm centres Alternate: 221 x 80 mm centres 3. AC Mains: 10A C lass 1 IE C 60320 power inlet 4. Output and B attery: 4W P luggable S crew T erminal B lock S uitable for up to 4 sq. mm wire. 5. Alarms: 6W P luggable S crew T erminal B lock S uitable for up to 1.5 sq. mm wire.
165.0
· Optional : Network Enabled · Models available Q1 2010
OUTPUT / BATTE R Y TE R MINATIONS
OUTPUT BATTE R Y
+- +-
ALAR M TE R MINATIONS
BAT OK DC OK
37.0
NC C NO NC C NO
Alternate Mounting
Specifications
EMC
Emissions comply with AS/NZS CISPR11,
Group 1, Class B. Complies with ACA EMC
12.0
INPUT
Scheme, Safety & EMC Regulatory
Voltage:
80.0
80.0
S tandard Mounting
190 to 264 vac, or 190 to 400VDC
Compliance Marked
67.0
232.00 190.00
62.0
P R E L I M I N A R Y 10.0
Line regulation: Current: Inrush current: Frequency: OUTPUT Voltage Current Load regulation Current limit type Current limit type
Short circuit protection
221.0
0.2%typical 1.4A maximum 10A maximum 45 to 65 Hz
See table See table
241.0 264.0
0.5%typical
load cct Constant current
batt. cct Constant current
Indefinite, auto-resetting
76.20 88.10
Over-voltage protection Ripple & noise
ENVIRONMENTAL Operating temperature
POWER SUPPLY
17.5 to 20V latching (13.8Vdc output) 31.5 to 39V latching (27.6Vdc output) 100 MHz bandwidth 28mVp-p (13.8Vdc output) 55mVp-p (27.6Vdc output)
428.00 TOP VIE W
0 to 70oC ambient with derating, 5...90% relative humidity (non-condensing)
Isolation input - output input - ground output - ground
4242V1D5C4.f0or 1 minute
2121VDC for 1 minute
707VDC for 1 minute OUTPUT +-
BATTE R Y
+-
ALARMS & BATTERY FUNCTIONS
BAT OK DC OK NC C NO NC C NO
DC OK
Green LED : ON=OK voltage free change over BATTE R Y OK
contacts (32V,1A) Alarms on loss of AC mains DC OK
power or failure of off-line AC/DC converter /
battery1c7h2a.0rger
Battery OK
186.0G(PreBe2n51LEAD- **:COMN-=HOOKnlvyo) ltage free change over
contacts (32V,1A) Alarms on battery low
voltage, failure of battery fuse or battery
P B 251A-**RML & -12BdMiscEonCnHecAteNd.ICAAlaLrmOcUanTcLelIlNedEwhen fuse or
battery replaced, or AC input restored
Battery Low Voltage Disconnect Low voltage disconnect 10.5V for 12V
(LVD)
battery, 21V for 24V battery, adjustable
NOTE S :
1.6 to 2.0V / cell all models
1. 2R U x 19" rack enclosure per IE C 297
Charger over-load p2r. oMteoucnttiiongnslots arAe usutiota-brleesfoertMti6nghaerdlweacrter.onic circuit breaker
3. Input connector is a 10A C lass 1 IE C 60320 inlet.
Reverse polarity pro4t. e2cmtieotner IE C mainIns tceorrdnwailthbAautstterarliyanfuplsueg is supplied with unit.
5. P B 251A-12B alarm terminal is DB 25 female.
Battery to load volt6a. gPeB2d5r1oAp-12B out0pu.2t atnod b0a.t3te5ryVcotnynpeicctoarlismHoirodseelpdn.eHpSe2n8dRa-4nAt.
Mating connector is Hirose pn. HS 28P -4A (not supplied).
OPTIONS
7. P B 251A-**R ML alarm and output terminals are M3.5 screws suitable for ring or fork lugs up to 8 mm wide.
Liquid Crystal Display
16 character 2 line display, add -LCD to rack
mount model
Network Enabled
Internal network card in conjunction with PB251A-**R MPL BAL2A5R M1AANbD eOcUoTPmUTesTEaR MnINeAtLwS ork enabled device
Over-temperature proteDCctOiKon
BATT
V
A
Automatic & auto-resetting
-
A
+
combining the benefits of SNMP V1, XML and
BATTE R Y OK
LOAD
an embedded webpage. Add -N to all model
Cooling requirement
NaturaVlOcLoTAnGvE ection LOAD CUR R E NT BATTE R Y CUR R E NT
NO C NC NO C NC
Efficiency
80% minimum448635..0500
MECHANICAL
DC OK
BATT OK
FR ONT VIE W
STANDARDS & APPROVALS
Safety
POWERSUPPLY Complies with AS/NZS 60950, class 1,
Chassis mount case size CM case size with heatsink
264 L x 172 W x 67 H mm
+
26+L4O
-
ALD
x
1- 8B6A-TWTE +R Yx
67
H
mm
76.20 88.10
MAINS ON FAULT
NSW Office of Fair Trading Approval N20602
Rack mount size
232 D x 19" W x 2RU H
Selection Table
82.00
MODEL NUMBER
PB251A-12CM
VDC 13.8V
465.50 483.00 FR ONT VIE W
OUTPUT ILOAD 16A
OUTPUT IBATT
2A
Weight Weight with heatsink
1.9 kg
P B 251A-12B OUT P UT & B AT T E R Y C ONNE C T OR
2.1 kg
Weight (rack mounted version) 5.5 kg
21
34
OUTPUT
POWER
MECHANICAL
220W chassis mount
PIN1: + OUTPUT
PIN2: - OUTPUT
PIN3: + BATTE R Y
PINN4: O- BTAETT:ENR Yon standard battery charging current available on request. ie PB251-12CM-H-10 for
82.00
PB251A-24CM PB251A-12CM-H PB251A-24CM-H PB251A-12RML
27.6V
3.8V
27.6V
21
13.8V3 4
R E AR 1VI1E W (P B 251A-**R ML) 2A
20A
2A
12A
2A
20A
4A
300W 275W 330W 275W
chassis mount
P B 251A-12B ALAR M C ONNE C T OR
chassis mount / heatsink
chassis mount / heatsink
PIN 1: C OMMON PIN 6: DC OK (NC)
rack mount / screw terminalsPIN 15: BATTE R Y OK (NO)
PB251A-24RML
27.6V
12A
2A
330W rack mount / screw terminals
PB251A-12B PB251A-24B
13.8V 27.6V
20A
20A
R E AR VIE W (P B 251A-12B )
12A
12A
275W 330W
rack mount / Hirose connector rack mount / Hirose connector
Q-Pulse Id: TMS1594
Active: 18/04/2016
Page 124 of 1068
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual J & P Richardson Industries Pty Ltd
1.5. SURGE PROTECTION & FUSES CRITEC TDS-1100-2SR-277 Surge Diverter CRITEC DAR-275V Surge Diverter Alarm Relay CRITEC TDF-10A-240V Surge Reduction Filter RTU NHP NC63FW + NTIS63 63A Fuse Cartridge & 63A Fuse Holder NHP NC32FW + NNIT6 6A Fuse Cartridge & 32A Fuse Holder RF Industries IS-50NX-C2 Radio Coax Surge Protection Unit
C63100-WB065_Manual_DRAFT.doc Revision 0
Q-Pulse Id: TMS1594
Active: 18/04/2016
Date: February 18, 2014
Page 125 of 1068
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Refer Catalogue NF
BS fuse holders
CIRSCUFUPUIETSREPISROORPTRSEOHCVOTIDRIOETN
Compact fuse holders (Bolt-in)
New compact size Front (FW) or stud/front (SFW) versions Smaller dimensions Saves panel space
S$A$V$EWPFIAUTNHSEENLHESOWPLACDCOEERMSSPAAVCET
UP TO 30% SMALLER
Rating (A)
Fuse link to suit
Front wired bolt in
32
NNIT
63
NTIA NTIS
100
NOS NTIA NTIS
200
NTIA 1) NTIS 1)
NTFP NOS 1) NTCP
Cat. No.
NC32FW NC63FW NC100FW NC200FW
Dimensions (mm) HW
NC32_ 87 27 NC63_ 109 31 NC100_ 118 35 NC200_ 154 54
Suggested Max. D cable size 50 10 mm2 62 25 mm2 72 50 mm2 108 95 mm2
Back stud/front wired bolt in
32
NNIT NC32SFW
63
NTIA NTIS
NC63SFW
100
NOS NTIA NTIS
NC100SFW
200
NTIA 1) NTIS 1) NC200SFW
NTFP NOS 1) NTCP
Note: 1) Fuses can be fitted using adaptor 100M FLK.
Standard fuse holders (Bolt-in)
Ratings from 20 to 200 A Front (FW) or stud/front (SFW) versions Complies with BS88
OLD STYLE
N20FW Dimensions (mm)
HW N20_ 87 27 N32_ 109 31 N63_ 118 35 N100_ 154 54 N200_ 193 70
Suggested Max. D cable size 50 10 mm2 62 10 mm2 72 50 mm2 108 70 mm2 149 150 mm2
Rating (A)
Fuse link to suit
Front wired bolt in
20
NNIT
32
NTIA
63
NTIA NTIS
100
NTIA 1) NTIS 1)
NOS 1) NTCP
200
NTBC NTC
NTF
Back stud/front wired bolt in
20
NNIT
32
NTIA
63
NTIA NTIS
100
NTIA 1) NTIS 1)
NOS 1) NTCP
200
NTBC NTC
NTF
Cat. No.
N20FW N32FW N63FW N100FW
N200FW
N20SFW N32SFW N63SFW N100SFW
N200SFW
Clip-in fuse holders - DIN rail mount
Fast, reliable fitting and removal of fuse links
Rating (A)
Fuse link to suit
Front wired clip-in Black
20
NSS
32
NSS
63
NES
Front wired Clip-in White
NV20FW
NV32FW
NV63FW
32
NNS
63
NES
Q-Pulse Id: TMS1594
Active: 18/04/2016
Cat. No.
NV20FW NV32FW NV63FW
NV32FWW NV63FWW
Page 126 of 1068
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Fuse equivalent chart
This chart is designed to help choose the correct fuse to fit a particular switch-fuse (or vice versa) and to help choose the correct replacement fuse. Some data is from other manufacturers publications and as such cannot be guaranteed by NHP. Beware that some motor start fuses are in a larger body size than a normal fuse. It is wise to consult the fuse manufacturer's data to determine their particular fuse sizes (i.e. A2-C3).
Fuse manufacturer's part numbers - Australian/British standard
BS
Ref.
Amps
EATON/ MEM Holec
Alstom
GEC
Bussmann
PDL
Siemens
F1
2...32
F2
20...63
A1
2...32
A2
2...32
A3
35...63
Hybrid (A3) 80...100
Hybrid (A3) 125...160
A4
80...100
Hybrid (A4) 125...200
-
2...32/40...63
B1
2...32/40...63
B1
80...100
B2
125...200
B3
250...315
-
250...315
B4
355...400
Hybrid (B4) 450...630
C1
355...400
C2
450...630
-
450...630
C3
710...800
-
710...800
D1
1000...1250
DIN pattern
NNS NES NNIT NTIA NTIS NOS NTSL00 NTCP NTFP 1) NTB NTBC NTC NTF NTKF NTKM NTMF NTSL3 NTM NTTM NTT NTLM NTLT NTXU
SN2
NS
SP
MES
SA2
NIT
SB3
TIA
SB4
TIS
SO
-
SD5
TCP
SD6
TFP
SE3/SE4 TB
SF3/SF4 TBC
SF5
TC
SF6
TF
SF7
TKF
SG7
TKM
SF8
TMF
SH8
TM
SH9
TTM
SY9
TT
SH10 TLM
SY10
TLT
SJ11
TXU
NS
NSD
N20C
3NW NS
ES
ESD
N63E
3NW ES
NIT
NITD
N20B
3NW NIT
TIA
AAO
N32B
3NW TIA
TIS
BAO
N63B
3NW TIS
OS
OSD
NOSD
3NW OS
TCP
CEO
N100B
3NW TCP
TFP
DEO
N200B
3NW TFP
TB
AC/BC
N_TB
3NW TB
TBC
AD/BD
N63B_
3NW TBC
TC
CD
N100B_C 3NW TC
TF
DD
N200B_C 3NW TF
TKF
ED
N315B_C 3NW TKF
TKM
EFS
N315B_C 3NW TKM
TMF
ED
N400B_C 3NW TMF
TM
EF
N404B_C 3NW TM
TTM
FF
N504B_C 3NW TTM
TT
FG
N630B_C 3NW TT
TLM
GF
N804B_C 3NW TLM
TLT
GG
B804B_C 3NW TLT
TXU
GH
N_U44 3NW TXU
00
6...160
1
25...250
2
80...400
3
315...800
Fuse holders
N00
NH00
-
N1
NH01
-
N2
NH02
-
N3
NH03
-
NHG-00
NH00G
-
NHG-1
NH1G
-
NHG-2
NH2G
-
NHG-3
NH3G
-
3NA5 3NA4 144 3NA4 260 3NA1
Clip-in
20A
32A
Front wired
20A
32A
63A
100A
200A
Stud/
20A
front wired
32A
11
63A 100A
200A
NV20FW NV32FW N20FW NC32FW NC63FW NC100FW NC200FW N20SFW NC32SFW NC63SFW NC100SFW NC200SFW
V20FF V32FF 20MFB 32MFB 63MFB 100MFB 200MFB 20MFD 32MFD 63MFD 100MFD 200MFD
200846 LCF63FCFC LCF32FCBC LCF63FCBC -
SC20H SC32H RSM20H RSM32H RSM63H RSM100H RSM200H RSM20PH RSM32PH RSM63PH RSM100PH RSM200PH
32NNSF -
FC20FW NC32FW FB20FW FB32FW FB63FW FB100FW FB200FW FB20SF FB32SF FB63SF FB100SF FB200SF
3NW 32NNSF 3NWCM20FC 3NW CM32F 3NW CM63F 3NW CM100F 3NW 200DF -
Note: 1) This hybrid type fuse is actually an A4 size fuse, but as it is over 100 amps it cannot be called an A4 fuse to AS 2005.
Q-Pulse Id: TMS1594
Active: 18/04/2016
Page 127 of 1068
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Fuse-link terminology NHP Compact fuses
HRC High rupturing capacity (HRC) or High breaking capacity denotes the ability of a fuse-link to interrupt extremely high fault currents, usually up to 80kA.
Current limiting fuse-link A fuse-link that limits the circuit current during it's operation to a value much lower than the peak value of the prospective current. In practice, the terms HRC and current limiting are synonymous.
Rated breaking capacity The highest value of fault current that a fuse-link has been tested to interrupt eg. 80kA.
Rated voltage The maximum system voltage that the fuse-link is designed to interrupt. Rated voltages may be in AC, DC, or both.
Current rating The value of current that a fuse-link will carry continuously without deterioration under specified conditions.
Minimum fusing current The minimum value of current that will cause melting of the fuse element.
Power dissipation The power released in a fuse-link carrying rated current under a specified condition, usually expressed in watts.
Time current characteristics (refer table 1) A curve detailing the pre-arcing or operating time as a function of prospective current.
Let through characteristics (I2t) (refer table 2) A curve or chart showing values `pre-arcing' and `operating' let through energies as a function of prospective current, I2t is proportional to energy in Amp2 seconds.
Cut off characteristics (refer table 3) A curve detailing the cut off current as a function of prospective current. Cut off current being the maximum instantaneous value of current let through by the fuse-link during operation.
Discrimination (refer tables 4 and 5) Discrimination is the ability of fuse-links to operate selectively and to disconnect only the parts of the circuit that are subject to faults. Discrimination can be checked by ensuring that the time current characteristics, including their tolerances, do not overlap at any point and that the total let through energy (I2t) of the downstream (or minor) fuse-link does not exceed the pre-arcing energy (I2t) of the upstream (or major) fuse-link at the applied system voltage. Discrimination is normally achieved with the ratio of 1.6 between upstream and downstream fuses.
Table 1
Typical time current curves
Table 2
I2t
Fuse rating
Operating and pre-arcing I2t values
Table 3
Table 4
Cut off characteristics
Table 5
Discrimination achieved
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I2t characteristics
BS fuses I2t data
I2t characteristics Rating (amperes) 2 4 6 10 16 20 20M25 20M32 25 32 35 32M40 32M50 32M63 40 50 63 80 & 63M80 100 & 63M100 125 & 100M125 160 & 100M160 200 & 100M200 250 & 200M250 315 & 200M315 355 400 & 315M400 450 500 560 630 710 800 1000 1250
I2t pre-arcing 2 10 34 188 92 155 574 574 826 826 1200 2482 3305 5875 2482 3305 5875 7800 14000 30000 58500 120000 210000 270000 365000 480000 755000 1100000 1200000 1550000 1903565 3820349 7000000 12000000
I2t total @ 240 volts 2 15 52 289 211 355 1084 1561 1084 1561 2400 4416 5879 10452 4416 5879 10452 15500 28000 51000 99000 205000 360000 460000 620000 820000 1300000 1850000 2400000 3100000 2992861 6006505 1500000 20500000
I2t total @ 415 volts 4 21 74 408 412 690 1809 2605 1809 2605 4100 7019 9345 16612 7019 9345 16612 26000 46000 75500 145000 300000 530000 680000 915000 1200000 1900000 2700000 4000000 5150000 4306813 8643534 16000000 30000000
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Fuse curves
BS fuse curves
NHP Compact BS fuses from 20 to 250 amps
CUT-OFF CURRENT PEAK kA
8
6
630 560
500
4
450 400
355
315
250
200
2
160
125
100
10
80
8
63
6
50
40
4
32
2
20
1 8 6
4
2
0.1 0.1
2
4 6 81
2
4 6 8 10
2
4 68
PROSPECTIVE CURRENT kA (R.M.S. SYMMETRICAL)
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Fuse curves
BS fuse curves
NHP Compact BS fuses from 80A to 630 amps (including motor rated fuses)
TIME (SECONDS)
10000 6 4
2
1000 6 4
2
100 6 4
2
10 6 4
2
1 6 4
2
0.1 6 4
2 0.01
100 2
FUSE RATING (A)
80 & 63M80 100 & 63M100 100SOM125
125 & 100M125 160 & 100M160 200 & 100M200 250 & 200M250 315 & 200M315 355 400 & 315M400 450 500 560 630
4 6 8 1000 2
4 6 8 10000 2
CURRENT (AMPERES)
4 68
NHP Compact BS fuses cut-off current data from 80 to 630 amps
Q-Pulse Id: TMS1594
CUT-OFF CURRENT PEAK kA
8
6
630
560
500
450
4
400
355
315
250
200
2
160
125
100
10
80
8
6
4
2
1 8 6 4
2
0.1 0.1
2
4 6 81
2
4 6 8 10
2
4 68
PROSPECTIVE CURRENT kA (R.M.S. SYMMETRICAL)
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DIN fuses curves and data DIN fuses curves and data
NHP Compact DIN fuses Pre-arcing and Total I2t energies, from 6 to 630 amps
NHP Compact DIN fuses cut-off current data from 6 to 500 amps
NHP Compact DIN fuses Fuse curves from 6 to 630 amps
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Detailed Specifications for ERICO's
TDS-DINLINE SURGE DIVERTER TDS180-4S
Applications
Features
Lightning transients and surges are a major cause of expensive electronic equip- · Robust against abnormal over-voltage
ment failure and business disruption. Damage may result in loss of computers,
data and communications, loss of revenue, and loss of profits. The new TDSDINLINE family of surge diverters and filters offer economical and reliable
· UL1449 Edition 2 compliant
protection from power transients in even the most strenuous applications.
· Single phase primary protection for
Transient Discriminating Technology (TDS) introduces the first quantum leap in transient suppression technology for mains powered equipment. It offers a new
medium exposure sites or secondary protection applications
level of safety and reliability, yet retains optimum protection levels critical for electronic equipment. TDS is an active frequency based device that discriminates between the slower mains voltages and the higher speed transients. When
· Single mode protection, configurable to Ph-N, Ph-E or N-E protection
transient frequencies are detected the patented TDS "Quick-Switch" technology "switches in" robust protection devices to limit the transient to safe levels. The frequency discrimination circuit controlling the TDS "Quick-Switch" ensures that
· 35mm DIN rail mount, DIN 43 880 profile matches common MCBs
the device is virtually immune to the effects of the 50/60Hz sustained overvoltages, allowing fault voltages of up to 480Vrms without degradation, and
· 72mm width compact design fits into
providing over-voltage robustness in excess of the demanding new and emerging
most switch and distribution boards
standards.
TDS technology is essential for any site where abnormal over-voltages can occur or where the possible catastrophic failure of traditional technologies due to over-
· Electronic status indicator ideal for poorly illuminated locations
voltage events can not be tolerated.
· Long Service life
The TDS180-4S unit provides this technology in a single mode shunt-only, 72mm
width module. Its unique design allows it to be configured for Ph-N or Ph-E or
· Optional retrofittable TDS Alarm
N-E applications.
Relay for remote alarms
Rated to a surge capacity of 80kA (8/20µs), internally 160kA of surge material is provided for additional robustness and to provide long service life. The unit is designed for sites with a medium risk of transients or for secondary protection applications. For the protection of high exposure sites or critical equipment higher surge rated TDS DINLINE units, or TDS MOVTECTM should be installed.
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TDS-DINLINE SURGE DIVERTER TDS180-4S
SPECIFICATIONS
100
Operation: Nominal input voltage
Input frequency Max. permissible abnormal over-voltage
Power systems Earth leakage current
Protection: Modes
Let through voltage @ 3kA 8/20µs Let through voltage @ 20kA 8/20µs
Surge rating 8/20µs Surge rating 10/350µs
Energy rating MultipulseTM capability Aggregate surge material Alarms and Indicators: Protection status indication
Alarm contacts Physicals:
Environmental rating Operating conditions
Enclosure style Dimensions (W x D x H)
Weight Encapsulation Enclosure material Surface finish Wiring terminals
Warranty Test standards:
Approvals
10
Surge rated to meet 1
0.1 1
20
1000
Number of Impulses
10000
220 -277 Vrms 50/60 Hz 480 Vrms TN-C, TN-S, TN-C-S (MEN), TT <2mA
Ph-N, Ph-E or N-E <720V <910V 80kA 16kA 3840J Yes 160kA 8/20µs
Two, electronic. On = OK User configurable, with optional TDS-AR
IP20 -35 to +55°C, 0-90% humidity DIN 43880 72 x 88 x 70mm 350g (approx.) Shockguard Flame Retardent UL94V-0 Spark eroded finish Accepts up to 6mm² 5 years
UL1449 Edition 2 AS 3260, IEC 950 Certificate of suitability, Electricity Regulator ANSI/IEEE C62.41-1991 Cat A, Cat B, Cat C. ANSI/IEEE C62.45-1987 Life cycle testing. AS/NZS 1768-1991 Cat A, Cat.B, Cat C. BS 6651:1992 Cat A, Cat B. IEC801-5 Installation Class 5. IEC 61643-1
Note: Other operating voltages and frequencies are available on application. For specifications on other DINLINE products, refer to relevant Specifications Sheet. Exceeding nominal operating voltage while transient events occur may affect product life.
TDS, MULTIPULSE, PROLINE, CRITEC, MOVTEC, DINLINE and SURGE REDUCTION FILTER are trademarks of ERICO.
Due to a policy of continual product development, specifications are subject to change without notice. © Copyright 1998
Model Number TDS180-4S-277
Description TDS 277V 80KA SURGE SUPPRESSOR
Impulse Magnitude (kA 8/20µs) TDS180.PM5 ISSUE 2.0
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DINLINE ALARM RELAY (DAR)
INSTALLATION INSTRUCTIONS
MODEL NUMBER DAR 275V
1. PREPARATION
DANGER: Electrical shock or burn hazard. Installation of this device should only be made by qualified personnel. Failure to lockout electrical power during installation or maintenance can result in fatal electrocution or severe burns. Before making any connections be sure that power has been removed from all associated wiring, electrical panels, and other electrical equipment.
CAUTION NOTES: 1. The installation of this device should follow all
applicable electrical codes, such as the National Electrical Code. 2. Check to make sure line voltage does not exceed DAR275V voltage ratings. 3. Follow all instructions to ensure correct and safe operation. 4. Do not attempt to open or tamper with the DAR in any way as this may compromise performance and will void warranty. No user serviceable parts are contained.
2. INTRODUCTION
Selected DSD, TDS & TDF DINLINE Surge Protection Devices include status monitoring circuits which provide visual status display of device capacity. They may also provide a low voltage opto-coupler alarm output circuit that can be connect to the DAR to provide potential free (Form C) change-over contacts. The DAR alarm contacts may be used to provide output to external alarm systems or remote monitoring circuits.
One DAR can be used per DSD/TDS/TDF opto-coupler alarm or up to 16 DSD opto-coupler alarms can be connected in series to the one DAR to provide a common output. It is recommended that the DAR be powered from the same power circuit that feeds the device(s) being monitored, however the DAR can be powered from other circuits. This allows for example, one DAR unit to be connected to separate SPDs that are protecting a three phase circuit.
Note. Depending upon the usage of the DAR output contacts, failure of power to the DAR may be interpreted as a failure of one or more of the SPDs being monitored. Visual inspection of the DAR and SPDs status displays would determine this. 3. MOUNTING
The DAR is designed to clip to 35mm (top hat) DIN rails (standard EN50022). Unless otherwise mechanically restrained, use horizontal DIN rails with the DAR module spring clips to the bottom and the label text the correct way up.
NOTE: The DAR must be installed in an enclosure or panel that:
· prevents the DAR temperature from exceeding
131°F (55°C)
· provides adequate electrical and safety protection
· prevents the ingress of moisture and water
· allows DAR status indicators to be inspected
4. ELECTRICAL CONNECTION
The interconnecting wiring should:
· be of size #10 to #14 AWG (2.5mm² to 6mm²) solid or stranded conductor.
· The wire insulation should be stripped back 5/16" (8mm).
· NOTE: Do not use greater than 9inlbs (1Nm) of torque when tightening the terminals.
CONNECTION TO TELECOMMUNICATIONS NETWORKS
The DAR is approved for use in Australia where the alarm contacts may be connected to private lines or building cabling associated with the telecommunications network. NO direct connection to the public switched network should be made.
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DINLINE ALARM RELAY
INSTALLATION INSTRUCTIONS
5. INTERCONNECTION
When connecting the DAR to a single opto-coupler output the + terminal of the SPD should connect to the + terminal on the DAR. The terminal should connect to the -- terminal.
To transient protected equipment
PhN E
DSD 2S/2T
Ph N
DAR
Voltage free contacts
Opto-coupler output
To remote alarm circuit
+/- terminal connections are polarity sensitive. Do not reverse.
When connecting the DAR to multiple opto-couplers the optocouplers should be connected in series with + terminal of one connected to the terminal of the next. The DAR + terminal should connect to + SPD terminal at one end of the series connection and the DAR terminal connect to the SPD terminal at the other end of the series connection.
Ph N E
PhN E
Ph N
DAR
Voltage free contacts
Up to 16 connections per DAR module
DSD 2S/2T
+/- terminal connections are polarity sensitive. Do not reverse.
5. STATUS INDICATION
STATUS DISPLAY
Protection Operational
Protection Alarm
Fault Mode
Normal
Normal
Normal
8
8
8
Fault
4 Fault
4 Fault
4
6
6
6
Normal operation
DSD in alarm mode or power Power to DAR removed to DSD has been removed Protection status unknown
EXPLANATION Normal (green) indicator ON Normal (green) indicator OFF Normal (green) indicatorOFF
Red indicator OFF
Red indicator ON
Red indicator OFF
Relay is energised
Relay is de-energised
Relay is de-energised
Power is supplied
Power is supplied
Power is OFF
6. FUSING AND ISOLATION
Overcurrent protection must be installed in the upstream circuit of the power supply to the DAR to provide protection to the unit itself and the wiring in case of fault conditions.
The fuse rating should be based on the wiring size used to connect to the DAR Ph & N terminals. Australian regulations AS3000-1991, Table B2 specifies the following upstream protection for single phase circuits, unenclosed in air.
Cable Size 1.5mm2 2.5mm2 4mm2 6mm2
HRC Fuse or 16A 20A 25A 32A
CB Rewirable Fuse 12A 16A 20A 25A
Where overcurrent protection of the appropriate rating or smaller is already fitted in the upstream circuit, overcurrent protection at the DAR will not be required
6. MAINTENANCE & TESTING
Before removing a DAR unit from service, ensure that the power has been removed. Maintenance, testing and replacement should only be undertaken by qualified personnel.
Testing of a DAR unit which is connected to a fully functional DSD unit can be accomplished by removing power to the DSD only. The DAR Status indication and output contacts should alter from the Normal to Fault condition.
Testing of the DAR unit alone may be accomplished by disconnecting the + / -connections to the unit. When power is applied the DAR "Fault" Status Indicator should be illuminated. By connecting the + / - terminals together, the "Normal" Status Indicator should be illuminated. The output contacts should alter to the appropriate state.
7. USE OF OTHER INTERFACES
Only DAR units are recommended for the interfacing of equipment to the DSD, TDS & TDF opto-coupler alarm output circuit(s). The direct connection of other equipment to these opto-coupler alarm outputs may not provide sufficient isolation or exceed the opto-coupler specifications. This may damage the SPD and/or the connected equipment. Warranty may be voided under such circumstances.
NOTE: In connecting to the SPD opto-coupler alarm
output(s), do not reverse the +/- connections as
damage
may
o c c u r Btuongdelet/thweisrt(KaNLeps4p-asra6cmtimcthsora)l
Sfyuploer feu s i n g d e t asi lescLNE t i o n
8
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Detailed specifications for ERICO's
TRANSIENT DISCRIMINATING FILTER, TDF-10A SERIES
Applications
Features
Lightning transients and surges are a major cause of expensive electronic · Compact design fits into most distribution
equipment failure and business disruption. Damage may result in loss of
boards and motor control centres
computers, data commmunications, loss of revenue, and loss of profits.
The new Transient Discriminating FilterTM family of TVSS devices offer · High efficiency filtering - ideal for the
economical and reliable protection from power transients with the conven- protection of switched mode power
ience of easy installation on 35mm DIN rail mountings.
supplies from large dv/dt and di/dt transients
· Three modes of protection L-N, L-G, N-G
The TDF series has been specifically designed for process control applica-
tions to protect the switched mode power supply units on devices such as · 35mm DIN rail mount - DIN 43 880
PLC controllers, SCADA systems and motor controllers. Units are avail-
profile matches common MCB's
able for 3A, 10A and 20A loads and in a range of clamping voltages including 30V, 150V, 275V. The range is intended for use in conjunction · LED indication and opto-isolated output with ERICO's Universal Transient Barrier UTB's to provide a coordinated for remote status monitoring
approach to protection of both the power and data control circuits.
· Transient Discriminating Technology
ensures safe operation during abnormal
The TDF is a series connected single phase surge filter providing an aggregate surge capacity of 50kA (8/20µs) - 20kA L-N & L-G and 10kA N-G. The space efficient low pass filter, provides some 65dB of attenua-
over-voltage events · UL1449 Edition 2 recognized
tion to voltage transients. Not only does this reduce the residual let through voltage, but it helps further reduce the steep rates of rise of voltage and current providing superior protection for sensitive electronic equipment.
· Large 50kA surge capacity provides a high level of protection and long operational life
· 5 year limited warranty
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PROCESS CONTROL TVSS PROTECTION
SPECIFICATIONS
Operation: Models available
Nominal line voltage
Max Continuous Operating Voltage MCOV
Max Load Current
Input frequency
Earth leakage current
Protection:
Max aggregate surge rating
Protection modes
Max surge current/mode L-N
L-G
N-G
SPD circuit description
Filter: Inductor Capacitor type
Attenuation @100kHz L-N Performance:
UL1449 SVR L-N ANSI/IEEE C62.41 Cat B3 - 500A ringwave
Cat C1 - 3kA, 8/20µs Alarms and Indicators: Protection status indication
Physical Data: Dimensions(W x D x H)
Weight Enclosure material Connection means
Wire size Mounting method
Enclosure style Environmental rating Opearting temperature
Humidity Surface finish
Warranty Test standards:
Approvals
Surge rated to meet
TDF-10A-120V 120VAC/125VDC 170Vrms 10A 50/60Hz <0.2mA
TDF-10A-240V 240VAC 340Vrms
50kA 8/20µs L-N, L-G and N-G 20kA 8/20µs 20kA 8/20µs 10kA 8/20µs Series low pass LC filter
Transient Discriminating Technology
Thermal fusing
Ferrite cored X & Y grade interference suppression polypropylene film 65dB
500V 22V 262V
700V 28V 481V
Red LED, On = OK. Opto-isolated output
144mm x 88mm x x70mm 750g (approx) Flame Retardant UL94V-O Screw terminals 1.0mm2 - 6.0mm2 DIN T35 Rail DIN 43880 IP20 -30oC to +55oC 0-90% Spark eroded finish 5 years
UL1449 Ed 2, UL1283 recognised, CSA22.2 C-Tick AS3260 ANSI/IEEE C62.41 Cat A, Cat B, Cat C AS/NZS 1768-1991 Cat A, B, C
Part Number Description TDF-10A-120V 120V 1 phase, 50kA 8/20µs, 10A series TVSS protector TDF-10A-240V 240V 1 phase, 50kA 8/20µs, 10A series TVSS protector
tdf10a.pm5
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual J & P Richardson Industries Pty Ltd
1.6. RTU & RADIO KINGFISHER BA-6 RTU Backplane (6 Slot) KINGFISHER PS-22 Power Supply KINGFISHER CP-12 Processor Module KINGFISHER DI-5 16 Channel Digital Input Module KINGFISHER DO-1 8 Channel Digital Output Module KINGFISHER IO-3 Mixed I/O Module RADTEL MIRI AD2006 - Radio
C63100-WB065_Manual_DRAFT.doc Revision 0
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Kingfisher PLUS+
Modular RTU Hardware Reference Manual 7.12
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Document Information
Document Control
Copyright Intellectual Property
Licence
Copyright CSE-Semaphore (Australia) Pty Ltd. ABN 35 006 805 910 www.cse-semaphore.com/mykingfisher, info.kingfisher@cse-semaphore.com
CSE-Semaphore asserts ownership of the intellectual property contained herein and claims copyright and authorship. CSE-Semaphore has and retains all rights of ownership and use of the material herein in its on-going business.
This document is provided to the intended recipient(s) under a non-exclusive licence. This licence permits Fair Use of the document for operational requirements, without payment of further royalty or licence fee. Fair Use includes making copies of the document for operational, backup and archive purposes. Fair Use includes distributing copies of the document to other entities for the purposes of their performing related works for the intended recipient(s). Fair Use does not include creating, selling or distributing copies of the document for other purposes. All copies must retain this statement of Intellectual Property and Copyright.
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Revision History
Version Number
6.11
7.0 7.1 7.12
Date
Summary
2/10/2010 28/10/2011
Added PSU-4 power supply (higher power version of the PSU-3). PS-xx temperature sensor wires are now red with a black stripe. Added PS-22, IO-5 and MC-31 modules
Update: adaptor ADP-22B (include Wavecom extend) Update: temp sensor is white / white with a black strip Update: power requirements of T option board Update: power calculation tables Update: Comms option boards selection table Update: safety warnings Update: Lenses for PS-12 and PS-22 Update: Lens for MC-31 Proposed `Linked Backplane Example' chapter removed Update: Various errors found in first release Added CP-12 power consumption Added CP-30/MC-30/MC-31 to compatibility chapter Corrected compatibility chapter and added CP-12 Corrected various spelling and grammatical mistakes.
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Contents
1. INTRODUCTION ................................................................................. 7 2. BACKPLANES ................................................................................... 8
2.1. MODULE DIMENSIONS...........................................................................................................................9 2.2. BA-4-PLUS: 4 SLOT BACKPLANE ...........................................................................................................10 2.3. BA-4-PLUS EXTERNAL CONNECTIONS ....................................................................................................11 2.4. BA-40-PLUS: 4 SLOT BACKPLANE .........................................................................................................12 2.5. BA-40-PLUS EXTERNAL CONNECTIONS...................................................................................................13 2.6. BA-6-PLUS: 6 SLOT BACKPLANE ...........................................................................................................14 2.7. BA-6-PLUS EXTERNAL CONNECTIONS ....................................................................................................15 2.8. BA-12-PLUS: 12 SLOT BACKPLANE .......................................................................................................16 2.9. BA-12-PLUS EXTERNAL CONNECTIONS...................................................................................................17 2.10. LINKING BACKPLANES ..........................................................................................................................18 2.11. RACK SLOT NUMBERING ......................................................................................................................19 2.12. BACKPLANE DIP SWITCH SETTINGS .........................................................................................................20 3. POWER SUPPLY MODULES ............................................................... 21 3.1. PS-12 POWER SUPPLY MODULE ............................................................................................................22 3.2. PS-22 POWER SUPPLY MODULE............................................................................................................31 3.3. PSU-3: 40 WATT AC POWER SUPPLY UNIT .............................................................................................39 3.4. PSU-4: 40 WATT AC POWER SUPPLY UNIT .............................................................................................42 3.5. CALCULATING POWER REQUIREMENTS ....................................................................................................45 3.6. 5 V RAIL OVERLOAD CHECK ..................................................................................................................47 3.7. TOTAL POWER LOAD ...........................................................................................................................49 3.8. BATTERY BACKUP ...............................................................................................................................50 4. PROCESSOR MODULES.................................................................... 51 4.1. PC-1: POWER & PROCESSOR MODULE....................................................................................................53 4.2. CP-12 PROCESSOR MODULE ................................................................................................................59 4.3. CP-30: HIGH PERFORMANCE PROCESSOR MODULE....................................................................................64 5. COMMUNICATIONS MODULES ........................................................... 69 5.1. MC-12 COMMUNICATIONS MODULE .....................................................................................................70 5.2. MC-31 COMMUNICATIONS MODULE .....................................................................................................74 6. COMMUNICATIONS OPTION BOARDS ................................................. 78 6.1. OPTION BOARD I: ISOLATED SERIAL .........................................................................................................79 6.2. OPTION BOARD F: FIBRE OPTIC SERIAL BOARD ..........................................................................................82 6.3. OPTION BOARD D: 33.6 KBPS DIAL OPTION BOARD...................................................................................83 6.4. OPTION BOARD L: LINE/ANALOGUE RADIO INTERFACE ................................................................................85 6.5. OPTION BOARD H: HART INTERFACE......................................................................................................90 6.6. OPTION BOARD T3: 10/100 ETHERNET CONTROLLER.................................................................................93 6.7. OPTION BOARD A3:FIBRE OPTIC ETHERNET..............................................................................................93 6.8. OPTION BOARD R2: AUSTRALIAN SPREAD SPECTRUM RADIO ........................................................................94 6.9. OPTION BOARD R3: INTERNATIONAL SPREAD SPECTRUM RADIO ....................................................................96 6.10. OPTION BOARD R4: US/CANADA SPREAD SPECTRUM RADIO........................................................................98 7. PC-1 OPTION BOARDS ....................................................................100 7.1. PC-1 SERIAL OPTION BOARD ..............................................................................................................100 7.2. PC-1 MODEM BOARD PL: TWO WIRE LINE............................................................................................101
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7.3. PC-1 MODEM BOARD: ANALOGUE RADIO INTERFACE ...............................................................................102 8. COMPATIBILITY ..............................................................................103
Communications Option Boards ...........................................................................................................103 9. ANALOGUE INPUT MODULES ...........................................................104
9.1. AI-1: 8 CHANNEL ANALOGUE CURRENT INPUT MODULE............................................................................105 9.2. AI-10: 8 CHANNEL HIGH IMPEDANCE ANALOGUE INPUT MODULE ...............................................................110 10. ANALOGUE OUTPUT MODULE........................................................115 10.1. AO-3: ANALOGUE OUTPUT MODULE....................................................................................................115 11. DIGITAL INPUT MODULES .............................................................120 11.1. DI-5: DC INPUT 16 CHANNEL DIGITAL INPUT MODULE .............................................................................121 12. DIGITAL OUTPUT MODULES ..........................................................130 12.1. DO-1: 8 CHANNEL ISOLATED RELAY OUTPUT MODULE .............................................................................132 12.2. DO-2: 16 CHANNEL RELAY OUTPUT MODULE ........................................................................................136 12.3. DO-6: 16 CHANNEL OPEN DRAIN OUTPUT MODULE................................................................................140 13. RELAY EXPANSION BOARDS..........................................................144 13.1. TEL REL 002: SPST RELAY BOARD ......................................................................................................145 13.2. TEL REL 003: SPST RELAY BOARD ......................................................................................................149 13.3. TEL REL 004: DPDT RELAY BOARD ....................................................................................................153 14. COMBINATION IO MODULES..........................................................157 14.1. IO-2: COMBINATIONAL DIGITAL IO MODULE..........................................................................................158 14.2. IO-3: COMBINATIONAL ANALOG/DIGITAL IO MODULE .............................................................................162 14.3. IO-4: COMBINATIONAL ANALOGUE / DIGITAL IO MODULE ........................................................................170 14.4. IO-5: COMBINATIONAL ANALOGUE / DIGITAL IO MODULE ........................................................................177 15. ADAPTORS AND CABLES ..............................................................184 15.1. RTU TEST CABLES ............................................................................................................................186
RJC-X-Over: Kingfisher PLUS RJ45 to RH45 RS232 Null Modem Cable (serial crossover) .........................186 RJC-X-Over-E: Kingfisher PLUS+ RJ45 to RJ45 Ethernet Crossover Cable .................................................186 15.2. DEVICE CABLES AND ADAPTORS ...........................................................................................................187 ADP-04: PC-1/MC-1 Radio Port to Tait T2010 or Maxon RDM-01 Radio (SD125)....................................187 ADP-05: RTU Serial Port to PC Serial Port (Creates a null modem cable) ................................................187 ADP-07: RTU Serial Port to External PSTN Modem ................................................................................188 ADP-08: RJ45 to DB9 Female Converter (Straight Connect)....................................................................188 ADP-08-M: Serial Port to Digi External Spread Spectrum Radio .............................................................189 ADP-09: Serial Port to HITECH or Nematron Display Panel ....................................................................189 ADP-16: Serial Port to Trio D-Series Radio or Trio E Series Radio............................................................190 RJC-ADP-17: PC-1/MC-1 Radio Port to Trio S- Series Radio ....................................................................190 RJC-ADP-18: CP-xx Line Option Board to Maxon Analogue Radio (Maxon SD-125).................................191 RJC-ADP-20: CP-xx Line Option Board to Trio S Series Analogue Radio ...................................................192 RJC-ADP-21: CP-xx Line Option Board to Tait T2010 Analogue Radio .....................................................193 RJC-ADP-22B: Serial Port to Wavecom GSM..........................................................................................194 RJC-ADP-23: PC-1/MC-1 Radio Port/Serial Port to Trio S- Series (SB) Repeater.......................................195 RJC-ADP-26: Serial Port to Maxon MM-6280IND 3G Data Modem.........................................................195 RJC-ADP-27: RTU Serial Port to Motorola 9522 Satellite Transceiver......................................................196 ADP-28: RTU Serial Port to Trio HSeries Spread Spectrum Radio ..........................................................196 ADP-29: Serial Port to Trio M Series Radio (with modem fitted) E.g. MR540 ..........................................197 RJC-ADP-30: CP-xx Line Option Board to Trio M Series Analogue Radio .................................................197 ADP-31: PC-1/MC-1 Radio Port to Trio M Series Analogue Radio (no modem fitted) E.g. MR540............198 CAB-FO-PATCH-1: A3 Ethernet MTRJ Fibre Optic to 2 × ST adaptor cable...............................................199
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CAB-FO-PATCH-2: A3 Ethernet MTRJ Fibre Optic to 2 × SC adaptor cable...............................................199 16. ACCESSORIES.............................................................................200 17. GLOSSARY .................................................................................203 18. APPENDIX...................................................................................204
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1. Introduction
A Kingfisher PLUS+ Remote Terminal Unit (RTU) is a highly configurable device that can monitor and control a wide range of equipment. This manual details the specifications for each type of module, option board, cable and accessory available for use with a Kingfisher PLUS+ Modular RTU. There are three types of Kingfisher PLUS+ modular RTUs identified by the processor module they contain: PC-1, CP-12 or CP-30
PC-1
CP-12
CP-30
Modular RTUs support up to 64 modules, 16 communications ports and 1008 IO (input/output) points. Each modular RTU has at least one backplane, a power supply and a processor module.
A PC-1 RTU is powered using an external AC/DC power supply. A PC-1 processor module is only used on a BA-4 PLUS backplane (4 slot).
A CP-12 or CP-30 RTU is powered using a power supply module (or modules) and utilizes one of three backplanes: a BA-40 PLUS (4 slot), a BA-6 PLUS (6 slot) or a BA-12 PLUS (12 slot).
IO (input/output) modules can be added to the RTU in any combination as required. To obtain more communications ports, one or more communications modules can be added to the RTU.
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2. Backplanes
Backplanes allow the processor module to communicate with the other modules in the RTU. The backplane also allows power to be supplied to each module. Multiple backplanes can be linked together to create an RTU with up to 64 modules. All backplanes can be surface mounted. BA-12 backplanes can also be mounted in a 19" rack. Backplanes are available in four versions:
BA-4 : 4 slot backplane for use with PC-1
BA-40 : 4 slot backplane
BA-6 : 6 slot backplane
BA-12 : 12 slot backplane
Note: the above part number is followed by -PLUS when the backplane uses the green Phoenix terminals for the inter-rack data connectors. A pair of Phoenix plugs can be obtained to create an inter-rack data cable. Use Phoenix Contact type Plug MC 1.5/7-ST-3.5 (1840418) or equivalent. Alternatively, data cables can be ordered from your Kingfisher supplier.
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2.1. Module Dimensions
Module is shown in backplane.
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2.2. BA-4-PLUS: 4 Slot Backplane
A BA-4 PLUS backplane is designed to be used with a PC-1 power and processor module. The PC-1 is installed in the left slot and any IO or communications modules can be installed in the other 3 slots.
Please use a BA-40 PLUS backplane if requiring a 4 slot backplane for use with a processor and PS-xx power supply. There are three (3) connectors at the far right of the backplane. There are two green 7-way connectors for linking backplanes together and there is one 6-way connector to supply power to a second linked backplane. The 4-slot backplane is designed for surface mounting. Mounting brackets (2 pieces) are supplied for user fitting.
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2.3. BA-4-PLUS External Connections
J14 Power Socket: J13 (in) and J15 (out) interrack Phoenix Data Sockets:
Orange SL9 Power Socket:
The SL9 connector is only present on the BA-4 PLUS backplane for use with the PC-1 Power Supply & Processor Module.
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2.4. BA-40-PLUS: 4 Slot Backplane
A BA-40 PLUS backplane is identical to a BA-4 PLUS backplane excepting the J5 (PC-1 lower connector) and SL-9 (PC-1 power) connectors have been removed. A BA-40 PLUS is designed to be used with a PS-xx power supply and a CP-xx processor module or linked to any other backplane to provide additional slots. There are three (3) connectors at the far right of the backplane. There are two green 7-way data connectors for linking backplanes together and there is one 6-way connector for external power (+5 V and +12 V DC) if a power supply module is not installed on the backplane. The 4-slot backplane is designed for surface mounting. Mounting brackets (2 pieces) are supplied for user fitting.
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2.5. BA-40-PLUS External Connections
J14 Power Socket: J13 (in) and J15 (out) interrack Phoenix Data Sockets:
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2.6. BA-6-PLUS: 6 Slot Backplane
The BA-6-PLUS six slot backplane is designed to support any power supply, IO or communications module in any slot position. A BA-6-PLUS is designed to be used with a PS-xx power supply and a CP-xx processor module or linked to any other backplane to provide additional slots. There are three (3) connectors at the far right of the backplane. There are two green 7-way data connectors for linking backplanes together and there is one 6-way connector for external power (+5 V and +12 V DC) if a power supply module is not installed on the backplane. This backplane is designed for surface mounting. Mounting brackets (2 pieces) are supplied for user fitting.
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2.7. BA-6-PLUS External Connections
J14 Power Socket: J13 (in) and J15 (out) interrack Phoenix Data Sockets:
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2.8. BA-12-PLUS: 12 Slot Backplane
TheBA-12-PLUS twelve slot backplane is designed to support any power supply, IO or communications module in any slot position. A BA-12-PLUS is designed to be used with a PS-xx power supply and a CP-xx processor module or linked to any other backplane to provide additional slots. There are three (3) connectors at the far right of the backplane. There are two green 7-way data connectors for linking backplanes together and there is one 6-way connector for external power (+5 V and +12 V DC) if a power supply module is not installed on the backplane. This backplane is designed for surface mounting. Mounting brackets (2 pieces) are supplied for user fitting. Mounting in a 19" rack may be achieved using the alternative MBR-3 rack mounting brackets.
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2.9. BA-12-PLUS External Connections
J14 Power Socket: J13 (in) and J15 (out) interrack Phoenix Data Sockets:
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2.10. Linking Backplanes
Backplanes can be linked together into `racks'. Each rack can have a maximum of 16 slots. Below is a full rack consisting of a BA-40 PLUS linked to a BA-12-PLUS.
Each backplane has an IN and an OUT connector linking it to the RTU data bus. The connector used (J13 or J15) varies according to the revision number of the backplane. A single RTU can support up to 4 racks providing a total of 64 modules slots. Each backplane has data bus terminators (resistors) that can be switched ON or OFF. A chain of backplanes requires the terminators to be switched ON for the first and last backplane in the chain as detailed below. Intermediate backplanes must have terminators switched OFF.
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2.11. Rack Slot Numbering
Backplanes have hard-coded Slot Numbers that can be set to four different ranges that determine the Rack Number. The BA-4 PLUS and BA-6-PLUS backplanes occupy the start of each rack, while the BA-4 PLUS (and BA-40 PLUS) occupies the later address space of each rack. Each backplane has an IN and OUT connector linking it to the data bus, and termination resistors that can be toggled ON and OFF via DIP switches. Linked backplanes that use the same address space (by default) must be set to different rack numbers to avoid clashes. Users should be mindful of these settings.
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2.12. Backplane DIP Switch Settings
The following table outlines the DIP switch configuration required for the most recent hardware revisions (2.1, 2.2 and 3.2).
For previous hardware versions please refer to the superseded hardware manual available on MyKingfisher.
Switch Settings
1 Rack
Total Number of Racks in RTU
2 Racks
3 Racks
4 Racks
1st Rack
2nd Rack
3rd Rack
4th Rack
Note that supplementary to the data bus connection, each backplane requires a Power Supply Module or a power cable connected to J14.
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3. Power Supply Modules
The Kingfisher Power Supply Modules allow real time monitoring of currents, voltages and temperatures supplied to the RTU and the backup battery. The monitoring capability also allows the RTU to determine when a supply has failed if in a redundant configuration. If fitted, auxiliary supplies can be overridden manually or by logic to allow for external equipment or sensor loops to be shut down or reset. The two following modules are the current hardware revision. For previous generations of Power Supply Modules, please refer to the superseded Hardware Manual available on MyKingfisher.
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3.1. PS-12 Power Supply module
· Monitoring of rail voltages, supply & battery currents and temperature · AC or DC input · Support for redundancy (several supplies per backplane) · Isolated DC output · Sealed Lead Acid battery connection with charging/monitoring and low voltage
protection · Software controlled power to the Backplane and Aux Outputs
The PS-12 provides AC/DC conversion into 12 VDC and 5 VDC for the backplane, as well as 12 VDC and optional 24 VDC auxiliary outputs. Both auxiliary outputs can be controlled by the RTU logic configuration.
The PS-12 is supplied with internal temperature sensor to monitor its PCB temperature and an optional external temperature sensor to monitor an attached battery. When a backup battery is connected, the supplied external sensor should be mounted as close as possible to the negative terminal of the battery to ensure correct temperature compensation. If readings from the external sensor are out of range, internal sensor data is used. Please note the charge circuitry is designed for float operation and short term boost of batteries already charged and in good condition. Use of this supply on flat or fully discharged batteries may cause damage to the module.
The Rail Voltage, Supply Current, Battery Current, internal and, optionally, external temperature monitoring circuits enable the RTU to monitor and to control all functions of the PS-12 module. The Processor Module has access to many of these values as analog and digital points in the system.
If the Mains supply fails and the system is powered from the backup battery, the PS-12 enters Low Battery Shutdown when battery voltage drops below 10.6 V. All outputs are switched OFF for battery preservation, including Backplane power as well effectively meaning that the whole RTU will be shut down. PS-12 switches itself to the lowest power consumption mode possible, further preserving the battery from deep discharge. PS-12 checks rail voltage regularly, and the Backplane power will be restored when +12V_RAIL voltage rises above 12.4 V (if no Mains present) or 11.5 V (if Mains present).
Besides various hardware protection features, PS-12 firmware provides additional protection from overload. If output power exceeds its maximum specified power, the SMPS will enter an Overload Mode. Its output voltage will be ramped down and, if overload still exists when it reaches 10.0 V (minimal output voltage), it will switch all outputs off, similar to Low Battery Shutdown. PS-12 will attempt to switch the Backplane ON again regularly. RTU power will be restored permanently when overload condition is removed.
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A power supply module can be installed in any I/O slot of a 4, 6 or 12 slot backplane. Several Power Supply modules of any type can be installed on a backplane thus providing redundant and alternative power source configurations.
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Fire Risks
A supply voltage outside the specified limits may cause fire.
Electrical Hazards
Only appropriately qualified and trained personnel can install and service this equipment. Mains Power must be connected in accordance with local national wiring rules and regulations. Building installation shall provide appropriate short-circuit backup protection. Always remove input mains voltage (by disconnecting power cord from the mains power outlet or by switching off an external circuit breaker, depending on installation) before performing any operation on this product. Failure to do so may cause fire and may result in a serious personnel injury or even death. Disconnect power cord from the Power Supply Module before wiring, removing or servicing.
Warning
The earth Terminals in the mains power inlet provide only FUNCTIONAL EARTH / Ground connection and cannot be relied upon for safety purposes.
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Battery Charging
Whenever the battery begins to draw more than 100 mA out of the power supply (e.g. when the power supply is first turned on or a battery is connected), the power supply assumes that a fully discharged backup battery just has been connected and starts its Boost charge. After Boost charging the battery for the estimated time (3-10 hours, see below for details, BATT DET and BATT BST LEDs ON), the power supply will switch to Float charging (BATT DET and BATT FLT LEDs ON).
PS-12 also maintains estimated capacity of the connected Sealed Lead Acid battery and this value is provided to the system Processor Module. For the algorithm to work properly, a correct battery capacity should be provided to the PS-12 via the Toolbox / RTU configuration setup. When battery is initially detected, it is assumed to be fully discharged. Boost charging time mentioned earlier is calculated based on the provided battery capacity value. Estimated battery capacity is increased by integrating measured current flowing into the battery over the time till it reaches the stated battery capacity. When battery current becomes negative (for instance, if Mains power is out and the RTU runs from the battery), this current is integrated over the time and subtracted from the estimated battery capacity till it reaches zero.
Please note that PS-12 cannot distinguish between the real battery connection and the connection of any other (generic) load or power source to the battery terminals, as it detects such connections only by measuring the Battery Current. As a result, all BATT LEDs may exhibit several various combinations depending on kind of load / source connected to the B terminals.
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Module LEDs
LED
OK
VIN
TX
RX
BATT DET BATT FLT BATT BST BATT SUPP BATT LOW OUT 12BP OUT 5BP OUT 12AUX OUT 24iAUX
OVLD
FAULT 12BP FAULT 5BP FAULT 12AUX FAULT 24iAUX
State
Description
OFF Module fault (no power)
Blinking No communications with RTU Processor Module
ON Normal
OFF Mains not present / SMPS not running
ON SMPS running 1
OFF No data being sent to Processor Module
ON The PS-12 is sending data to Processor Module via Backplane
OFF No data being sent by other modules
ON Any RTU module sends data via Backplane
OFF No battery nor load nor DC source connected to B terminals2
ON Battery or load or DC source connected to B terminals
OFF Battery is not in Float Charge mode
ON Battery is slow (float) charging
OFF Battery is not in Boost Charge mode
ON Battery is fast (boost) charging
OFF Battery does not supply current to the PS-12
ON Battery sources more than 0.1 A3 current to the PS-124
OFF +12V_RAIL voltage has risen above 12.4 V4
ON +12V_RAIL voltage has fallen below 11.5 V4
OFF Backplane power is switched OFF: either start-up or shutdown
ON Backplane power is switched ON
OFF Backplane power is switched OFF: either start-up or shutdown
ON Backplane power is switched ON
OFF 12VAUX is switched OFF
ON 12VAUX is switched ON
OFF 24ViAUX is switched OFF
ON 24ViAUX is switched ON
OFF PS-12 is not in Overload Mode
BLINKING In Overload Mode. Output voltage will be ramped down
OFF Backplane power is switched OFF or it is ON and 12VBP is above 9 V4
ON Backplane power is switched ON and 12VBP is below 9 V4
OFF Backplane power is switched OFF or it is ON and 5VBP above 2 V4
ON Backplane power is switched ON and 5VBP is below 2 V4
OFF 12VAUX is switched OFF or it is ON and above 9 V4
ON 12VAUX is switched ON and it is below 9 V4
OFF 24ViAUX is switched OFF or it is ON and above 18 V4
ON 24ViAUX is switched ON and it is below 18 V4
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PS-12 Specifications
AC Mains Input Rated Voltage Range DC Mains Input Rated Voltage Range Safety Isolation: Primary (Mains) to Secondary (Backplane, Field) Mains Inlet Connector Input Supply from B terminals Backup Battery Power Outputs
Output Power Filed Connector Monitoring
Operating Temperature
100 - 240 V, 50 - 60 Hz, 1.5 0.7 A
96 - 340 VDC, 2.0 0.5 A
3kVpeak In accordance with IEC 60950
7.62 mm pitch TB Plug (Phoenix PC4/3-ST-7.62) with optional Cable Housing Phoenix KGG-PC 4/3 Note. Phoenix PC4/3-G-7.62 Header mounted on the module's PCB
12.0-16.0 VDC
12 V Sealed Lead-Acid, 26 AH max. Note: Batteries exceeding 26 AH can be used. However, full charging and
estimated battery capacity value cannot be guaranteed.
Item
Range
Max.
Protection Switchable from
Current
Logic?
12 V
10.5 - 15.6 V 4.5 A
Firmware
No
Backplane #
5 V Backplane 5 V + 5%
3.0 A
Electronic
No
Battery #
10.5 - 15.6 V 4.5 A Crowbar over-
No
voltage and
reverse polarity
protection;
Polyfuse
12 V Aux.#
10.5 - 15.6 V 2.0 A
Polyfuse
Yes
24 V Isolated 24 V + 5% 0.25 A
Polyfuse
Yes
Aux.
# Nominal value is 13.8 V @ 25°C. These voltages are electrically linked and
are controlled by the module when charging a battery. They will depend
only on backup battery voltage when RTU runs from the battery (e.g. when
there is a Mains outage).
60 W max (Note: This is total power from all outputs)
5 mm pitch TB plug (Phoenix MSTB2.5/7-ST or similar)
Item
Range
Accuracy
Rail Voltage (12 VBP, Battery, 12 VAUX)
9.0 - 15.6 V
± 2%
Supply Current Battery: Supply Current from
Battery Charge Current to Battery
0.0 - 4.0 A -4.0 - 0.0 A 0.0 - +4.0 A
± 10% ± 10% ± 10%
External Temperature
-40 - +100 °C ± 2 °C typ @25 °C
Internal Temperature
-30 - +100 °C ± 2 °C typ @25 °C
-20 - +70 °C
Storage Temperature -40 - +85 °C
Humidity
5 - 98% RH non-condensing
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Maximum Working Voltage on any contact of the field connector (7pin TB)
42.4 Vpeak / 60 VDC relative to system (backplane) ground
Hot Swap
Yes. Module can be swapped while RTU is running, assuming that there is an alternative source for the RTU to be powered during such swap for instance, another (redundant) PS-xx.
1) May keep switching ON and OFF intermittently at very light or no load. 2) Short periodic flashes indicate that PS-12 is trying to detect connection. 3) Current value given to the Processor Module is negative 4) approximate values
Part Numbers:
PS-12-C AC input, Auxiliary 24 V converter fitted
PS-12-0 AC input, Auxiliary 24 V converter not fitted
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Wiring Diagrams
Safety Warning
Ensure power cord is un-powered before disconnecting power cord from module. Disconnect power cord from module before wiring, removing or servicing the module. Connect module to Mains supply in accordance with national wiring regulations. Mains connections of PS-12 must comply with all requirements listed in Kingfisher Plus+ Installation Manual AC/DC Supply with battery backup:
For best results tape or cable-tie the temperature sensor directly to the battery. Connect the black stripped wire to B- or R-.
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12 16 VDC Supply:
A battery or other low voltage DC supply can be connected to the B terminals to power the PS-12.
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3.2. PS-22 Power Supply Module
· Monitoring of rail voltage, supply & battery currents, and temperature
· DC input · Support for redundancy (several supplies per backplane) · Isolated DC Output · Sealed Lead Acid Battery connection with charging/monitoring and low voltage
protection · Software controlled power to the Backplane and Aux outputs
The PS-22 power supply module provides Medium Voltage DC to DC conversion for the backplane, 12V auxiliary output and for an optional 24V isolated auxiliary output. Both auxiliary outputs can be controlled (switched ON or OFF) by the RTU configuration.
The PS-22 is supplied with internal and optional external temperature sensors. When a backup battery is connected, the supplied external sensor should be mounted close to the negative terminal of the battery to ensure correct charging temperature compensated battery charging. If readings from the external sensor are out of range, internal sensor data is used. Please note the charge circuitry is designed for float operation and short term boost of batteries already charged and in good condition. Use of this supply on flat or fully discharged batteries may cause damage to the module.
The Rail Voltage, Supply Current, Battery Current, internal and, optionally, external temperature monitoring circuits enable the RTU to monitor and to control all functions of the PS-22 module. The Processor Module has access to many of these values as analog and digital points in the system.
If the Mains supply fails and the system is powered from the backup battery, the PS-22 enters Low Battery Shutdown when battery voltage drops below 10.6V. All outputs are switched OFF for battery preservation, including Backplane power as well effectively meaning that the whole RTU will be shut down. PS-22 switches itself to the lowest power consumption mode possible, further preserving the battery from deep discharge. PS-22 checks rail voltage regularly, and the Backplane power will be restored when +12V_RAIL voltage rises above 12.4 V (if no Mains present) or 11.5 V (if Mains present).
Besides various hardware protection features, PS-22 firmware provides additional protection from overload. If output power exceeds its maximum specified power, the SMPS will enter an Overload Mode. Its output voltage will be ramped down and, if overload still exists when it reaches 10.0 V (minimal output voltage), it will switch all outputs off, similar to Low Battery Shutdown. PS-22 will attempt to switch the Backplane ON again regularly. RTU power will be restored permanently when overload condition is removed.
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A power supply module can be installed in any I/O slot of a 4, 6 or 12 slot backplane. Several Power Supply modules of any type can be installed on a backplane thus providing redundant and alternative power source configurations
Fire Risks
A supply voltage outside the specified limits may cause fire.
Electrical Hazards
Only appropriately qualified and trained personnel can install and service this equipment. Mains Power must be connected in accordance with local national wiring rules and regulations. Building installation shall provide appropriate short-circuit backup protection. Always remove input mains voltage (by disconnecting power cord from the mains power outlet or by switching off an external circuit breaker, depending on installation) before performing any operation on this product. Failure to do so may cause fire and may result in a serious personnel injury or even death. Disconnect power cord from the Power Supply Module before wiring, removing or servicing.
Warning
The earth Terminals in the mains power inlet provide only FUNCTIONAL EARTH / Ground connection and cannot be relied upon for safety purposes.
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Battery Charging
Whenever the battery begins to draw more than 100 mA out of the power supply (e.g. when the power supply is first turned on or a battery is connected), the power supply assumes that a fully discharged backup battery just has been connected and starts its Boost charge. After Boost charging the battery for the estimated time (3-10 hours, see below for details, BATT DET and BATT BST LEDs ON), the power supply will switch to Float charging (BATT DET and BATT FLT LEDs ON). Note: if the battery charging current falls below 100 mA at any stage during Boost or Float charging, the Power Supply will stop charging the battery (BATT FLT and BATT BST LEDs OFF, BATT DET shortly flashes every second indicating that PS-22 is trying to detect battery).
PS-22 also maintains estimated capacity of the connected Sealed Lead Acid battery and this value is provided to the system Processor Module. For the algorithm to work properly, a correct battery capacity should be provided to the PS-22 via the Toolbox / RTU configuration setup. When battery is initially detected, it is assumed to be fully discharged. Boost charging time mentioned earlier is calculated based on the provided battery capacity value. Estimated battery capacity is increased by integrating measured current flowing into the battery over the time till it reaches the stated battery capacity. When battery current becomes negative (for instance, if Mains power is out and the RTU runs from the battery), this current is integrated over the time and subtracted from the estimated battery capacity till it reaches zero.
Please note that PS-22 cannot distinguish between the real battery connection and the connection of any other (generic) load or power source to the battery terminals, as it detects such connections only by measuring the Battery Current. As a result, all BATT LEDs may exhibit several various combinations depending on kind of load / source connected to the B terminals.
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PS-22 Module LEDs
LED
OK
VIN
TX
RX
BATT DET BATT FLT BATT BST BATT SUPP BATT LOW OUT 12BP OUT 5BP OUT 12AUX OUT 24iAUX
OVLD
FAULT 12BP FAULT 5BP FAULT 12AUX FAULT 24iAUX
State
Description
OFF Module fault (no power)
Blinking No communications with RTU Processor Module
ON Normal
OFF Mains not present / SMPS not running
ON SMPS running 1
OFF No data being sent to Processor Module
ON The PS-22 is sending data to Processor Module via Backplane
OFF No data being sent by other modules
ON Any RTU module sends data via Backplane
OFF No battery nor load nor DC source connected to B terminals2
ON Battery or load or DC source connected to B terminals
OFF Battery is not in Float Charge mode
ON Battery is slow (float) charging
OFF Battery is not in Boost Charge mode
ON Battery is fast (boost) charging
OFF Battery does not supply current to the PS-22
ON Battery sources more than 0.1 A3 current to the PS-224
OFF +12V_RAIL voltage has risen above 12.4 V4
ON +12V_RAIL voltage has fallen below 11.5 V4
OFF Backplane power is switched OFF: either start-up or shutdown
ON Backplane power is switched ON
OFF Backplane power is switched OFF: either start-up or shutdown
ON Backplane power is switched ON
OFF 12VAUX is switched OFF
ON 12VAUX is switched ON
OFF 24ViAUX is switched OFF
ON 24ViAUX is switched ON
OFF PS-22 is not in Overload Mode
BLINKING In Overload Mode. Output voltage will be ramped down
OFF Backplane power is switched OFF or it is ON and 12VBP is above 9 V4
ON Backplane power is switched ON and 12VBP is below 9 V4
OFF Backplane power is switched OFF or it is ON and 5VBP above 2 V4
ON Backplane power is switched ON and 5VBP is below 2 V4
OFF 12VAUX is switched OFF or it is ON and above 9 V4
ON 12VAUX is switched ON and it is below 9 V4
OFF 24ViAUX is switched OFF or it is ON and above 18 V4
ON 24ViAUX is switched ON and it is below 18 V4
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PS-22 Specifications
DC Mains Input Rated Voltage Range Isolation: Primary to Secondary DC Inlet Connector
20 - 60 VDC, 4.0 A
3 kVpeak In accordance with IEC 60950 7.62 mm pitch TB Plug (Weidmuller BLZ 7.62/90-3 or Phoenix GMSTBA 2.5/3-G-7.62 or similar) Note. Weidmuller SL 7.62/90B-3 or Phoenix GMVSTBR 2.5/3-ST-7.62 or similar Header mounted on the module's PCB
Input Supply from B terminals Backup Battery
Power Outputs
12.0-16.0 VDC
12 V Sealed Lead-Acid, 26 AH max. Note: Batteries exceeding 26 AH can be used. However, full charging and
estimated battery capacity value cannot be guaranteed.
Item
Range
Max.
Protection Switchable from
Current
Logic?
12 V Backplane # 10.5 - 15.6 V 4.5 A
Firmware
No
5 V Backplane # 5 V + 5%
3.0 A
Electronic
No
Battery #
10.5 - 15.6 V 4.5 A Crowbar over-
No
voltage and
reverse polarity
protection;
Polyfuse
Output Power Filed Connector Monitoring
Operating Temperature
12 V Aux.#
10.5 - 15.6 V 2.0 A
Polyfuse
Yes
24 V Isolated Aux. 24 V + 5% 0.25 A
Polyfuse
Yes
# Nominal value is 13.8 V @ 25°C. These voltages are electrically linked and
are controlled by the module when charging a battery. They will depend only
on backup battery voltage when RTU runs from the battery (e.g. when there is
a Mains outage).
60 W max (Note this is total power from all outputs)
5 mm pitch TB plug (Phoenix MSTB2.5/7-ST or similar)
Item Rail Voltage (12 VBP, Battery, 12 VAUX)
Range 9.0 - 15.6 V
Supply Current Battery: Supply Current from Battery
Charge Current to Battery
0.0 - 4.0 A -4.0 - 0.0 A 0.0 - +4.0 A
External Temperature Internal Temperature
-40 - +100 °C -30 - +100 °C
-20 - +70 °C
Accuracy + 2%
+ 10% + 10% + 10% + 2 °C typ @25 °C + 2 °C typ @25 °C
Storage Temperature -40 - +85 °C
Humidity
5 - 98% RH non-condensing
Maximum Working
42.4 Vpeak / 60 VDC relative to system (backplane) ground
Voltage on any contact
Hot Swap
Yes. Module can be swapped while RTU is running, assuming that there is an alternative source for the RTU to be powered during such swap for instance, another (redundant) PS-xx.
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1) May keep switching ON and OFF intermittently at very light or no load. 2) Short periodic flashes indicate that PS-22 is trying to detect connection. 3) Current value given to the Processor Module is negative 4) approximate values Part Numbers: PS-22-C DC input, Auxiliary 24 V converter fitted PS-22-0 DC input, Auxiliary 24 V converter not fitted
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Wiring Diagrams
Safety Warning
Ensure power cord is un-powered before disconnecting power cord from module. Disconnect power cord from module before wiring, removing or servicing the module. Connect module to Mains supply in accordance with national wiring regulations. Mains connections of PS-22 must comply with all requirements listed in Kingfisher Plus+ Installation Manual
AC/DC Supply with battery backup:
For best results tape or cable-tie the temperature sensor to the negative battery terminal (or as close as possible). Connect the black stripped wire to B- or R-.
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12 16 VDC Supply:
A battery or other low voltage DC supply can be connected to the B terminals to power the PS-22.
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3.3. PSU-3: 40 Watt AC Power Supply Unit
· AC input supply · 40 Watt DC output The PSU-3 AC to DC power supply is intended as a standalone unit to provide 13.8 VDC (adjustable) typically for PC-1 based RTUs. The PSU-3 does not have any power monitoring functions. Power monitoring is performed by the PC-1 processor module. Specifications:
Input Supply 90 to 260 VAC 50/60 Hz Load Capacity 40 W
Outputs +13.8 VDC @ 2.8 A Isolation 2.5 kV AC input/DC output Supply Fuse 3 A, M205 internal Monitoring Circuits Nil Status Indicators Nil Connector Screw Terminals
Weight 430 gm
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Fire Risks
A supply voltage outside the specified limits may cause fire.
Electrical Hazards
Only appropriately qualified and trained personnel can install and service this equipment. Disconnect power cord from the Power Supply Module before wiring, removing or servicing.
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PSU-3 Block Diagram Mounting and Connections
PSU-3 Output Characteristics
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3.4. PSU-4: 60 Watt AC Power Supply Unit
· AC Input Supply · 60 Watt DC Output The PSU-4 AC to DC power supply is intended as a standalone unit to provide 13.8 VDC (adjustable) typically for PC-1 based RTUs. The PSU-3 does not have any power monitoring functions. Power monitoring is performed by the PC-1 processor module. Specifications:
Input Supply 90 to 260 VAC 50/60 Hz Load Capacity 60 W
Outputs +13.8 VDC @ 2.8 A Isolation 2.5 kV AC input/DC output Supply Fuse 3.15 A, M205 internal Monitoring Circuits Nil Status Indicators Nil Connector Screw Terminals
Weight 480 gm
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Fire Risks
A supply voltage outside the specified limits may cause fire.
Electrical Hazards
Only appropriately qualified and trained personnel can install and service this equipment. Mains Power must be connected in accordance with local national wiring rules and regulations. Building installation shall provide appropriate short-circuit backup protection. Always remove input mains voltage (by disconnecting power cord from the mains power outlet or by switching off an external circuit breaker, depending on installation) before performing any operation on this product. Failure to do so may cause fire and may result in a serious personnel injury or even death. Disconnect power cord from the Power Supply Module before wiring, removing or servicing.
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PSU-4 Block Diagram
Mounting and Connections
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3.5. Calculating Power Requirements
This chapter aims to assist you in selecting an appropriate power supply module/s and backup battery for your RTU. It also allows the power requirements of the RTU to be checked to ensure the power supplies are not overloaded.
Note that there is a spreadsheet available from MyKingfisher (called "Kingfisher RTU Backup Battery and Solar Panel Calculator") that can perform the following calculations automatically.
PS-22 Typical current consumption at various DC voltages (mA)
Input Voltage 20 V 40 V 60 V
Basic Module, no options 34
20
19
24 VDC Aux Converter Installed 49
27
25
PS-12 Typical efficiency at various AC supply voltages
Input Voltage 100 V Efficiency 85%
Note: No DC-DC converter installed
170 V 87%
240 V 88%
Processor Modules current consumption (mA at 13.8 VDC)
Item CP-12 CP-30 Basic Module, no options 140 135
PC-1 Typical current consumption (mA at 13.8 VDC)
Bare Module
54
24 V Aux Converter Installed
+53
Option S Board Installed
59
Option R Board Installed
62
Option P Board Installed
59
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IO Module typical current consumption (mA at 13.8 VDC)
Part number
AI-1 AI-10 AO-3 DI-5 DI-10 DO-1 DO-2 DO-5/6 IO-2 IO-3 IO-4 IO-5
24 V Converter
OFF
11 25 5 23 40 7 7 3 5 10 8 TBA
24 V Converter
ON
80 185 180
-53 44 TBA
Extra current per Analogue
Input ON +50 [+0] +62 [+3]
+46 [-1] +44 [-2] TBA
Extra current per Analogue
Input OFF -
+50 -
+42 -
TBA
Extra current per Digital Input ON +7 [+2] +11 [+5] +7 [+3] +10 [+1] +9 [+1] TBA
Extra current per Digital Input OFF +31 +13 +1 +12 +12 +12 TBA
Absolute Max current draw
480 681 380 135 216 255 215 19 157 367 228 TBA
Note: Values shown are for inputs powered by the IO module itself when power is available from the 13.8 VDC supply. Values in square brackets `[ ]' denote current consumption when inputs re powered by an external supply.
Communications Modules current consumption (mA at 13.8 VDC)
Item MC-12 Basic Module, no options 140
MC-31 135
For Communications Option Boards please refer to the 5 V Rail Overload Check chapter. Superseded Communications Modules current consumption (mA at 13.8 VDC)
Item Basic Module, no options
MC-11 165
MC-30 165
Superseded IO Module typical current consumption (mA at 13.8 VDC)
AO-2
11
115
-
+55
-
-
335
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3.6. 5 V Rail Overload Check
The PS-12 and PS-22 modules supply 5 VDC to the backplane for powering modules. A maximum of 3 Amps can be drawn on the 5 VDC rail from each power supply module.
Please ensure that this limit us not exceeded by totaling the 5 V current requirements for your RTU.
CP-xx and MC-xx typical 5 V Rail current consumption (mA at 5 VDC)
CP-11 310
CP-12 150
CP-21 360
CP-30 290
MC-11 / MC-30 370
MC-xx CP-xx Option Board typical 5 V Rail consumption (mA at 5 VDC)
Option Board Type
A3 Fibre Optic Ethernet Board Dial (PSTN)
Fibre Optic Serial HART
Isolated Serial (RS232) Private Line or Analogue Radio Interface 2.4 GHz (50 mW) Spread Spectrum Radio:
Transmitting Receiving
900 MHz (1 W) Spread Spectrum Radio: Transmitting Receiving
T3 Ethernet Option Board
Port label A3 D F H I L
R3
R2 / R4
T3
Consumption 600 165 40 90 70 90
100 85
100 670 300
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IO Module 5 V Rail current consumption (mA at 5 VDC)
Module AI-1 AI-10 AO-2 AO-3 DI-5 DI-10 DO-1 DO-2
DO-5/6 IO-2 IO-3 IO-4 IO-5
All IO inactive 22 15 22 9 6 54 15 9 48 10 26 23 TBA
All IO active and powered by module 27 66 28 30 40 85 27 39 39 37 36 37 TBA
Superseded Option Boards typical 5 V Rail consumption (mA at 5 VDC)
Option Board Type
CP-12 Ethernet CP-21 Port 2 Only Ethernet
CP-30 Ethernet CP-21 Ethernet Serial (RS232) Line (original version) Image Capture
Port label
ENET-T ENET-A ENT-T2 ENET-E SER-S
L(1) J
Consumption
130 65 20 0 idle / 850 max 5 120 1000
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3.7. Total Power Load
The total Current load required to power the RTU is as follows:
Total Power load is therefore:
Note: If Amps is used in the `Total Current Load' calculation in place of milliamps, dividing by 1000 can be omitted (1 Amp = 1000 mA).
· The Total Current Load for a PS-12/22 should not exceed 4.5 Amps. Loads greater than 4.5 Amps will require a second PS-12/22 module.
· The Total Current Load for a PC-1 should not exceed 4 Amps. Loads greater than 4 Amps will require a PS-12/22 supply to be installed.
· Users should be mindful of the current draw on the 5 VDC rail. See the Rail Overload Check chapter for more details
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3.8. Battery Backup
For maximum battery life, a maximum discharge depth of 50% is normally used. E.g. for a 7 AH battery, there is 3.5 AH of backup power. Therefore the battery can supply 3.5 Amps for 1 hour or 1 Amp for 3.5 hours etc. The size of the backup battery required depends on how long the RTU needs to be able to run without mains power. In addition to the Total Current Load above, a backup battery will also need to power the PS-11/21 if present (not applicable if using a PC-1 processor).
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4. Processor Modules
The amount of memory, speed, and flexibility of an RTU is determined by the processor module selected.
There are three processor modules available in the Kingfisher modular RTU range. These modules are not equipped with any I/O or communications natively and require additional modules to be attached to the backplane.
Processor modules summary
Model Number CPU Speed
PC-1
16 MHz
CP-12
40 MHz
CP-30
166 MHz
Memory
128 KB Flash 256 KB SRAM
512 KB Flash 512 KB NVRAM 128 KB SRAM 16 MB Flash 32 MB NVRAM
optional expansions
Part number
Bare module
24 VDC Aux Supply fitted
V.23 FSK Radio
2-wire line V.23 FSK
4-wire line V.23 FSK (obsolete)
See Chapters Communications Options Boards and Compatibility
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Lithium Battery
This product contains a lithium battery. Risk of explosion if battery is replaced by an incorrect type. Dispose of used batteries in accordance with local regulations or return to the supplier.
Fire Risks
A supply voltage outside the specified limits may cause fire.
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4.1. PC-1: Power & Processor Module
· Monitoring of battery and input supplies · Isolated DC Outputs · 16 MHz Processor · DC Input Supply · Up to two Communications Ports · Low Voltage Battery Protection · 256 KB SRAM The PC-1 is one of the best supported processors available to a kingfisher RTU. It is well suited to small and mid-size installations as it features an integrated power supply, reduces the system complexity by negating the need for additional power supply modules. With remote installations in mind the PC-1 was designed to be capable of running from a backup battery, and has a fully isolated low power DC output for external equipment. To configure the PC1, a PC running the Toolbox32 software is required. The Toolbox32 software allows the user to implement ladder logic. The PC-1 can only be installed in the first slot of a 4-slot backplane (BA-4) and operates from a nominal +12 VDC supply (typically 13.8 VDC). The module has one fixed RS-232 port and one option port.
A PC-1 has two links that can be accessed from the rear of the module as shown below.
The SRAM battery is enabled at shipping time by the factory. The user can clear the SRAM by removing the SRAM link for five minutes. This will clear the RTU configuration and ladder logic.
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Part Numbers
The PC-1 is available with 3 options (A, P, M) as detailed below.
PC -
A
P
Device: 24 V 10 W Auxiliary Supply Converter
Port 2 Option Board Type
Part Number: 0 = Not Fitted C = Fitted
0 = Not Fitted R = Radio, V.23 FSK* P = 2-Wire Line, V.23 FSK S = Serial RS232/RS485
M Memory
0=128 KB RAM (obsolete)
1=256 KB RAM (standard)
* Radio option boards must be factory modified to suit Trio radios (resistor R15 [150 K] is replaced with a 2K2 resistor). Please add the comment "for Trio radio" when ordering a radio option board for use with a Trio radio.
Example: PC-1-CR1 is a PC-1 with 24 VDC auxiliary converter, radio option port and extra RAM.
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PC-1 Module LEDs
Both of the communications ports have Tx, Rx, RTS and CD LEDs in a vertical group as shown above.
PC-1 LED
Description
OK
ON when module is functioning OK
ON when the internal 5 V supply is OK. This LED should DC +5 V
always be on
+12 V
ON when the internal 12 V supply is OK. This LED should always be on (software controlled)
T1
Test LED 1. Flashes during Power Down mode.
+Vs
ON when the Auxiliary 24 V supply is OK (will only display if
the 24 V converter is installed).
BATT CHG* ON when the battery is being charged
DIS* ON when the battery is being discharged
LO
ON when the battery voltage is low (For a PC-1 this occurs
when the supply voltage is less than about 11.2 V)
T2
Test LED 2. Not currently used.
Tx
ON when port is transmitting
Rx
ON when port is receiving
RTS Request to send. Set ON to begin transmitting
CD
Carrier detect: ON while a communications signal is
detected.
WD
Processor Watchdog Timer. Set ON when the processor is
reset.
* The battery charging (BATT CHG) and battery discharging (DIS) LEDs will sometimes flicker on and off when the battery is charged to the optimum level or if no battery is connected.
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PROCESSOR SPECIFICATIONS
Processor Type Intel 80C188
Word Size
16 Bit internal data bus 8 Bit external data bus
Clock Speed 16 MHz
BIOS Yes
Flash Memory 128 KB Total. 28 KB for firmware drivers.
SRAM 256 KB
Real-time Clock (RTC) 1 minute per month (+/- 20 ppm)
Watchdog Timer Yes
Status Indication Yes
Battery Type Lithium. Not rechargeable.
Battery Life - module unpowered 7 years @ 25°C
Communications Ports 2
Port 1 (RS232) Serial, 300 to 115200 Baud
Port 2 (Optional) Serial, Analogue Radio Interface, 2-Wire Line or 4-Wire Line 300 to 115200 Baud (depending on port type)
Modem Port 2 CCITT V23 (Optional) 1200 Baud
Configuration Software Toolbox 32
Diagnostics Software Yes
Basic Configuration Auto on power-up
RTU Address Range 1 249
Communications P rotocol Kingfisher, DNP3, Modbus, plus many more...
Analogue Block Processing Yes
PID Block Processing Yes
Redundant Power Supplies Not supported
Redundant Processors Not supported
Redundant Communications Yes
Internal Power Consumption 120 mA from +5 VDC
I/O Bus Data Rate 250 Kbps
CM Bus Data Rate 83 Kbps
Cyclic Redundancy Port 1 and 2
Operating Temperature -20 to 70 °C
Storage Temperature -40 to 85 °C
Operating Humidity 5 to 98% RH non-condensing
Hot Swap Not supported. Removing the PC-1 will power down the RTU.
PC-1 POWER SUPPLY
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Input Supply to PC-1 11.5-15 VDC @ 4 A Max (60 W) Typically 13.8 VDC if backup battery connected
Outputs From PC-1
+5 VDC @ 1 A Max (5 W) to Backplane +12 VDC @ 4 A Max to Backplane* +12 VDC @ 2 A Max to Vr* +24 VDC @ 400 mA (10 W) Optional Auxiliary Output (3 kV Isolation) #
Backup Battery 12 V, 7 AH typical. 26 AH max
Deep Discharge Protection RTU Shutdown at 10.6 V RTU Start-up at 11.8 V
Supply Fuse 7 A (Maximum Current into the PC-1)
Battery Fuse 7 A (Maximum Current into or out of battery)
Combined Vr and 24 VDC Fuse 3 A Polyfuse
Monitoring Item
Accuracy
Battery Current PC-1 Supply Voltage PC-1 Supply Current PC-1 Temperature
± 10% ± 5% ± 10% ± 5%
* Note: backplane rail voltages are dependent on power supply to the PC-1. Most PC-1s are powered using the 40 W PSU-3 Power Supply set to 13.8 VDC when using a 12 VDC backup battery.
# the +24 V converter is optional and must be ordered with the PC-1.
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PC-1 Pinout
Port 1 Pins 1 2 3 4 5 6 7 8
Direction OUT OUT OUT IN COM IN IN OUT
RS-232 Definition DTR
+12 V low power RTS DCD
GND (0 V) CTS RXD TXD
Please refer to the PC-1 Option boards for more information regarding port 2 option boards.
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4.2. CP-12 Processor Module
· Support for Processor and Communications Redundancy · Up to 3 communications ports · 40 MHz x86 CPU The CP-12 processor module has up to three independent communications ports. Ports 2 and 3 can house option boards while port 1 is a fixed serial port (RS-232). This processor is targeted at the application space that is too complex for the PC-1 but does not required the additional features made available with a CP-30 based system. The CP-12 has extended functionality over the PC-1 such as redundant processor and communications modules support, and is compatible with Ethernet based boards. The CP-12 uses the same configuration software as the PC-1 processor, and as such is programmable with ladder logic. The CP-12 has 512 KB of flash memory for operating code and system parameter storage, and 512 KB of battery backed SRAM for all configuration and event storage data.
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CP-12 Reset Procedures
The SRAM battery is enabled from the factory by default. The user can clear the SRAM by removing the SRAM link for five minutes. This will clear the RTU configuration and Ladder Logic.
Clearing Configuration with Monitor Mode (Kingfisher Bootloader Self-Test) Behind the LED lens of the CP-12 there is a diagonally mounted jumper. This is a hardware feature unique to the CP-12 processor. When the jumper pins are shorted while the module is being reset (or power cycled), the processor will enter Monitor Mode (the Kingfisher bootloader) and perform a read/write test of the SRAM. This will forcefully remote any configuration and logic in the RTU. Monitor Mode is a deterministic and efficient way of clearing a Processor as the module does not need to be removed from the Backplane, and as the SRAM is forcibly overwritten.
Note: The RAM test is extremely fast. The CP-12 will clear the RAM nearly instantly. To exit monitor mode, remove the short and power cycle the unit again.
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CP-12 Module LEDs
CP-12 LED
Description
OK
ON when Processor is functioning correctly
MON ON when Processor is in Monitor mode
WDT ON when Processor watchdog timer is overflows, such as in the event of a software crash.
RST ON when in reset. Will be lit for 200 ms when cold starting.
TxD ON when transmitting data on corresponding Port
RxD ON when receiving data on corresponding Port
RTS ON when asserting Request To Send on corresponding Port
DCD ON when Data Carrier Detect affirmed on corresponding Port
10ACT ON when Ethernet is operating at 10 Mbps on corresponding Port
100ACT ON when Ethernet is operating at 100 Mbps on corresponding Port
LINK ON when Ethernet Link is established
COL ON when Ethernet Collision is detected
IOTX IORX
Intensity is proportional to load on backplane IO Bus (this bus is used to poll all IO modules)
CMTX CMRX
Intensity is proportional to load on load on backplane Communications Bus (this bus is used for communications modules data transmission)
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PROCESSOR SPECIFICATIONS
Processor 40 MHz x86
Word Size 16 bit data bus
BIOS Yes
Flash Memory 512 KB
SRAM 512 KB
Battery Type Lithium Primary (not rechargeable)
Battery Life - module unpowered 7 years @ 25°C
Real-time Clock (RTC) 1 minute per month (+/- 20 ppm)
Watchdog timer Yes
Status Indication Yes
Communications P orts 1-3 (1 fixed, 2 option ports)
Port 1 (RS232) 300 to 115200 Baud (factory default 9600 8-N-1)
Ports 2 and 3 (Optional) For supported port types, please see the Option Boards chapter
Configuration Software Toolbox 32
RTU Address Range 1 249 (expandable to 2000 by using multiple masters)
Communications P rotocol Kingfisher, Modbus + many more
Default Data Format 8 data bits, no parity, 1 stop (8, N, 1)
Analogue Block Processing Yes
PID Block Processing Yes
Redundancy
Yes. Two CP-12 modules can be installed in the one RTU. One processor module must be installed in an odd numbered slot and one in an even numbered slot.
Internal Power Consumption 275 mA from +5 VDC bus on backplane
I/O Bus Data Rate 250 Kbps
CM Bus Data Rate 83 Kbps
Operating Temperature -20 to 70 °C
Storage Temperature -40 to 85 °C
Operating Humidity 5 to 98% RH non-condensing
Hot Swap
Yes. When 2 processors are present on the backplane, one processor can be swapped while the RTU is still running. However, a hot swap will cause a Warm Start of the remaining processor. All ports will be reinitialized and ready for communications within 6 seconds. New data received during the changeover may be lost. To preserve data and for more information please see the Redundancy appendix in the Toolbox 32 manual.
CP-12 Ports
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The CP-12 has a fixed serial port (RS-232) on port 1. Ports 2 and 3 can house option boards. For more information regarding communications capabilities please refer to the Option Board Chapter.
Port 1 Pins
1 2 3 4 5 6 7 8
Direction
OUT -
OUT IN
COM IN IN
OUT
RS-232 Definition
DTR N/C RTS DCD GND (0 V) CTS RXD TXD
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4.3. CP-30: High Performance Processor Module
· Compliant with IEC-61131 programming languages · Up to 3 communications ports · 166 MHz ARM 9 CPU · Supports Communications and Processing Redundancy · 16 MB Flash · 32 MB DRAM
The CP-30 is a high performance processor module that can provide exceptional speed, memory and functionality to your RTU.
Targeting large RTU Systems, the CP-30 is equipped with a 166 MHz ARM9 CPU, capable of running all IEC-61131-3 certified languages, and utilizes an Ethernet port as the default connection and configuration medium.
To configure the CP-30, a PC with an Ethernet port and the Toolbox PLUS software is required.
Toolbox PLUS features ISaGRAFTM software, which provides logic programming in the IEC-61131 standard languages: Structured Text, Ladder Logic, Function Blocks, Instruction Lists and Sequential Function Charts.
The processor module has up to three independent communications ports. Ports 2 and 3 can use plug-in option boards while port 1 is fixed as Ethernet.
RTUs can use a second CP-30 module to provide processor redundancy. One processor is installed in an odd-numbered backplane slot (the passive processor) and the other in an even-numbered slot (the active processor). The passive standby processor will switch to active mode if communications stop on the backplane for 1500 ms (by default).
This could be caused by:
· Failure, removal or reset of the active processor · Download of the configuration, logic or firmware to the active processor
The CP-30 has 16 MB of flash memory for the storage of all operating code, RTU configuration and event logs. It also has 32 MB of SDRAM for program operation and general data storage and 128 KB of battery backed SRAM for non-volatile data such as retained variables.
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The SRAM battery is enabled at shipping time by the factory. The user can clear the SRAM by removing the SRAM link for five minutes. Note: this will not clear the RTU configuration.
CAUTION: After removing and re-installing the SRAM link, please ensure that the CP-30 is powered up for at least one second. The SRAM battery will then function for the specified life span.
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CP-30 Module LEDs
CP-30 LED
Description
OK *
Steady: Operating system Ok. Set ON after start-up checks pass (see F1, F2 and F3 LEDs below). Slow flash: starting operating system after downloading firmware Fast flash: firmware download error
10
Port 1 10 Mbps Ethernet connection. Flashes when communicating otherwise ON
continuously
100
Port 1 100 Mbps Ethernet connection. Flashes when communicating otherwise ON
continuously
LNK
Port 1 Ethernet link established (port is connected to an Ethernet network)
COL
Port 1 Ethernet collisions detected
Tx
ON when port is transmitting
Rx
ON when port is receiving
RTS
Request to send. RTU Sets RTS ON to begin transmitting
CD
Ports 2, 3: Carrier detect. ON while a communications signal is detected.
F1 *
During start-up: set ON if Firmware running OK.
When RTU running: flashes if port 2 configuration error.
During firmware download: flashes fast if an error occurs. Reset power to clear.
F2 *
During start-up: set ON if Linux operating system running OK.
When RTU running: flashes if port 3 configuration error.
During firmware download: flashes fast if an error occurs. Reset power to clear.
F3 *
During start-up: set ON if ISaGRAFTM and RTU configuration running OK.
After start-up: remains steady ON if active (or only) processor or flashes at 1 Hz if passive (redundant standby) processor. Note: the F3 LED may be turned off briefly (less than 1 second) during initial synchronization between redundant processors.
Flashes quickly if watchdog timer error return to supplier for repair.
During firmware download: flashes fast if an error occurs. Reset power to clear.
* As the CP30 starts up, the F1, F2 and F3 LEDs are progressively set ON when successful. After a successful start up, F1 and F2 are set OFF, F3 is left ON and the OK LED is set ON
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PROCESSOR SPECIFICATIONS
Processor Cirrus EP9301 (ARM9) / 166 MHz / 32 bit data bus
BIOS Yes
SRAM 128 KB (Battery backed)
Flash Memory
16 MB. Permanent memory. Used to store the RTU configuration, logic, retained variables and event logs. If power to the processor is lost, nonretained variables and the current state of execution will be reset.
SDRAM 32 MB
Real-time Clock (RTC) 1 minute per month (+/- 20 ppm)
Watchdog timer Yes
Status Indication Yes
Battery Life module unpowered 7 years @ 25°C
Communications P orts 1-3 (1 fixed, 2 option ports)
Comms Port 1 (Ethernet)
10 or 100 Mbps auto negotiation Default IP address: 192.168.0.1 Isolation: Transient voltage: 1 kV
Comms Ports 2 and 3 (Optional) For supported port types, please see the Option Boards chapter
Configuration Software Toolbox PLUS+
Diagnostics Software Yes
RTU Address Range 1 65520
Communications Protocol
Kingfisher, Modbus (RTU, ASCII and TCP), DNP3 and more (see the protocols document for further details)
Default Data Format 8 data bits, no parity, 1 stop (8, N, 1)
Analog Block Processing Yes
PID Block Processing Yes
Redundancy Yes. Two CP-30 modules can be used in the one RTU.
Logic Processing
IEC 61131 Languages: Ladder Logic, Structured Text, Function Block Diagram, Sequential Function Chart, Instruction List and Flowchart
Internal Power Consumption 500 mA from +5 VDC bus on backplane
I/O Bus Data Rate 250 Kbps
CM Bus Data Rate 250 Kbps
Operating Temperature -20 to 70 °C
Storage Temperature -40 to 85 °C
Operating Humidity 5 to 98% RH non-condensing
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CP-30 Pinout
Port 1 Pins 1 2 3 4 5 6 7 8
Ethernet Function DTR N/C RTS DCD
GND (0 V) CTS RXD TXD
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5. Communications Modules
Communications modules can be utilized to add additional ports and multiple protocol capability to your RTU.
Each module is equipped with two expansion ports that can house a wide range of specialized option boards as follows:
Part Number
Option Board Description
I
Isolated Serial Interface, RS232/RS485/RS422
F
Fiber Optic Interface
D
Dialup Modem (PSTN) V34 33.6 Kbps
L
Private Line or Analogue Radio Interface
H
HART / Bell 202 interface
A3
Ethernet MTRJ Fiber Optic Interface
T3
Ethernet RJ54 Copper 10/100 Mbps
R2
900 MHz Spread Spectrum Radio for Australia
R3
2.4 GHz Spread Spectrum Radio for International
R4
900 MHz Spread Spectrum Radio for USA
For more information regarding option boards and compatibility with superseded hardware, please refer to the chapter Option Boards.
Lithium Battery
These products contain a lithium battery. There is a risk of explosion if battery is replaced by an incorrect type. Dispose of used batteries in accordance with local regulations or return to the supplier.
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5.1. MC-12 Communications Module
· Up to three communications ports per module · Supports Communications Redundancy · Wide range of available option boards · Fixed Serial (RS232) port on port 1 The MC-12 multi-communications module provides up to three additional communications ports. Ports two and three can house option boards while port 1 is fixed as a serial (RS-232) port. An MC-12 supports a maximum baud rate of 83 Kbps between itself and the RTU processor module. This bandwidth can be split across a maximum of 16 ports. Users should be mindful of this limitation when determining the number of ports used simultaneously in one installation. The MC-12 is identical to the CP-12 with the exception of labelling, the lens cover, and firmware. This module consumes power from the +5 VDC bus on the backplane. It also requires +12 VDC. One or more MC-xx modules can be installed in any I/O slot of a 4, 6 or 12 slot backplane.
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MC-12 Module LEDs
MC-12 LED
Description
OK
ON when Module is functioning correctly
MON ON when Module is in Monitor mode
WDT ON when Module watchdog timer is overflows, such as in the event of a software crash.
RST ON when in reset. Will be lit for 200 ms when cold starting.
TxD ON when transmitting data on corresponding Port
RxD ON when receiving data on corresponding Port
RTS ON when Request To Send on corresponding Port is asserted
DCD ON when Data Carrier Detect affirmed on corresponding Port
10ACT ON when Ethernet is operating at 10 Mbps on corresponding Port
100ACT ON when Ethernet is operating at 100 Mbps on corresponding Port
LINK ON when Ethernet Link is established
COL ON when Ethernet Collision is detected
IOTX IORX
Brightness of each indicates load on backplane IO Bus (this bus is used to poll all IO modules)
CMTX Brightness of each indicates load on backplane Communications Bus CMRX (this bus is used for communications modules data transmission)
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MC-12 COMMUNICATIONS MODULE SPECIFICATIONS
Processor 40 MHz x86
Word Size 16 bit data bus
BIOS Yes
Flash Memory 512 KB
SRAM 512 KB (Non-Volatile, Battery Backed)
Battery Type Lithium Primary (not rechargeable)
Battery Life -- module 7 years @ 25°C unpowered
Real-time clock Yes. Accuracy ± 1 min/month
Watchdog timer Yes
Status Indication Yes
Communications P orts 1-3 (1 fixed, 2 option ports)
Port 1 (RS-232) 300 to 115200 Baud (factory default = 9600 bps)
Default Data Format 8 data bits, no parity, 1 stop (8, N, 1)
Ports 2 and 3 (Optional) For supported port types, please see the Option Boards chapter
Configuration Software Toolbox 32
RTU Address Range 1 249 (expandable to 2000 by using multiple masters)
Communications P rotocol Kingfisher, Modbus + many more
Analogue Block Processing Yes
Redundancy
Yes. Two CP-12 modules can be installed in the one RTU. One processor module must be installed in an odd numbered slot and one in an even numbered slot.
Internal Power Consumption 275 mA from +5 VDC bus on backplane
I/O Bus Data Rate 250 Kbps
CM Bus Data Rate 83 Kbps
Operating Temperature -20 to 70 °C
Storage Temperature -40 to 85 °C
Operating Humidity 5 to 98% RH non-condensing
Hot Swap
Yes. When 2 processors are present on the backplane, one processor can be swapped while the RTU is still running. However, a hot swap will cause a Warm Start of the remaining processor. All ports will be reinitialized and ready for communications within 6 seconds. New data received during the changeover may be lost. To preserve data and for more information please see the Redundancy appendix in the Toolbox 32 manual.
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MC-12 Pinout
The MC-12 has a fixed serial port (RS-232) on port 1. Ports 2 and 3 can house option boards. For more information regarding communications capabilities please refer to the Option Board chapter.
Port 1 Pins
1 2 3 4 5 6 7 8
Direction
OUT N/C OUT IN COM IN IN OUT
RS-232 Definition
DTR N/C RTS DCD GND (0 V) CTS RXD TXD
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5.2. MC-31 Communications Module
· Up to three communications ports per module · Supports Communications Redundancy · Wide range of available option boards · Fixed Ethernet port on port 1 · 128 KB SRAM · 16 MB Flash · 32 MB DRAM The MC-31 Communications Module provides three additional communications ports. Ports 2 and 3 are optional and house option boards while port 1 is a fixed Ethernet port. The MC-31 is identical to the CP-30 with the exception of labelling, the lens cover, and firmware. The MC-31 module is only for use with CP-30 based RTUs. This module consumes power from the +5 VDC bus on the backplane. It also requires +12 VDC. One or more MC-31 modules can be installed in any I/O slot of a 4, 6 or 12 slot backplane. An RTU can have up to 16 ports.
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MC-31 Module LEDs
MC-31 LED
Description
OK * Steady: Operating system Ok. Set ON after start-up checks pass (see F1, F2 and F3 LEDs below). Slow flash: starting operating system after downloading firmware Fast flash: firmware download error
10
Port 1 10 Mbps Ethernet connection. Flashes when communicating otherwise
ON continuously
100
Port 1 100 Mbps Ethernet connection. Flashes when communicating otherwise
ON continuously
LNK
Port 1 Ethernet link established (port is connected to an Ethernet network)
COL
Port 1 Ethernet collisions detected
Tx
ON when port is transmitting
Rx
ON when port is receiving
RTS
Request to Send. RTU sets RTS ON to begin transmitting
CD
Ports 2, 3: Carrier Detect. ON while a communications signal is detected.
L1 *
During start-up: set ON if Firmware running OK.
When RTU running: flashes if port 2 configuration error.
During firmware download: flashes fast if an error occurs. Reset power to clear.
L2 *
During start-up: set ON if Linux operating system running OK.
When RTU running: flashes if port 3 configuration error.
During firmware download: flashes fast if an error occurs. Reset power to clear.
* As the MC-31 starts up, the top row LEDs are progressively set ON when successful. After a successful start up, L1 and L2 are set OFF.
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MC-31 COMMUNICATIONS MODULE SPECIFICATIONS Processor Cirrus EP9301 (ARM9) / 166 MHz / 32 bit data bus SRAM 128 KB (Battery backed)
Flash Memory 16 MB SRAM 32 MB SDRAM (Non-Volatile, Battery Backed)
Battery Type Lithium Primary (not rechargeable) Battery Life -- module 7 years @ 25°C
unpowered Status Indication Front Panel LEDs Communications P orts 1-3 (1 fixed, 2 option ports)
Port 1 (RS-232) Fixed Ethernet Default Data Format 8 data bits, no parity, 1 stop (8, N, 1) Ports 2 and 3 (Optional) For supported port types, please see the Option Boards chapter Communications P rotocol Kingfisher, Modbus (RTU, ASCII and TCP) and DNP3 Default Data Format 8 data bits, no parity, 1 stop (8, N, 1) MC-30/31 modules per RTU Maximum of 16 ports per RTU
E.g. Can use 5 MCs if each has 3 ports Internal Power Consumption 500 mA from +5 VDC bus on backplane
Hot Swap Yes. Module can be swapped while RTU is running. Operating Temperature -20 to 70 °C
Storage Temperature -40 to 85 °C Operating Humidity 5 to 98% RH non-condensing
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MC-31 Pinout
Port 1 Pins 1 2 3 4 5 6 7 8
Ethernet Function DTR N/C RTS DCD
GND (0 V) CTS RXD TXD
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6. Communications Option Boards
The following option boards are compatible with the CP-12/30 processor modules and the MC-12/31 communications modules (and the LP-3 stand-alone RTU). For PC-1 option boards please see the following chapter.
These are the currently supported option boards:
Part Number I F D L H A3 T3 R2 R3 R4
Option Board Description Isolated Serial Fiber Optic Interface Dialup Modem (PSTN) V34 33.6 Kbps Private Line or Analogue Radio Interface HART / Bell 202 interface Ethernet MTRJ Fiber Optic Interface Ethernet RJ54 Copper 10/100 Mbps 900 MHz Spread Spectrum Radio for Australia 2.4 GHz Spread Spectrum Radio for International 900 MHz Spread Spectrum Radio for USA
For previous generation hardware, please refer to the section Compatibility.
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6.1. Option Board I: Isolated serial
The isolated serial option board provides an RS-232, RS485 or an RS422 interface. The port is software configurable for any of these modes. When RS485 is configured for an isolated serial option board, the RTS and CD LEDs are set on and when RS422 is configured the RTS LED is set on (there are no LEDs set on for RS232). RS485 requires a 120 terminating resistor at each end of the transmission line and RS422 requires a 100 terminating resistor at the receiver end of the transmission line only (Please see the wiring diagrams at the end of this section).
Option Board I Specifications
Baud rate 300 115200 bps
Internal Power Consumption 15 mA from +5 VDC Bus on backplane
Output Power +4.3 V @ 100 mA max.
RS422 Line drive 10 Receivers
RS485 Line drive 32 Receivers
Communications 8 data bits, no parity, 1 stop (8, N, 1)
Isolation Transient voltage: 2.5 kV
Operating Temperature -20 to 70 °C
Storage Temperature -40 to 85 °C
Operating Humidity 5 to 98% RH non-condensing
RTU Hardware Required
Can be installed in any of the following ports:
CP-10/11/21/30 Port 2 or Port 3 MC-10/11/30/31 Port 2 or Port 3 LP-1/2 Port4 LP-3 Port 3 or Port 4
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Serial Option Board Connections
RJ45 Pin 1 2 3 4 5 6 7 8
Direction OUT OUT OUT IN
Common IN IN
OUT
RS-232 DTR 4.3 V RTS DCD GND TCS RxD TxD
RS422 / RS485 N/A N/A TX+ N/A GND RX+ RXTX-
RS232 Wiring Diagram (Null Modem Cable) Note maximum recommended RS232 length is 15 meters.
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RS485 Wiring Diagram
If the ground resistor is not available, each GND terminal can be tied to EARTH locally via 100 0.5 W resistor. For short cable runs (less than 5 m) a single 60 terminating resistor can be used at one end of the RS485 cable. RS422 Wiring Diagram The master RTU can transmit/receive to any one outstation RTU at any time or each outstation can transmit/receive to the master RTU, one at a time. Note: outstation RTUs cannot communicate with each other. Up to 10 RTUs (or other RS422 devices) can be connected to the RS422 bus. Maximum RS422 Wire Length: 1200 m
If GND wire is not available, each GND terminal can be earthed locally via 100 0.5 W resistors.
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6.2. Option Board F: Fibre Optic Serial Board
The fibre optic serial option board provides a serial interface via a fibre optic cable. A fibre optic port is treated the same way as a standard serial port except a fibre optic cable is used for the communications medium. A fibre optic link offers excellent electrical isolation and a high data rate. Two fibre optic cables are required for each fibre optic port.
Option Board F Specifications Maximum Baud rate 115.2 Kbps (equivalent to RS232 port)
Communications 8 data bits, no parity, 1 stop (8, N, 1) Maximum Fiber Optic Cable Approx. 4 km (depends on cable and other factors)
Length Supported Fiber Optic Cables Multimode 50/125 um, 62.5/125 um, 100/140 um, and 200
um HCS Option Board Connectors Tx: ST female (light grey port) (use male connectors on cable) Rx: ST female (dark grey port) Power Consumption (Tx) 200 mA max. from +5 VDC Bus on backplane
Line drive 1 Receiver (point to point) Electrical Isolation 15 kV Operating Temperature -20 to 70 °C Storage Temperature -40 to 85 °C Operating Humidity 5 to 98% RH non-condensing RTU Hardware Required Can be installed in any of the following ports:
CP-10/11/21/30 Port 2 or Port 3 MC-10/11/30/31 Port 2 or Port 3 LP-1/2 Port4 LP-3 Port 3 or Port 4
Cabling
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6.3.
Option Board D: 33.6 Kbps Dial Option Board
The dial option board provides a V34 PSTN interface to the Kingfisher RTU. The port speed is software configurable, and the dial board is designed to be compliant with telecommunications standards worldwide.
Dial Option Board Connections
RJ45 Pin 1 2 3 4 5 6 7 8
PSTN Function -
Reserved Line Line +
Reserved -
Telecommunication Line Cord
To reduce risk of fire, use only 26 AWG or larger telecommunications line cord.
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Dial Option Board Specifications
PSTN Modem / Data Rate V.34, 300 to 33600 bps, auto-negotiating
RTU DTE Port Speed 300 115200 bps
Line Impedance 600
Approval International
Transmit level -10 dBm
Receive level -43 dBm to -- 9 dBm
Dialling Pulse or Tone
Internal Power Consumption 175 mA from +5 VDC Bus on backplane
Isolation Maximum working voltage in respect to system earth/ground must not exceed TNV-2 limits (80 V) Transient voltage: 5 kV
Recommended Initialization D Option: AT&FE0V0S0=2&W String Original D Option: AT&FE0V0S0=2X0&W (ignores dial tone)
Operating Temperature -20 to 70 °C
Storage Temperature -40 to 85 °C
Operating Humidity 5 to 98% RH non-condensing
Compatibility
Can be installed in any of the following ports:
CP-10/11/21/30 Port 2 or Port 3 MC-10/11/30/31 Port 2 or Port 3 LP-1/2 Port4 LP-3 Port 3 or Port 4
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6.4. Option Board L: Line/Analogue Radio Interface
The line option board provides a Private Line or analogue radio interface and is software configurable for either of these modes.
The board is optically isolated, operates at 1200 bps and provides FSK CCITT V.23 modulation.
Line Board Connections
RJ45 Pin 1 2 3 4 5 6 7 8
Direction OUT IN OUT IN IN IN IN OUT
Line / Radio Function Tx Rx -
RTS/PTT CD
GND (0 V) 12 V Rx + Tx +
Telecommunications Line Cord
To reduce risk of fire, use only 26 AWG or larger telecommunications line cord.
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Connecting a Radio As the port is isolated it is necessary to use an external voltage source (normally from the RTU `radio' connection +12 V) to power not only the radio but also the carrier detect circuit. Some radios have a very low audio interface level (TX Audio), e.g. Maxon DM 0530, DM-2850, SD-125 and Tait T2010 / 2015. These radios will most likely require a resistor network external to the port to drop the TX Audio level. Some radios (e.g. Maxon) have an internal pull up resistor to +5 V on the carrier detect line, if +12 V is used on the carrier detect optocoupler and then run to the carrier detect output on the radio, the optocoupler will always be driven. There are several ways to get around this: Use a radio without an internal pull up to +5 V (Trio SR, possibly Tait) Modify the radio by removing the internal pull up, as per manufacturer's instructions. Use +5 V to supply the carrier detect optoisolation circuit. (DO NOT USE +5 V FROM THE BACKPLANE UTILUX CONNECTOR AS IT IS NOT ISOLATED)
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2-Wire Line, point-to-point Either RTU can transmit/receive one at a time.
Note line termination is required. 2-Wire Line, multi-drop Any RTU can transmit/receive one at a time.
Note line termination is required.
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4-Wire Line, point-to-point Either RTU can transmit/receive at any time.
4-Wire Line, multi-drop Master RTU can transmit/receive to any one outstation RTU at any time or each outstation can transmit/receive to master RTU, one at a time. Note that outstations cannot communicate to each other.
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Line/Radio Option Board Specifications
Baud rate 1200 Baud
Modulation FSK, CCITT V.23
Carrier detect input
Optical isolation Active low or high Min. input 2 mA (70 VDC max.)
RTS/PTT output
Optical isolation Open collector output Active low 30 VDC max @ 20 mA max.
Microwave networks typically use a negative supply rail for the carrier detect circuit. The more positive rail should be connected to pin #6 (RTS/PTT) and the difference between the rails must not exceed 30 VDC.
Output impedance 30 k
Input impedance 30 k
Line termination 600
Line configuration
2 or 4 wire The port is not full duplex and cannot use the full duplex functionality of a 4-wire configuration. 4-wire configurations eliminate the ability to communicate peer to peer but allow an increased number of drops on one link.
Line driv e in multi-drop 10 drops for 2 wire configuration 20 drops for 4 wire
Transmit output lev el -6 dBm (LINE-2) -6 to 21 dBm software configurable (LINE-L)
Receive level -43 dBm to -9 dBm
Internal Power Consumption 85 mA from +5 VDC Bus on backplane
Transmission Distance
Allowing 3dB for background noise and a 10dB fade margin, up to 24dB of cable loss can be tolerated. Therefore, transmission distance = 24 / cable loss per Km (dB). Note: if there are more than 2 RTUs (or other devices) on the line, reduce the allowable cable loss (24) by 1dB per additional RTU or device.
Isolation Operating Temperature
Maximum working voltage in respect to system earth/ground must not exceed TNV-2 limits (80 V) Transient voltage: 3.88 kV -20 to 70 °C
Storage Temperature -40 to 85 °C
Operating Humidity 5 to 98% RH non-condensing
Compatibility
Can be installed in any of the following ports: CP-10/11/21/30 Port 2 or Port 3 MC-10/11/30/31 Port 2 or Port 3 LP-1/2 Port4 LP-3 Port 3 or Port 4
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6.5. Option Board H: HART Interface
The HART option board provides a Bell 202 interface to devices supporting the HART protocol. Each HART option board can communicate with up to 15 Hart devices. Two HART option boards can be installed on the one RTU allowing up to 2 point-to-point circuits or 2 multi-drop circuits.
In a point-to-point installation, the loop current can be measured using an RTU analogue input channel. If using two separate point to point circuits and reading the loop current in each, the RTU analogue input channels must be isolated from each other.
In a multi-drop installation, the loop current is not used or measured.
For more information regarding HART configurations please refer to the HART Implementation Guide available on MyKingfisher.
HART Board Connections
RJ45 Pin 1
2 to 8 8
HART Function Line +
Not Connected Line -
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Point-to-point Wiring Configuration (Utilizing Analogue Input)
Note resistor should be approximately 500 . Multi-drop Wiring Configuration
Note the more HART devices connected, the closer the resistor value needs to be to 50
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Hybrid Wiring Configuration When using multiple HART networks on a single RTU, be sure to isolate the 24 V supplies.
HART Option Board Specifications
Baud-rate 1200 Baud, Half Duplex
Modulation Bell 202
Logical Frequencies 1 = 1200 Hz 0 = 2200 Hz
Internal Power Consumption 1 mA from +5 VDC Bus on backplane
Maximum No. HART Devices 15 (multi-drop)
Data Available HART and loop current for point-to-point HART only for multi-drop
Isolation Operating Temperature
Maximum working voltage in respect to system earth/ground must not exceed TNV-2 limits (80 V) Transient voltage: 3.88 kV -20 to 70 °C
Storage Temperature -40 to 85 °C
Operating Humidity 5 to 98% RH non-condensing
Compatibility
Can be installed in any of the following ports: CP-10/11/30 Port 2 or Port 3 MC-30/31 Port 2 or Port 3
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6.6. Option Board T3: 10/100 Ethernet Controller
The T3 Ethernet Option Board provides Ethernet connectivity via the W5300 chipset allowing full MAC & TCP/IP integration, and simultaneous connection to 8 separate sockets with automatic negotiation.
T3 Ethernet Option Board Specifications
Connection Speed 10/100 auto negotiated (up to 50 Mbps actual)
Max Simultaneous S ockets 8 (with 0 ~ 64 KByte memory for data allocation)
Connection Durability Approximately 750 cycles
Operating Temperature 0 to 70 °C
Storage Temperature -40 to85 °C
Compatibility
Can be installed in any of the following ports: CP-10/11/30 Port 2 or Port 3 MC-30/31 Port 2 or Port 3
6.7. Option Board A3:Fibre Optic Ethernet
The A3 option board provides Ethernet connectivity via fibre optic cable. The A3 is functionally equivalent to a T3 Ethernet board, but fibre optical cabling is used in place of copper cabling allowing for excellent electrical isolation.
A3 Ethernet Option Board Specifications
Connection Speed 10/100 Mbps
Optical Compliance Full ATM 100 Mbps physical layer Full 100 Mbps-FX (IEEE802.3u)
Fiber Optic Transceiver AFBR-5903Z
Supported Fiber Opt ic Cables Multimode 50/125 um, 62.5/125 um, 100/140 um, and 200 um HCS
Option Board Connectors (use male connectors on
cable)
Tx: ST female (light grey port) Rx: ST female (dark grey port)
Supported Fiber Opt ic Cables Multimode 50/125 um, 62.5/125 um, 100/140 um, and 200 um HCS
Option Board Connectors (use male connectors on
cable)
MTRJ connector. Available from Semaphore are the MTRJ-SC and MTRJ-ST adaptors.
Compatibility
Can be installed in any of the following ports: CP-10/11/30 Port 2 or Port 3 MC-30/31 Port 2 or Port 3
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6.8. Option Board R2: Australian Spread Spectrum Radio
The R2 Spread Spectrum radio option board uses the MaxStream 900 MHz RF module to provide a high speed data link in Australia. This radio uses the public frequency band and does not need to be licensed.
When installed in a Communications or processor, the corresponding port CD (Carrier Detect) LED will be lit when the board is functioning correctly (weather antenna is connected or not).
RF Exposure
900 MHz Spread Spectrum Radio This equipment is approved only for mobile and base station transmitting devices. Antenna(s) used for this transmitter must be installed to provide a separation distance of at least 30 cm from all persons and must not be co-located or operating in conjunction with any other antenna or transmitter.
Modifications
Use of unauthorised antenna or other changes or modifications not expressly approved by the party responsible for compliance could void the user's authority to operate this product.
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R2 Spread Spectrum Radio Board Specifications
Countries Supported Australia
Frequency 902-928 MHz
Transmit P ower 1-1000 mW configurable
Range Indoors 900 m
Range Outdoors 22 km
Range with Yagi Up to 32 km
Data rate -- RTU to Radio 9600 bps
Data rate -- Radio to Radio 115200 or 9600 bps
Power Consumption 3.7W maximum
Spread Spectrum Type FHSS (Frequency Hopping Spread Spectrum)
Encryption None #
Antenna Connector RPSMA (reverse polarity SMA) Male (on radio)
Receiver Sens itivity -110 dBm @ 9600 bps
Operating Temperature -20 to 70 °C
Operating Temperature -20 to 70 °C
Storage Temperature -40 to 85 °C
Operating Humidity 5 to 98% RH non-condensing
Compatibility
Can be installed in any of the following ports:
CP-10/11/30 Port 2 or Port 3 MC-10/11/30/31 Port 2 or Port 3 LP-1/2 Port4 LP-3 Port 3 or Port 4
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6.9. Option Board R3: International Spread Spectrum Radio
The R3 Spread Spectrum radio option board uses the 2.4 GHz RF module to provide a high speed data link anywhere in the world (international). This radio uses the public frequency band and does not need to be licensed.
When installed in a Communications or processor, the corresponding port CD (Carrier Detect) LED will be lit when the board is functioning correctly (weather antenna is connected or not).
RF Exposure
2.4 GHz Spread Spectrum Radio This equipment is approved only for mobile and base station transmitting devices. Separation distances of (i) 20 centimetres or more for antennas with gains < 6 dBi or (ii) 2 meters or more for antennas with gains > 6 dBi should be maintained between the antenna of this device and nearby persons during operation. To ensure compliance, operation at distances closer than this is not recommended.
Modifications
Use of unauthorised antenna or other changes or modifications not expressly approved by the party responsible for compliance could void the user's authority to operate this product.
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R3 Spread Spectrum Radio Board Specifications
Countries Supported International
Frequency 2.4000-2.4835 GHz
Transmit Power 50 mW
Range Indoors 180 m
Range Outdoors 5 km
Range with Yagi Up to 8 km
Data rate -- RTU to Radio 19200 bps
Data rate -- Radio to Radio 9600 bps
Power Consumption 0.75W maximum
Spread Spectrum Type FHSS (Frequency Hopping Spread Spectrum)
Encryption None #
Antenna Connector RPSMA (reverse polarity SMA) Male (on radio)
Receiver Sens itivity -105 dBm
Operating Temperature -20 to 70 °C
Operating Temperature -20 to 70 °C
Storage Temperature -40 to 85 °C
Operating Humidity 5 to 98% RH non-condensing
Compatibility
Can be installed in any of the following ports:
CP-10/11/30 Port 3 only MC-10/11/30/31 Port 3 only LP-2 Port4 LP-3 Port 3 or Port 4
# Encryption by special request in the USA only.
Please see www.digi.com/products/wireless for more information.
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6.10. Option Board R4: US/Canada Spread Spectrum Radio
The R4 Spread Spectrum radio option board uses the MaxStream 900 MHz RF module to provide a high speed data link in the US and Canada. This radio uses the public frequency band and does not need to be licensed.
When installed in a Communications or processor, the corresponding port CD (Carrier Detect) LED will be lit when the board is functioning correctly (weather antenna is connected or not).
RF Exposure
900 MHz Spread Spectrum Radio This equipment is approved only for mobile and base station transmitting devices. Antenna(s) used for this transmitter must be installed to provide a separation distance of at least 30 cm from all persons and must not be co-located or operating in conjunction with any other antenna or transmitter.
Modifications
Use of unauthorised antenna or other changes or modifications not expressly approved by the party responsible for compliance could void the user's authority to operate this product.
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R4 Spread Spectrum Radio Board Specifications
Countries Supported US & Canada
Frequency 902-928 MHz
Transmit P ower 1-1000 mW configurable
Range Indoors 900 m
Range Outdoors 22 km
Range with Yagi Up to 32 km
Data rate -- RTU to Radio 9600 bps
Data rate -- Radio to Radio 115200 or 9600 bps
Power Consumption 3.7W maximum
Spread Spectrum Type FHSS (Frequency Hopping Spread Spectrum)
Encryption None #
Antenna Connector RPSMA (reverse polarity SMA) Male (on radio)
Receiver Sens itivity -110 dBm @ 9600 bps
Operating Temperature -20 to 70 °C
Operating Temperature -20 to 70 °C
Storage Temperature -40 to 85 °C
Operating Humidity 5 to 98% RH non-condensing
Compatibility
Can be installed in any of the following ports:
CP-10/11/30 Port 2 or Port 3 MC-10/11/30/31 Port 2 or Port 3 LP-1/2 Port4 LP-3 Port 3 or Port 4
# Encryption by special request in the USA only.
Please see www.digi.com/products/wireless for more information.
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7. PC-1 Option Boards
The PC-1 hybrid power supply and processor module has an accompanying range of communications option boards. These are not compatible with the CP series boards.
7.1. PC-1 Serial Option Board
The serial option board provides a RS-232 or RS485 interface. The port is software configurable for either of these modes. When RS485 is used, a 120 terminating resistor is required at each end of the transmission line.
PC-1 Serial Board Connections
RJ45 Pin 1 2
3 4 5 6 7 8
Direction OUT OUT
OUT IN
COM IN IN
OUT
RS-232 DTR +12 V
low power RTS DCD
GND (0 V) CTS RXD TXD
RS485 N/A N/A
LINE - * N/A
GND (0 V) N/A N/A
LINE + *
* Polarity is opposite to CP-xx
For RS485 wiring diagram please refer to CP-xx/MC-xx serial board RS486 Diagrams
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7.2. PC-1 Modem Board PL: Two Wire Line
The 2-wire (Private) line option board provides a 2-wire point-to-point connection to another RTU with a line option board.
The board is optically isolated, operates at 1200 bps and utilizes FSK CCITT V.23 modulation.
PC-1 Modem Board Connections
RJ45 Pin 1 2
3 4 5 6 7 8
Direction OUT OUT
OUT IN
COM IN IN
OUT
Radio Function DTR +12 V
low power RTS DCD
GND (0 V) CTS RXA TXA
* Polarity is opposite to CP-xx
PC-1 2 Wire Line Wiring Diagram (point-to-point)
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7.3. PC-1 Modem Board: Analogue Radio Interface
The analogue radio option board provides an FSK interface to external analogue radios (typically Maxon or Trio). When used with a Trio radio, one of the resistors must be factory modified.
PC-1 Analog Radio Board Connections
RJ12 Pin 1 2 3 4 5 6 7 8
Direction OUT OUT OUT IN COM IN IN OUT
Radio Function DTR
+12 V low power RTS DCD
GND (0 V) CTS RXA TXA
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8. Compatibility
Not all option boards are universally compatible with all processors and communications modules. The following tables are a selection guide for assuring the hardware you have selected will function as expected.
Communications Option Boards
CPU/Comms Module
A A3 D E F H I J L R2 R3 R4 T T2 T3
CP-30 2676 firmware
MC-31 2676 firmware
MC-30 276 firmware
CP-10/11 1.45b firmware CP-10 previous firmware
CP-12
CP-21
MC-10/11
MC-11 V160 Firmware
MC-12
PC-1 with MC-10/11
PC-1 with MC-12
Note: The above table was correct at the time of writing. Please refer to MyKingfisher for any recent changes.
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9. Analogue Input Modules
Analogue input modules provide analogue inputs to the Kingfisher RTU. Each module is equipped with a fully isolated 24 VDC power supply for energizing field equipment such as sensor loops.
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9.1. AI-1: 8 Channel Analogue Current Input Module
· 12 Bit resolution · 1.5 kV Field to Logic Isolation · 2 ms scan rate · 24 VDC isolated DC output · 0 -- 20 mA or 4 20 mA current inputs · 0 5 VDC or 1 5 VDC Voltage Inputs (requires factory modification)
The analogue input module provides eight input channels, each capable of converting an analogue input signal to a digital variable for use as required by your application. A link on the rear of the module selects 4-20 mA or 0-20 mA for all 8 channels. The default range is 4 to 20 mA.
The module can also be factory modified to handle voltage inputs of 0-5 VDC or 1-5 VDC.
Conversion speed for each of the eight channels is 20 µs and this provides a total update rate of two milliseconds for the module. Resolution of the converted signal is 12 bits binary (1 part in 4096) over the range. The placement of the 12 bits from the A/D converter in the #AI data word is as follows:
LSB
MSB
0 D11 D10 D9 D8 D7 D6 D5 D4 D3 D2 D1 D0 0 0 0
If the current source is reversed into the input, or is less than the low end of the current range, then the module will output a data word corresponding to the low end of the current range (0000H in #AI). If an input that is out of range is entered (i.e. greater than 20 mA), the A/D converter will output up to full scale (corresponding to 7FF8H in #AI).
Scaling of the input is shown below:
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Input protection for the module is sufficient to guarantee operation with reduced performance with up to 1500 V common-mode. The module provides electrical isolation of externally generated noise between field wiring and the backplane through the use of optical isolation. To minimise the capacitive loading and noise, all field connections to the module should be wired using a good grade of twisted, shielded instrumentation cable. The shields can be connected to GND. The GND connection provides access to the backplane (frame ground).
This module can be installed in any I/O slot of a 4, 6 or 12-slot backplane. Up to 10 Analogue Current Input modules can be installed on a single 12-slot backplane.
An insert goes between the inside and outside surface of the hinged door. The surface towards the inside of the module (when the hinged door is closed) has circuit wiring information and circuit identification information can be recorded on the outside surface. The outside left edge of the insert is colour-coded blue to indicate a low-voltage module. (Image for demonstration purposes only)
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AI-1 Module LEDs
LED OK
FU A1-A8
State OFF
ON OFF ON OFF ON
Description Module fault (no power)
Normal Fuse OK Fuse fail Channel Input level < 1% Channel Input level > 1%
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AI-1 Analogue Input Module Specifications
Input Current Ranges
4-20 mA and 0-20 mA
Input Voltage Ranges
1-5 V and 0-5 V *
Inputs per Module Calibration
8 Factory calibrated to 5µA
Update Rate
2 ms (all eight channels)
Accuracy
+ 0.25% @ 25°C
Resolution
12 bit (no sign bit)
Common Mode Voltage
1500 V
Linearity
< 1 Least Significant Bit
Isolation
1.5 kV between field and logic
Common Mode Rejection
> 70 dB at DC; >70 dB at 60 Hz
Cross-Channel Rejection
> 80 dB from DC to 1 kHz
Input Impedance
250 standard 11 k optional *. The internal load resistors can be factory removed if high impedance voltage inputs are required.
Input Filter Response
2 kHz
Output Power
24 VDC @ 400 mA Isolated (10 W)
Operating Temperature
-20 to 70°C
Storage Temperature
-40 to +85°C
Operating Humidity
5 to 98% RH non-condensing
Hot Swap
Yes. Module can be swapped while RTU is running. Hot swap will not cause a Warm Start. Inputs are cleared in RTU memory while module is removed.
* Analogue inputs can be modified from current inputs to voltage inputs by lifting one leg of the 250 channel resistor. Each channel has its own resistor, so any combination of channels can be converted. It is recommended that modules be returned to Semaphore for factory conversion if required. No responsibility will be taken by Semaphore for damage caused to boards during modification performed by clients. The circuit board resistors to change are: channels 1 -- 8 = R9 -- R16.
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AI-1 Wiring Diagram
2 wire transmitter (powered by module)
3 wire transmitter (powered by module)
4 wire transmitter (powered by module)
2 wire transmitter (powered externally)
3 wire transmitter (powered externally)
4 wire transmitter (powered externally)
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9.2. AI-10: 8 Channel High Impedance Analogue Input Module
· 16 Bit resolution · 5 kV field to logic isolation · Channel to channel isolation · 24 VDC isolated DC output · AI-10: Current / Low Impedance Inputs · AI-10-V: High Impedance Voltage Inputs · 10 ms scan rate
The AI-10 and AI-10-V modules are identical except the AI-10-V has the 250 sensing resistors removed. This increases the input impedance for each channel to more than 1 M which is suitably high for voltage transducers.
Both modules provide:
· 8 analogue inputs with high electrical isolation between the field terminals and the RTU logic.
· A 24 V isolated output that can be used to power field sensors / transducers · 16 bit input resolution · Full compatibility with the AI-1 and AI-4 analogue input modules. However, the
resolution has been enhanced to provide a positive raw scale range of 0-32767 (AI-1 and AI-4 use 0-32760)
The AI-10 supports various current and voltage input ranges as follows:
· 4-20 mA / 1-5 V · 0-20 mA / 0-5 V · ±10 V · ±20 mA / ±5 V · ±10 mA / ±2.5 V
The AI-10-V supports various voltage input ranges as follows:
· 1-5 V · 0-5 V · ±10 V · ±5 V · ±2.5 V
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To minimize the capacitive loading and noise, all field connections to the module should be wired using a good grade of twisted, shielded instrumentation cable. The shields can be connected to ground.
This module consumes power from the +5 VDC and +12 VDC RTU rails. A 24 V DC-DC converter mounted within the module is used to provide isolated power to the analogue front-end and to provide power to the field devices as required.
This module can be installed in any I/O slot of a 4, 6 or 12 slot backplane. Up to 11 Analogue Input modules can be installed on each backplane.
An insert goes between the inside and outside surface of the hinged door. The surface towards the inside of the module (when the hinged door is closed) has circuit wiring information and circuit identification information can be recorded on the outside surface. The outside left edge of the insert is colour-coded blue to indicate a low-voltage module.
(Image for demonstration purposes only)
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AI-10 Module LEDs
AI-1 LEDs OK *
DC OK
1-8 (left side)
1-8 (right side)
State OFF ON One second flash* OFF ON OFF ON OFF ON
Description Module Fault (no power) Module OK Module Fault
AI-10 loop power OFF AI-10 loop power ON Channel Input level < 1% Channel Input level > 1% Channel Normal Channel Fault (under/over range, data invalid)
* Early revision modules used ON (a very fast flash) for module OK and steady ON for module fault.
Note: On power up some LED's may come on for a short time.
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IA-10 / AI-10-V Analogue Input Module Specifications
Input Current ranges 4-20, 0-20, +10, +20 mA (software selectable) (AI-10 only)
Input Voltage ranges * 1-5, 0-5, +2.5, +5, +10# VDC (software selectable)
Inputs per Module 8
Sub System Isolation The analogue subsystem of the AI-10 is fully isolated from the RTU's digital system.
Isolation 3 kV Transient
Input impedance AI-10: 250 standard, > 1 M optional* AI-10-V: > 1 M
Maximum Input Voltage +12 V on 10 V range, +7 V on other ranges
Accuracy ± 0.1% @ 25 °C. ± 0.25% @ -20 to 70 °C
Resolution 16 bit (15 data bits and 1 sign bit)
Scanning Rate 10 ms per channel max.
Input Protection The input multiplexer integrated circuits are designed to withstand pulses of up to 100 V
Output Power Isolated 24 VDC @ 160 mA
Operating Temperature -20 to 70°C
Storage Temperature -40 to +85°C
Operating Humidity 5 to 98% RH non-condensing
Hot Swap Yes. Module can be swapped while RTU is running. Hot swap will not cause a Warm Start. Inputs are cleared in RTU memory while module is removed.
Compatibility
One range setting for all channels when used with a PC-1 or CP-11/12/21 processor.
Individual range setting for each channel when used with a CP-30 processor.
* Analogue Input channels can be modified from low impedance to high impedance by lifting one leg of the 250 channel resistor. Each channel has its own current sensing resistor, so any combination of channels can be converted. It is recommended that modules be returned to Semaphore for factory conversion if required. No responsibility will be taken by Semaphore for damage caused to boards during modification performed by clients. The circuit board resistors to change are: channels 1 to 8 = R64 to R71.
# the +10 V input range can only be used on an AI-10 input channel if the current sensing resistor has been removed. Resistors have already been removed in an AI-10-V.
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AI-10 / AI-10-V wiring diagram
2 wire transmitter (powered by module)
3 wire transmitter (powered by module)
4 wire transmitter (powered by module)
2 wire transmitter (powered externally)
3 wire transmitter (powered externally)
4 wire transmitter (powered externally)
Loop
* When using the +24 V output to power a transducer, the negative input terminal of the analogue input channel (2, 4, 6, 8, 12, 14, 16 or 18) must be wired to the OV terminal (10 or 20). This will complete the current loop due to electrical isolation between the input channel and the module +24 V Output.
Note: Any channels sharing the same power source (e.g. +24 V from module or a field power supply) are no longer isolated from one other.
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10. Analogue Output Module
The AO-3 analogue output module provides four 12 bit differential outputs allowing a Kingfisher RTU to drive analogue loads.
10.1. AO-3: Analogue Output Module
· 12 bit resolution · 3 kV field to logic isolation · Open loop detection · 0 20 or 4 20 mA outputs · 3 kV channel group to channel group isolation
The AO-3 provides four current output channels that use 12-bit digital to analog converters (DAC). The AO-3 also provides open loop detection.
The sign bit is not used in the digital to analog conversion process. The placement of the 12 bits within the data word is as follows:
LSB
MSB
0 D11 D10 D9 D8 D7 D6 D5 D4 D3 D2 D1 D0 0 0 0
This module provides two output ranges. The default range is 4 to 20 mA with user data scaled so that a count of 0 corresponds to 4 mA and a count of 32760 corresponds to 20 mA. A range link (on the rear of the module) selects either 4-20 mA or 0-20 mA for all four channels. The default condition is 4-20 mA with the link on. The module provides 12 bits of resolution in either range.
Scaling of the output is as shown below.
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Analogue outputs 1 & 2 and analogue outputs 3 & 4 form two groups that are isolated from each other and from the backplane logic. Each group is powered by a separate DC-DC converter module that produces an isolated voltage of +24 V to drive the current loop outputs and analog front-end.
The current loop drivers on the module are source type drivers. To minimize the capacitive loading and noise, all field connections to the module should be wired using a good grade of twisted, shielded instrumentation cable. The shields should be connected to E (Shield) on the user terminal connector block. The E connection provides path to the backplane (frame Earth / Ground) resulting in attenuation of noise caused by the shield drain currents. To further improve noise immunity, direct connection of the analog cable shields to the Earth / Ground rails with metal clamps or similar method is recommended, especially in environments with high electromagnetic noise levels.
This module can be installed in any I/O slot of a 4, 6 or 12 slot backplane in a system.
This module can be installed in any I/O slot of a 4, 6 or 12-slot backplane. Up to 10 Analogue output modules can be installed on a single 12-slot backplane.
An insert goes between the inside and outside surface of the hinged door. The surface towards the inside of the module (when the hinged door is closed) has circuit wiring information and circuit identification information can be recorded on the outside surface. The outside left edge of the insert is colour-coded blue to indicate a low-voltage module.
(Image for demonstration purposes only)
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AO-3 Module LEDs
AO-3 LEDs OK RST
ANALOG OUT 1-4 OPEN LOOP 1-4
State OFF ON OFF ON OFF ON OFF ON
Description Module fault / no power
Normal Module running Module in Reset (power-on or watchdog) Channel output set to 0% Channel output greater than 0% Closed Loop (load detected) Open Loop (no load)
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AO-3 Analog Output Module Specifications Output Current Range 4 to 20 mA [default] or 0 to 20 mA (loop current is supplied by
module) Outputs per Module 4
Output Power Isolated 24 VDC @ 40 mA for outputs 1 & 2 Isolated 24 VDC @ 40 mA for outputs 3 & 4
Supply Voltage (nominal) +5 VDC and +12 VDC from backplane Update Rate 250 ms (all channels) Determined by I/O scan time and is application dependent Resolution 12 bit (no sign bit) Accuracy ± 0.2% @ 25 °C ± 0.5% @ -20 to 70 °C
Load Resistance 0 to 850 Load Capacitance, max 2000 pF
Load Inductance, max 1 H Isolation Analog outputs 1 & 2 and analog outputs 3 & 4 form two groups. Each group is isolated from the other group and from the backplane logic. There is no isolation between outputs 1 & 2 and no isolation between outputs 3 & 4. Transient voltage (Group to Group and Group to Logic): 5 kV Maximum working voltage in respect to system earth/ground must not exceed SELV limits (42.4 Vpeak / 60 VDC)
Operating Temperature -20 to 70 °C Storage Temperature -40 to 85 °C Operating Humidity 5 to 90% RH non-condensing Hot Swap Yes. Module can be swapped while RTU is running. Hot swap will not cause a Warm Start. Outputs will be restored within 2 seconds once module is replaced. Open Loop Detection Yes. Monitors output circuit for failure (e.g. cable breakage) or if the load is disconnected. Note: when using the 0-20 mA range, Open Loop Detection cannot be guaranteed on an output when set below 160 / 0.1 mA / 0.5%.
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AO-3 wiring diagram
0 20 / 4 20 mA Current Loop Receiver
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11. Digital Input Modules
The Digital Input Modules allow various level digital signals to be interpreted by your RTU.
All modules provide a minimum of 1 kV field isolation, 16 input channels and can be configured to use counters and input buffers to count incoming pulses.
Summary:
Module
Max input Voltage
10 to 28 VDC D I-5-1 (supports reverse polarity)
30 to 60 VDC D I-5-1-48 (supports reverse polarity)
DI-10-1 +10 to +110 VDC 20 126 VAC 35 to 130 VDC
DI-10-1-48 27 260 VAC
Channel group 1 capture speed
Channels 1 and 2 10 kHz max
Channels 1 and 2 10 kHz max
Channels 1 to 4 10 kHz max
Channels 1 to 4 10 kHz max
Channel group 2 capture speed
Channels 3 and 4 255 Hz max
Channels 3 and 4 255 Hz max
Channels 5 to 16 1 kHz max
Channels 5 to 16 1 kHz max
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11.1. DI-5: DC Input 16 Channel Digital Input Module
· Pulse counting on channels 1 to 4 (up to 10 kHz) · Positive or Negative Polarity Inputs · Isolated DC Outputs for powering inputs
The DI-5 provides 16 input channels with one common. As a wide input voltage is accepted a wide range of input devices can be used such as buttons, red switches, line switches, PIR sensors, and proximity sensors. Any combination of inputs powered externally or by the modules own isolated DC supply (+12 V) can be used.
Applying a high input voltage results in logic 1 in the modules status register. Low (or not present) input voltages result in logic 0.
The DI-5 counter can also count pulses in the first 4 digital inputs. It is able to count up to 10 kHz on inputs 1 and 2 and can count up to 255 Hz on inputs 3 and 4. The pulse total and the frequency for each of the first 4 digital inputs are stored.
This module can be installed in any I/O slot of a 4, 6 or 12 slot backplane system.
The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit identification information can be recorded on the outside surface of the insert. The outside left edge of the insert is colour-coded red to indicate a highvoltage module.
(Note the DO-5 module differs from the image shown to the left)
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DI-5 Module LEDs
LED OK 1 - 16
State OFF ON OFF ON
Description Module fault (no power)
Normal Digital Input OFF Digital Input ON
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DO-5 Isolated Relay Output Module Specifications
Rated Voltage
+ 12 to 24 VDC nominal (supports reverse polarity) Note: The DI-5-1-48 High Input Voltage module in the Custom Products chapter supports higher DC input voltages (48 VDC nominal)
Inputs per Module 16
Input Characteristics Impedance
2.7 k
On-state Voltage Chs 1&2: 10 to 28 VDC maximum Chs 3-16: 7.5 to 28 VDC maximum
Off-state Voltage Chs 1&2: 0 to 3.5 VDC Chs 3-16: 0 to 3.0 VDC
On-state Current 4.3 mA minimum
Off-state Current 1 mA maximum
On response Time Channels 1 and 2: 50 µs maximum Channels 3 and 4: 500 µs maximum Channels 5 to 16: 10 ms maximum
Off response Time Channels 1 and 2: 50 µs maximum Channels 3 and 4: 500 µs maximum Channels 5 to 16: 17 ms maximum
Isolation 5 kV Transient
Output Power 12 VDC @ 250 mA (3 W) isolated, supplied by module
Operating -20 to 70 °C Temperature
Storage Temperature -40 to 85 °C
Operating Humidity 5 to 98% RH non-condensing
Pulse Tantalization Channels 1 to 4: 0-65535 Pulses
Pulse Rates / Channels 1 and 2: 10 kHz maximum Frequency Channels 3 and 4: 255 Hz maximum
Hot Swap Yes. Module can be swapped while RTU is running. Hot swap will not cause a Warm Start. Inputs are cleared in RTU memory while module is removed.
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DI-5 Wiring Diagram
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11.2. DI-10: AC or DC Input, 16 Channel
· Frequency/Pulse/Quadrature counters (on up to 7 input pairs) · Isolated DC Field Output · Software Debounce · AC or DC Inputs · Sequence of event recording The DI-10 provides 16 AC or DC input channels allowing it to interface a wide range of input devices to your RTU. Inputs can be powered by the modules own +12 VDC Output Power or from AC or DC field voltages. Applying a high input voltage results in a logical 1 in the status register, no or low input voltage results in a logical 0. The DI-10 features software configurable pre-conditioning of inputs such as debounce filters, channel inversion and sequence-of-event recording selectable on any channel(s). The DI-10 can also perform frequency or pulse counting for up to 7 pairs of input channels. The DI-10 module provides all the functionality of the DI-1 and DI-5 modules except the input voltage cannot be reversed. This module can be installed in any I/O slot of a 4, 6 or 12 slot backplane system.
The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit identification information can be recorded on the outside surface of the insert. The outside left edge of the insert is colourcoded red to indicate a high-voltage module. (Note the DO-10 module differs from the image shown to the left)
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Configurable Functions The fist 4 channels of the DI-10 are high speed and capable of counting up to 10kHz, while channels 5 to 16 can count up to 1 kHz. Seven user configurable counter inputs are available which appear as 16-bit unsigned integer values in the analogue input register. Each of these counters can be configured to determine frequency, count pulses, or quadrature counters which work with quadrature inputs or pairs of channels. Channel inversion can be configured on any input channel. Normally a high voltage level results in a logical HIGH state (1) to be set in the digital input register with the corresponding LED illuminating on the front panel. By enabling channel inversion, a low voltage level applied to an input will result in a logical HIGH (1). Software debounce can be activated on any input channel. The time constant can be configured from 1 ms to 250 ms. When using software debounce with AC inputs, the input channel must be configured with the debounce filter set to `AC Filter' as shown below.
Sequence of Events Recording Sequence-of-Event (SoE) recording can be configured for any input channel. When enabled, any change of state (event) on the input is logged to 1 millisecond accuracy. These events are automatically included in the Event Log of the RTU. The DI-10 module has an internal timer that is synchronized with the Real Time Clock of the processor. The DI-10 module has a buffer capable of storing 1000 events. This means bursts of up to 1000 events can be recorded at a time. Events are uploaded to the processor module at a maximum rate of 100 events per second. Please note that SoE recording is not supported when using a PC-1 processor.
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DI-5 Module LEDs
LED OK PCON 1 - 16
State OFF ON OFF ON OFF ON
Description Module fault (no power)
Normal DI-10 Output Power OFF DI-10 Output Power ON
Digital Input OFF Digital Input ON
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DI-10: AC or DC Input, 16 Channel
Rated Voltage +10 to +110 VDC nominal 20 to 125 VAC
Inputs per Module 16
Input Characteristics Impedance
1.2 k approx.
On-state Voltage
7.5 to 130 VDC maximum 20 to 125 VAC
Off-state Voltage 0 to 3.0 VDC
On-state Current 3.5 mA minimum
Off-state Current 1 mA maximum
On response Time Channels 1 to 4: 50 µs maximum Channels 5 to 16: 500 µs maximum
Off response Time
Channels 1 to 4: 50 µs maximum (DC) Channels 5 to 16: 500 µs maximum (DC) Channels 1-16: 30 ms (AC)
Isolation Maximum working voltage in respect to system earth/ground must not exceed 125 VAC or 130 VDC Transient voltage: 3 kV
Output Power 12 VDC @ 80 mA (1 W) isolated, supplied by module
Operating -20 to 70 °C Temperature
Storage Temperature -40 to 85 °C
Operating Humidity 5 to 98% RH non-condensing
Pulse Rates / Channels 1 to 4: 10 kHz maximum * Frequency Channels 5 to 16: 1 kHz maximum
Frequency Counting 1 Hz resolution on any input(s) (7 counters max.)
Pulse Totalisation 0-65535 Pulses on any input(s) (7 counters max.)
Quadrature Counting 0-65535 Pulses on any of the following pairs of inputs: 1&2, 3&4, 5&6, 7&8, 9&10, 11&12, 13&14 and 15&16 (7 counters max.)
Channel Inversion Selectable on any input(s)
Debounce Filtering Time constant 1-250 ms on any input(s) or AC Filter (for AC inputs).
1 ms resolution Sequence of Events Buffering for 1000 events, uploaded to CPU at 100 events/second
Selectable on any input(s)
Yes. Module can be swapped while RTU is running. Hot swap will Hot Swap not cause a Warm Start. Inputs are cleared in RTU memory while
module is removed.
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DI-10 Wiring Diagram
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12. Digital Output Modules
The digital output modules provide relay and transistor outputs to the Kingfisher series of RTUs. The DO-1 and DO-2 offer relay outputs, eight and sixteen respectively, while the DO-6 is transistor based. The DO-6 is compatible with the TEL-REL-00x series of relay output boards to allow for higher current and voltage switching.
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MVTech_LT2003G_Origional.rar Switching Inductive Loads When switching inductive loads, users should be mindful of possible reduced relay life due to back-EMF. To mitigate this negative effect, suppression circuits should be used when switching inductive loads.
Switching DC Supplied inductive loads
(high switching relay output)
Switching DC Supplied inductive loads
(ground switching relay output)
Switching AC supplied inductive loads
(*MOV = Metal Oxide Varistor)
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12.1. DO-1: 8 Channel Isolated Relay Output Module
· 8 SPDT isolated relay outputs · 500 V channel pair isolation · One common per channel pair · Can switch AC or DC voltages · 3 kV coil to contact isolation
The DO-1 provides 8 normally open or normally closed relay circuits for controlling output loads. All output channels are isolated from each other and arranged into pairs. Each channel pair shares a separate common terminal (see the wiring in this chapter for clarification).
The relay outputs can control a wide range of user supplied load devices such as motors, starters, solenoids, and indicators. The user is required to supply the AC or DC power to operate the field devices connected to this module. Internal fuses offer protection to the relay contacts should their maximum load be exceeded.
This module can be installed in any I/O slot of a 4, 6 or 12 slot backplane.
The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit identification information can be recorded on the outside surface of the insert. The outside left edge of the insert is colour-coded red to indicate a highvoltage module.
(Note the DO-1 module differs from the image shown to the left)
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D0-1 Module LEDs
LED OK
FU
A1, A2 B3, B4 C5, C6 D7, D8
State OFF ON OFF ON OFF ON
Description Module fault (no power)
Normal Fuse OK Fuse fail Digital output OFF (open) Digital output ON (closed)
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DO-1 Isolated Relay Output Module Specifications Outputs per Module 8
Commons 4 (each common supplies 2 outputs) Relay Type SPDT (Single Pole, Double Throw) Rated Load (per contact) 5 A at 250 VAC Resistive
5 A at 30 VDC Resistive (20 A maximum per DO-1 module) Maximum Operating Voltage 380 VAC, 125 VDC Maximum Switching Power - 1250 VA, 150 W Resistive Maximum Switching Power - 375 VA, 80 W Inductive Minimum Load 10 mA at 5 VDC Relay Operations 100,000 minimum at 1800 operations per hour at rated load Operating Temperature -20 to 70 °C Storage Temperature -40 to 85 °C Operating Humidity 5 to 98% RH non-condensing Isolation 3 kV coil to contacts 500 V between channel groups Coil Rated Voltage 12 VDC @ 16.7 mA Coil Resistance 480 @ 12 VDC Relay Part Number Omron G6B-2114P-US (G6B datasheet is available from www.europe.omron.com) Hot Swap Yes. Module can be swapped while RTU is running. Hot swap will not cause a Warm Start. Outputs will be restored within 2 seconds once module is replaced.
CAUTION! Contacts should be protected with appropriate suppression devices when wired with inductive loads to increase life of relays (please see DO-1 Switching Inductive Loads). Contacts should also be protected with external fusing.
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DO-1 Wiring Diagram
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12.2. DO-2: 16 Channel Relay Output Module
· 16 SPST relay outputs · One common per 8 channels · 3 kV coil to contact isolation · Can switch AC or DC voltages The DO-2 provides 16 normally-open relay circuits for controlling output loads provided by the user. The output points are arranged in two groups of eight. Each group shares a common terminal. The relay outputs can be used to control a wide range of devices such as motor starters, solenoids, and indicators. Internal fuses protect the DO-2 relay contacts should ratings be exceeded. This module can be installed in any I/O slot of a 4, 6 or 12 slot backplane.
The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit identification information can be recorded on the outside surface of the insert. The outside left edge of the insert is colour-coded red to indicate a highvoltage module. (Note the DO-2 module differs from the image shown to the left)
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D0-2 Module LEDs
LED
State
OK
OFF
ON
FU
OFF
ON
1-16
OFF
ON
Description Module fault (no power)
Normal Fuse OK Fuse fail Digital output OFF (open) Digital output ON (closed)
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DO-2 16 Channel Digital Output Module Specifications
Outputs per Module 16
Commons 2 (each common supplies 8 outputs)
Relay Type SPST (Single Pole Single Throw, Normally Open)
Maximum Switched Voltage 30 VDC, 250 VAC
Maximum Switched Current 5 A per channel 7 A per common
Minimum Load 10 mA @ 5 VDC (wetting current)
Contact Resistance 100 m maximum
Operating Temperature -20 to 70 °C
Storage Temperature -40 to 85 °C
Operating Humidity 5 to 98% RH non-condensing
Isolation
Maximum working voltage in respect to system earth/ground must not exceed 250 VAC / 130 VDC Transient voltage: 3 kV
Relay Operations 70,000 minimum at 1800 operations per hour at rated load
Fuse Monitor LED Enabled when the common is wired to pins 10 and 20. CAUTION! When wired, a maximum voltage of 30 V AC or DC can be used to power the common.
Relay Part Number Omron G6D-1A-12VDC (G6D datasheet is available from http://www.europe.omron.com)
Hot Swap Yes. Module can be swapped while RTU is running. Hot swap will not cause a Warm Start. Outputs will be restored within 2 seconds once module is replaced.
CAUTION! Contacts should be protected with appropriate suppression devices when wired with inductive loads to increase life of relays (please see the beginning of the chapter Switching Inductive Loads). Contacts should also be protected with external fusing.
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DO-2 Wiring Diagram
Note * Optional Link for DC Supply Only. Enables the use of fail LED FU. Caution: A maximum of 30 V (AC or DC) can be used to power the common if the link is installed.
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12.3. DO-6: 16 Channel Open Drain Output Module
· 16 Open-drain outputs · Designed to operate TELREL 00x relay board · DC Field Output (non-isolated) The DO-6 provides 16 open drain NFET outputs for controlling various loads including the TELREL series of relay boards. Power for external loads can be provided from the modules +12 VDC which is sourced from the backplane rail. The DO-6 output channels are current limited and are protected from high levels of EMI (electro-magnetic interference) that may trigger false outputs. This module can be installed in any I/O slot of a 4, 6 or 12 slot backplane.
The insert in the hinged cover of the terminal strip has circuit wiring information. Circuit identification information can be recorded on the outside surface of the insert. The outside left edge of the insert is colour-coded red to indicate a highvoltage module. (Note the DO-6 module differs from the image shown to the left)
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D0-6 Module LEDs
LED OK
A1-A16
State OFF ON OFF ON
Description Module fault (no power)
Normal Digital output OFF (open) Digital output ON (closed)
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DO-6 Channel Open Drain Output Module Specifications Outputs per Module 16
Commons 1 Rated Voltage 30 VDC maximum.
Output Type N-FET, Open Drain Rated Load 70 mA per channel Current Limit 90 mA per channel Output Power 12 VDC @ 1.6 A, non-isolated, supplied by module On Response Time 15 ms maximum Off Response Time 15 ms maximum Operating Temperature -20 to 70 °C Storage Temperature -40 to +85 °C Operating Humidity 5 to 98% RH non-condensing
Hot Swap Yes. Module can be swapped while RTU is running. Hot swap will not cause a Warm Start. Outputs will be restored within 2 seconds once module is replaced.
Compatibility The DO-6 is functionally equivalent and pin compatible with the superseded DO-5.
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DO-6 Wiring Diagram
Note: The +12 V Output is sourced from the backplane power rail and is not isolated. Users should exercise caution to avoid shorting or overloading this output.
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13. Relay Expansion Boards
The Kingfisher Relay Expansion Boards are designed to be used in conjunction to the DO-6 module. The relay boards allow much more flexible use of the DO-6 module due to the wide range of relay types available.
Each relay board has unique internal wiring. Users should be mindful that they are not completely pin-compatible. Please refer to individual wiring diagrams for details.
TEL REL 002 TEL REL 003 TEL REL 004
· 16 Channel Isolated Relay SPDT for DO-6-x complete with 1.5m cable · Max Voltage 380VAC, 125VDC, 16 commons, (1 common per channel) · Max Current 16A @ 250VAC resistive, 16A @ 30 VDC resistive, 0.45A @ 125
VDC Inductive. · 5kV isolation (Coil to Contact) · Omron G2R-1-E Relay
· Relay Board - 16 Channel Isolated Relay SPST for DO-6-x complete with 1.5m cable
· Max Voltage 380VAC, 125VDC, 16 commons, (1 common per channel) · Max Current 8A @ 250VAC resistive, 8A @ 30 VDC resistive 1A @ 125 VDC
Inductive · 5kV isolation (Coil to Contact) · Omron G2RG-2A4-DC12 Relay
· Relay Board - 16 Channel Isolated Relay DPDT for DO-6-x complete with 1.5m cable
· Max Voltage 380VAC, 125VDC, 32 commons, (2 common per channel) · Max Current 5A @ 250VAC resistive, 5A @ 30 VDC resistive · 5kV isolation (Coil to Contact) · Omron G2R-2-12V Relay
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13.1. TEL REL 002: SPDT Relay Board
· 16 SPDT Relay Outputs · Common for each channel · 5 kV coil to contact isolation · Can switch AC or DC voltages The TEL REL 002 is designed to accompany the DO-6 to provide 16 SPDT voltage free output contacts. Each relay consumes 43 mA @ +12 VDC from the backplane power supply. An external supply can be connected to a screw terminal on the PCV is available (this is not the case if the standard cable supplied with the DO-6 modules is utilized). LED indicators are provided for each relay on the relay board. LED ON = relay active.
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TEL REL 002 SPDT Relay Boards Specifications
Outputs per Terminal Board 16
Commons 16 (1 common per channel)
Relay Type (per channel) SPDT (Single Pole, Double Throw)
Rated Load (per contact) 16 A @ 250 VAC Resistive 16 A @ 30 VDC Resistive
Maximum Operating Voltage 380 VAC, 125 VDC
Maximum Switching Power - 16 A @ 30 VDC Resistive 5 A @ 48 VDC 0.6 A @ 125 VDC
Maximum Switching Power Inductive
16 A @ 12 VDC 8 A @ 30 VDC 0.7 A @ 48 VDC 0.45 A @ 125 VDC
Minimum Load 100 mA at 5 VDC
Contact Resistance 100 m maximum
Relay Operations 100,000 minimum at 1800 operations per hour at rated load
Operating Temperature -20 to 70 °C (no icing)
Storage Temperature -40 to +85 °C
Humidity 5 to 98% RH non-condensing
Isolation 5 kV coil to contacts
Coil Rated Voltage 12 VDC @ 43 mA
Coil Resistance 275 @ 12 VDC
Dimensions 253 mm(L) x 90 mm(W) x 70 mm(H) (280 mm long with 2 end clamps)
Mounting 35 mm DIN rail
Interface cable length 1500 mm (for connection to the DO-6 module)
Phoenix double height PCB terminal unit arranged in a Connection Terminals dual three way terminal (please see wiring diagram).
These terminals can take wire sizes up to 4 mm2.
Omron G2R-1-E Relay Part Number (datasheet is available from
www.omroncomponents.eu)
CAUTION! Contacts should be protected with appropriate suppression devices when wired with inductive loads to increase life of relays (please see Switching Inductive Loads). Contacts should also be protected with external fusing.
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TEL REL 002 Wiring Diagram
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DO-6 to TEL REL 00x Interface Cable
Fujicon DO-6 Pin DO-6 Outputs Belden 9431 Cable Color Panduit 20 way header pins
1
Channel 1
Black
1
2
Channel 2
White
2
4
Channel 3
Red
4
4
Channel 4
Green
4
5
Channel 5
Orange
5
6
Channel 6
Blue
6
7
Channel 7
White/Black
7
8
Channel 8
Red/Black
8
9
0 V
Green/Black
9
10
0 V
Orange/Black
10
11
Channel 9
Blue/Black
11
12
Channel 10
Black/White
12
13
Channel 11
Red/White
13
14
Channel 12
Green/White
14
15
Channel 13
Blue/White
15
16
Channel 14
Black/Red
16
17
Channel 15
White/Red
17
18
Channel 16
Orange/Red
18
19
+ 12 VDC
Blue/Red
19
20
+ 12 VDC
Green/Red
20
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13.2. TEL REL 003: SPST Relay Board
· 16 SPST Relay Outputs · Common for each channel · 5 kV coil to contact isolation · Can switch AC or DC voltages · Higher inductive rating than other TEL REL 002
(1 A @ 125 V as opposed to 0.4 A @ 125 V) The TEL REL 003 board is designed to be used in conjunction with the DO-6 (or superseded DO-5) and provides superior inductive load rating than the TEL REL 002. LED indicators are provided for each relay on the relay board. LED ON = relay active.
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TEL REL 003 SPST Relay Board Specifications
Outputs per Terminal 16 Board
Commons 16 (1 common per channel)
Relay Type (per channel) SPST (Single Pole, Single Throw)
Rated Load (per contact) 8 A at 250 VAC Resistive 8 A at 30 VDC Resistive 1 A at 125 VDC Inductive
Maximum Operating 380 VAC, 125 VDC Voltage
Maximum Switching 2000 VA, 240 W Power - Resistive
Contact Resistance 100 m maximum
Relay Operations
100,000 minimum at 1800 operations per hour at rated resistive load 50,000 minimum at 360 operations per hour at rated inductive load
Operating Temperature -20 to 70 °C (no icing)
Humidity 5 to 98% RH non-condensing
Isolation 5 kV coil to contacts
Coil Rated Voltage 12 VDC @ 66 mA
Coil Resistance 180 @ 12 VDC
Dimensions 253 mm(L) x 90 mm(W) x 70 mm(H) (280 mm long with 2 end clamps)
Mounting 35 mm DIN rail
Interface cable length 1.5 m (for connection to the DO-6 module)
Connection Terminals Weidmuller single height PCB 3-way terminal unit (please see wiring diagram). These terminals can take wire sizes up to 4 mm2.
Relay Part Number Omron G2RG-2A4-DC12 (datasheet is available from www.omroncomponents.eu)
CAUTION! Contacts should be protected with appropriate suppression devices when wired with inductive loads to increase life of relays (please see DO-1 Switching Inductive Loads). Contacts should also be protected with external fusing.
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TEL REL 003 Wiring Diagram
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DO-6 to TEL REL 00x Interface Cable
Fujicon DO-6 Pin DO-6 Outputs Belden 9431 Cable Color Panduit 20 way header pins
1
Channel 1
Black
1
2
Channel 2
White
2
4
Channel 3
Red
4
4
Channel 4
Green
4
5
Channel 5
Orange
5
6
Channel 6
Blue
6
7
Channel 7
White/Black
7
8
Channel 8
Red/Black
8
9
0 V
Green/Black
9
10
0 V
Orange/Black
10
11
Channel 9
Blue/Black
11
12
Channel 10
Black/White
12
13
Channel 11
Red/White
13
14
Channel 12
Green/White
14
15
Channel 13
Blue/White
15
16
Channel 14
Black/Red
16
17
Channel 15
White/Red
17
18
Channel 16
Orange/Red
18
19
+ 12 VDC
Blue/Red
19
20
+ 12 VDC
Green/Red
20
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13.3. TEL REL 004: DPDT Relay Board
· 16 DPDT relay outputs · 2 commons per channel · 5 kV coil to contact isolation · Can switch AC or DC voltages The TEL REL 004 is designed to be used in conjunction with the DO-6 (or superseded DO-5) and provides Double Pole Double Throw (DPDT) relays. This allows the user to utilize both normally open and normally closed relay operation. LED indicators are provided for each relay on the relay board. LED ON = relay active.
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TEL REL 004 DPDT Relay Board Specifications Outputs per Terminal Board 16
Commons 32 (2 commons per channel) Relay Type (per channel) DPDT (Double Pole, Double Throw) Rated Load (per contact) 5 A at 250 VAC Resistive
5 A at 30 VDC Resistive Maximum Current 5 A Maximum Operating Voltage 380 VAC, 125 VDC (2 A max.) Maximum Switching Power 750 VA, 90 W Resistive
Minimum Load 10 mA at 5 VDC Contact Resistance 50 m maximum
Relay Operations >10,000,000 Operating Temperature -20 to 70 °C (no icing)
Humidity 5 to 98% RH non-condensing Isolation 5 kV coil to contacts Coil Rated Voltage 12 VDC @ 44 mA per coil Coil Resistance 275 @ 12 VDC Dimensions 253 mm(L) x 90 mm(W) x 70 mm(H)
(280 mm long with 2 end clamps) Mounting 35 mm DIN rail Interface cable length 1.5 m (for connection to the DO-5/6 module) Relay Part Number Omron G2R-2-12 V
(datasheet is available from www.omroncomponents.eu )
CAUTION! Contacts should be protected with appropriate suppression devices when wired with inductive loads to increase life of relays (please see DO-1 Switching Inductive Loads). Contacts should also be protected with external fusing.
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TEL REL 004 Wiring Diagram
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DO-6 to TEL REL 00x Interface Cable
Fujicon DO-6 Pin DO-6 Outputs Belden 9431 Cable Color Panduit 20 way header pins
1
Channel 1
Black
1
2
Channel 2
White
2
4
Channel 3
Red
4
4
Channel 4
Green
4
5
Channel 5
Orange
5
6
Channel 6
Blue
6
7
Channel 7
White/Black
7
8
Channel 8
Red/Black
8
9
0 V
Green/Black
9
10
0 V
Orange/Black
10
11
Channel 9
Blue/Black
11
12
Channel 10
Black/White
12
13
Channel 11
Red/White
13
14
Channel 12
Green/White
14
15
Channel 13
Blue/White
15
16
Channel 14
Black/Red
16
17
Channel 15
White/Red
17
18
Channel 16
Orange/Red
18
19
+ 12 VDC
Blue/Red
19
20
+ 12 VDC
Green/Red
20
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14. Combination IO Modules
Combinational IO modules provide digital and analogue IO in a single module. They can be installed in any 4, 6, or 12 slot backplane.
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14.1. IO-2: Combinational Digital IO Module
· 8 SPST relay outputs · Digital inputs This module can be installed in any slot of a 4, 6 or 12 slot backplane. Digital Inputs
The digital inputs are designed to be powered using an external power supply. A wide range of digital input devices can be used such as push buttons, limit switches and electronic proximity switches. Current through an input (in either direction) results in a logic 1 in the status register. Power to operate the field devices must also be supplied by the user. Digital Outputs
The output points are arranged in one group of eight points with one common. The output switching capacity of each output is 2 amps. The relay outputs can control a wide range of load devices such as motor starters, solenoids and indicators. Power for the internal relay circuits is provided by the +12 VDC bus on the backplane. The user must supply the AC or DC power to operate the field devices. An internal fuse protects the relay contacts should ratings be exceeded.
An insert goes between the inside and outside surface of the hinged door. The surface towards the inside of the module (when the hinged door is closed) has circuit wiring information and circuit identification information can be recorded on the outside surface. The outside left edge of the insert is colour-coded blue to indicate a low-voltage module. (Image for demonstration purposes only)
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IO-2 Module LEDs
LED OK FU A1-A8 B1-B8
State OFF ON OFF ON OFF ON OFF ON
Description Module fault (no power)
Normal Fuse OK Fuse fail Digital input OFF Digital input ON Digital output OFF (open) Digital output ON (closed)
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IO-2 Combinational IO Module Specifications
Operating Temperature -20 to 70 °C
Storage Temperature -40 to 85 °C
Humidity 5 to 95% RH non-condensing
Hot Swap
Yes. Module can be swapped while RTU is running. Hot swap will not cause a Warm Start. Outputs will be restored within 2 seconds once module is replaced. Inputs will be cleared while module is removed.
DIGITAL INPUTS
Rated Voltage 12 to 24 VAC/DC (can use reverse polarity)
Inputs per Module 8
Input Characteristics On-state Voltage 11.5 to 30 VAC/DC maximum
Off-state Voltage 0 to +4 VAC/DC
On-state Current 3.2 mA minimum
Off-state Current 1 mA maximum
On response Time 10 ms typical
Off response Time 17 ms typical
Input Current 4 mA (typical) at rated voltage
Isolation 3 kV between field and logic
DIGITAL OUTPUTS
Outputs per Module 8
Commons 1 (common supplies all 8 outputs)
Relay Type SPST (Single Pole Single Throw)
Rated Switched Voltage 24 VDC, 120/240 VAC
Maximum Switched Voltage 30 VDC, 250 VAC
Maximum Switched Current 5 A per channel 8 A per common
Isolation 3 kV coil to contacts
Minimum Load 10 mA @ 5 VDC
Contact Resistance 100 m maximum
Relay Operations 70,000 minimum at 1800 operations per hour at rated load
Relay Part Number Omron G6D-1A-12 VDC (G6D datasheet is available from www.europe.omron.com)
CAUTION! Contacts should be protected with appropriate suppression devices when wired with inductive loads to increase life of relays (please see DO-1 Switching Inductive Loads). Contacts should also be protected with external fusing.
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IO-2 Wiring Diagram
Digital Input Example:
(Note polarity can be reversed on power supply)
Digital Output Example:
* Optional link for DC SUPPLY ONLY. Enables fuse fail LED `FU' on module. CAUTION: when the link is installed a maximum of 30 V AC or DC can be used to power the common. Note: DC powered inputs and low voltage AC inputs can both be used on the same module.
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14.2. IO-3: Combinational Analog/Digital IO Module
· 4 SPST relay outputs · 4 analog inputs · 4 digital inputs · 1 analog output
This module can be installed in any slot of a 4, 6 or 12 slot backplane.
Analogue IO
The IO-3 provides two signal ranges, 0 to 20 mA and 4 to 20 mA. The default range is 4 - 20 mA. A link on the rear of the module selects 4 - 20 mA (link installed) or 0 - 20 mA I/O for all channels.
Resolution of the converted signals is 12 bits binary (1 part in 4096). The sign bit is not used in the conversion process. All channels are updated four times per second (250 ms refresh time). The placement of the bits within the data word is shown below.
LSB
MSB
0 D11 D10 D9 D8 D7 D6 D5 D4 D3 D2 D1 D0 0 0 0
Scaling of the input is shown below:
All inputs share a single common and all outputs share a separate common at the zero volt rail.
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Input protection for the module is sufficient to guarantee operation with reduced performance with up to 1500 V common-mode. The module provides electrical isolation of externally generated noise between field wiring and the backplane through the use of optical isolation. To minimise the capacitive loading and noise, all field connections to the module should be wired using a good grade of twisted, shielded instrumentation cable. The shields can be connected to E. The E connection provides access to the backplane (frame ground).
Digital IO
Input characteristics are compatible with a wide range of user supplied input devices, such as push buttons, limit switches and electronic proximity switches, whilst outputs can control a wide range of user supplied load devices such as: motor starters, solenoids and indicators. Power for the internal relay circuits is provided by the +12 VDC bus on the backplane. The user must supply the AC or DC power to operate field devices. An internal fuse protects the relay contacts should ratings be exceeded.
An insert goes between the inside and outside surface of the hinged door. The surface towards the inside of the module (when the hinged door is closed) has circuit wiring information and circuit identification information can be recorded on the outside surface. The outside left edge of the insert is colour-coded blue to indicate a low-voltage module.
(Image for demonstration purposes only)
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IO-3 Module LEDs
LED OK
FU
A1-A4 B1
C1-C4
D1-D4
State OFF ON OFF ON
OFF ON OFF ON
Description Module fault (no power)
Normal Fuse OK Fuse fail Not used Not used Digital input OFF Digital input ON Digital output OFF (open) Digital output ON (closed)
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IO-3 Analogue/Digital Combinational IO Module Specifications
Operating Temperature -20 to 70 °C
Storage Temperature -40 to +85 °C
Humidity 5 to 95% RH non-condensing
Output Power 24 VDC @ 125 mA (3 W) Isolated
Hot Swap
Yes. Module can be swapped while RTU is running. Hot swap will not cause a Warm Start. Outputs will be restored within 2 seconds once module is replaced. Inputs will be cleared while module is removed.
ANALOG INPUTS
Input Current Ranges
4 to 20 mA or 0 to 20 mA
Input Voltage Ranges *
1 to 5 V and 0 to 5 V *
Inputs per Module
4
Calibration
Factory calibrated to 5 µA
Update Rate
2 ms (all four channels)
Accuracy
+ 0.25% @ 25 °C
Resolution
12 bit (no sign bit)
Linearity
<1 Least Significant Bit
Isolation
Transient voltage: 1 kV
Common Mode Rejection
> 70 dB at DC; >70 dB at 60 Hz
Cross-Channel Rejection
> 80 dB from DC to 1 kHz
Input Impedance
250 standard 15 k optional *. The internal load resistors can be factory removed if high impedance voltage inputs are required.
Input Filter Response
325 Hz
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ANALOG OUTPUT Output Current Range Outputs per Module Calibration Supply Voltage (nominal) Update Rate
Accuracy Resolution User Load Output Load Capacitance Output Load Inductance Isolation DIGITAL INPUTS Rated Voltage Inputs per Module Input Characteristics
Input Current Isolation DIGITAL OUTPUTS Outputs per Module Commons Relay Type Maximum Switched Voltage Maximum Switched Current
Isolation Minimum Load Contact Resistance Relay Operations Relay Part Number
4 to 20 mA or 0 to 20 mA 1 Factory calibrated to 68 µA pe r c ount +5 VDC and +12 VDC from backplane 250 ms (all channels) Determined by I/O scan time and is application dependent + 0.25% @ 25 °C 12 bit (no sign bit) 0 to 850 2000 pF 1 H 5 kV Transient
12 to 24 VAC/DC (can use reverse polarity)
4
On-state Voltage
11.5 to 30 VAC/DC maximum
Off-state Voltage
0 to +4 VAC/DC
On-state Current
3.2 mA minimum
Off-state Current
1 mA maximum
On response Time
10 ms typical
Off response Time
17 ms typical
4 mA (typical) at rated voltage
5 kV Transient
4 1 (common supplies all 4 outputs) SPNO (Single Pole, Normally Open) 30 VDC, 250 VAC 4 A per channel 5 A per common 5 kV Transient 10 mA @ 5 VDC (wetting current) 100 m maximum 70,000 minimum at 1800 operations per hour at rated load Omron G6D-1A-12VDC (G6D datasheet is available from www.europe.omron.com)
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CAUTION! Contacts should be protected with appropriate suppression devices when wired with inductive loads to increase life of relays (please see DO-1 Switching Inductive Loads). Contacts should also be protected with external fusing. * Analogue inputs can be modified from current inputs to voltage inputs by lifting one leg of the 250 channel resistor. Each channel has its own resistor, so any combination of channels can be converted. It is recommended that modules be returned to Semaphore for factory conversion if required. No responsibility will be taken by Semaphore for damage caused to boards during modification performed by clients. The circuit board resistors to change are: channels 1 - 4 = R 39, R41, R43 and R45
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IO-3 Wiring Diagram
* Optional link for DC SUPPLY ONLY. Enables fuse fail LED `FU' on module. CAUTION: when the link is installed a maximum of 30 V AC or DC can be used to power the common. Note: DC powered inputs are low voltage AC inputs can both be used on the same module.
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Analogue Input Examples: 2 wire transmitter
(powered by module) 3 wire transmitter
(powered by module)
4 wire transmitter (powered by module)
2 wire transmitter (powered externally)
3 wire transmitter (powered externally)
4 wire transmitter (powered externally)
Analogue Output Example: Analogue load
Digital Input Examples: Sensing the output form a field contact
Digital Output Examples: Driving external load from digital output
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14.3. IO-4: Combinational Analogue / Digital IO Module
· 2 SPST relay outputs · 2 analogue inputs · 8 digital inputs
This module can be installed in any I/O slot of a 4, 6 or 12 slot backplane. Analogue IO
The IO-3 provides two signal ranges, 0 to 20 mA and 4 to 20 mA. The default range is 4 - 20 mA. A link on the rear of the module selects 4 - 20 mA (link installed) or 0 - 20 mA I/O for all channels.
Channel 1 can be utilized for a strain gauge input of range approximately 50 mV. 5 V excitation voltage is supplied from this module (please refer to the wiring diagram for further information).
Resolution of the converted signals is 12 bits binary (1 part in 4096). The sign bit is not used in the conversion process. The placement of the bits within the data word is shown below.
LSB
MSB
0 D11 D10 D9 D8 D7 D6 D5 D4 D3 D2 D1 D0 0 0 0
Scaling of the input is shown below:
All inputs share a single common and all outputs share a separate common at the zero volt rail.
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Input protection for the module is sufficient to guarantee operation with reduced performance with up to 1500 V common-mode. The module provides electrical isolation of externally generated noise between field wiring and the backplane through the use of optical isolation. To minimise the capacitive loading and noise, all field connections to the module should be wired using a good grade of twisted, shielded instrumentation cable. The shields can be connected to E. The E connection provides access to the backplane (frame ground).
Digital IO
Input characteristics are compatible with a wide range of user supplied input devices, such as push buttons, limit switches and electronic proximity switches, whilst outputs can control a wide range of user supplied load devices such as: motor starters, solenoids and indicators. Power for the internal relay circuits is provided by the +12 VDC bus on the backplane. The user must supply the AC or DC power to operate field devices. An internal fuse protects the relay contacts should ratings be exceeded.
An insert goes between the inside and outside surface of the hinged door. The surface towards the inside of the module (when the hinged door is closed) has circuit wiring information and circuit identification information can be recorded on the outside surface. The outside left edge of the insert is colour-coded blue to indicate a low-voltage module.
(Image for demonstration purposes only)
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IO-4 Module LEDs
LED OK FU A1-A8 B1-B2
State
OFF ON OFF ON OFF ON OFF ON
Description
Module fault (no power) Normal Fuse OK Fuse fail
Digital input OFF Digital input ON Digital output OFF (open) Digital output ON (closed)
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IO-4 Analogue / Digital Combinational Module Specifications
Operating Temperature -20 to 70 °C
Storage Temperature -40 to +85 °C
Humidity 5 to 95% RH non-condensing
Output Power 24 VDC @ 125 mA (3 W) Isolated
Hot Swap
Yes. Module can be swapped while RTU is running. Hot swap will not cause a Warm Start. Outputs will be restored within 2 seconds once module is replaced. Inputs will be cleared while module is removed.
ANALOG INPUTS
Input Current Ranges 4-20 mA and 0-20 mA
Input Voltage Ranges * 1-5 V and 0-5 V *
Inputs per Module 2
Calibration Factory calibrated to 5 µA
Update Rate 2 ms (all four channels)
Accuracy + 0.25% @ 25 °C
Resolution 12 bit (no sign bit)
Common Mode Voltage 1500 V
Linearity <1 Least Significant Bit
Isolation 1000 VRMS between field and logic
Common Mode Rejection >70 dB at DC; >70 dB at 60 Hz
Cross-Channel Rejection >80 dB from DC to 1 kHz
Input Impedance 250 standard 15 k optional *. The internal load resistors can be factory removed if high impedance voltage inputs are required.
Input Filter Response 325 Hz
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DIGITAL INPUTS
Rated Voltage 12 to 24 VAC/DC (can use reverse polarity)
Inputs per Module 8
Input Characteristics On-state Voltage 11.5 to 30 VAC/DC maximum
Off-state Voltage 0 to +4 VAC/DC
On-state Current 3.2 mA minimum
Off-state Current 1 mA maximum
On response Time 10 ms typical
Off response Time 17 ms typical
Input Current
4 mA (typical) at rated voltage
Isolation
1000 Vrms between field and logic
DIGITAL OUTPUTS
Outputs per Module 2
Commons 1 (common supplies both outputs)
Relay Type SPST (Single Pole Single Throw)
Maximum Switched Voltage 30 VDC, 250 VAC
Maximum Switched Current 5 A per channel 8 A per common
Isolation 3 kV coil to contacts
Minimum Load 10 mA @ 5 VDC
Contact Resistance 100 m maximum
Relay Operations 70,000 minimum at 1800 operations per hour at rated load
Relay Part Number Omron G6D-1A-12 VDC (G6D datasheet is available from www.europe.omron.com)
CAUTION! Contacts should be protected with appropriate suppression devices when wired with inductive loads to increase life of relays (please see DO-1 Switching Inductive Loads). Contacts should also be protected with external fusing.
* Analogue inputs can be modified from current inputs to voltage inputs by lifting one leg of the 250 channel resistor. Each channel has its own resistor, so any combination of channels can be converted. It is recommended that modules be returned to Semaphore for factory conversion if required. No responsibility will be taken by Semaphore for damage caused to boards during modification performed by clients. The circuit board resistors to change are: channels 1 - 2 = R85 & R41
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IO-4 Wiring Diagram
* Optional link for DC SUPPLY ONLY. Enables fuse fail LED `FU' on module. CAUTION! When link is installed, a maximum voltage of 30 V AC or DC can be used to power the common
Strain gauge input (4 wire Wheatstone bridge)
2 wire transmitter (powered by module)
3 wire transmitter (powered by module)
4 wire transmitter (powered by module)
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2 wire transmitter (externally powered)
3 wire transmitter (externally powered)
4 wire transmitter (externally powered)
Field contact input (externally powered)
Driving digital load (externally powered) Passive field contact (powered by module)
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14.4. IO-5: Combinational Analogue / Digital IO Module
· 4 sinking solid state outputs · 4 analog inputs · 4 digital inputs · 1 analog output with open line detection
This module can be installed in any I/O slot of a 4, 6 or 12 slot backplane.
Analogue IO
Input protection for the module is sufficient to guarantee operation with reduced performance with up to 1500 V common-mode. The module provides electrical isolation of externally generated noise between field wiring and the backplane through the use of optical isolation.
To minimise the capacitive loading and noise, all field connections to the module should be wired using a good grade of twisted, shielded instrumentation cable. The shields can be connected to E. The E connection provides access to the backplane (frame ground).
Resolution of the converted signals is 12 bits binary (1 part in 4096). The sign bit is not used in the conversion process. The placement of the bits within the data word is shown below.
LSB
MSB
0 D11 D10 D9 D8 D7 D6 D5 D4 D3 D2 D1 D0 0 0 0
Scaling of the input is shown below:
All inputs share a single common and all outputs share a separate common at the zero volt rail.
For analogue outputs, an Open Line Detection circuit will indicate whether current loop is open or closed. Please note that open line detection circuit performance cannot be guaranteed when AO value is set to less than 1% (328 decimal) of full scale in the 0-20 mA range.
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The IO-3 provides two signal ranges, 0 to 20 mA and 4 to 20 mA. The default range is 4 - 20 mA. A link on the rear of the module selects 4 - 20 mA (link installed) or 0 - 20 mA I/O for all channels.
Digital Inputs For high speed isolated digital inputs are provided on the module. All four digital inputs share on one common rail. All channels can be configured as pulse counters that appear 16 bit unsigned integer values in the analogue input registers of the RTU processor module. Because of processor module limitations, only channels 1 and 2 can be configured as pulse counters when used with the CP-11/12/21 and PC-1 processors (Toolbox32). All four channels can be used as pulse counters when used with CP-30 processor module (Toolbox PLUS+). Input characteristics are compatible with a wide range of user supplied input devices, such as push buttons, limit switches, Hall sensors, proximity switches, etc. Digital Outputs Input characteristics are compatible with a wide range of user supplied input devices, such as push buttons, limit switches and electronic proximity switches, whilst outputs can control a wide range of user supplied load devices such as: motor starters, solenoids and indicators. Power for the internal relay circuits is provided by the +12 VDC bus on the backplane. The user must supply the AC or DC power to operate field devices. An internal fuse protects the relay contacts should ratings be exceeded.
An insert goes between the inside and outside surface of the hinged door. The surface towards the inside of the module (when the hinged door is closed) has circuit wiring information and circuit identification information can be recorded on the outside surface. The outside left edge of the insert is colour-coded blue to indicate a low-voltage module. (Image for demonstration purposes only)
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IO-5 Module LEDs
LED OK RST 24Va AI 1-4 AO1 OL DI 1-4 DO 1-4
State OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON
Description Module fault (no power) Normal
Module Reset in progress Field Power disabled Field Power enabled Analogue input is less or equal to 1% of range Analogue input is greater than 1% of range Analogue output is set to less or equal to 1% of range Analogue output is set to greater than 1% of range Analogue output line is closed (loaded) Analogue output line is open / loop current equal to zero Digital input OFF Digital input ON Digital output OFF (Output switch does not conduct) Digital output ON (Output switch conducts)
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IO-5 Analogue / Digital Combinational Module Specifications Operating Temperature -20 to 70 °C
Storage Temperature -40 to +85 °C Humidity 5 to 95% RH non-condensing
Maximum Working 42.4 Vpeak / 60 VDC relative to system (backplane) ground Voltage on any contact
of the field connector Hot Swap Yes. Module can be swapped while RTU is running. Hot swap will not cause a Warm Start.
ANALOG INPUTS Input Current Ranges 4 - 20 mA or 0 - 20 mA
Input Voltage Ranges * 1 - 5 V or 0 - 5 V * Inputs per Module 4 Resolution Unsigned 12 bit
Accuracy (includes Gain, ± 0.25% @ 25 °C Linearity and Offset ± 0.50% @ -20 to 70 °C errors) Update Rate 120 ms
Cross-Channel Rejection > 115 dB from DC to 1 kHz Input Impedance 250 standard 1 M optional *. The internal load resistors can be factory removed if high impedance voltage inputs are required.
Input Filter Bandwidth (- 7 Hz 3 dB cut-off)
AC noise attenuation 16 dB @ 50 Hz 18 dB @ 60 Hz
Output Field Power 24 VDC @ 80 mA Isolated Isolation 5 kV Transient
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ANALOG OUTPUT Output Current Range 4 - 20 mA or 0 - 20 mA Outputs per Module 1 Output Type Isolated, Sourcing Resolution Unsigned 12 bit Update Rate 250 ms Determined by I/O scan time and is application dependent
Accuracy (includes Gain, ± 0.25% @ 25°C Linearity and Offset errors) ± 0.50% @ -20 to 70 °C
User Load 0 to 850 Isolat ion 5 kV Transient
DIGITAL INPUTS Inputs per Module 4 with one common Input Type Optically isolated, Sinking Max Input Voltage 30 VDC
Guaranteed On-state 10 VDC min Voltage
Guaranteed Off-state 4.0 VDC max Voltage
Counters Type Pulse, Unsigned 16-bit (all channels) Maximum Counters Speed 10 kHz
Input Current Approx. (Vin / 4.7) mA: 2 mA @ 9.4 V in; 6.4 mA @ 30 V in
Isolat ion 5 kV Transient
DIGITAL OUTPUTS Outputs per Module 4 with one common Output Type Optically isolated, Solid State, Sinking Maximum Switched 30 VDC Voltage Maximum Switched 2 A per channel Current Isolat ion 5 kV Transient
* Analogue inputs can be modified from current inputs to voltage inputs by lifting one leg or by the complete removal of the 250 channel resistor from the board. Each channel has its own resistor, so any combination of channels can be converted. It is recommended that modules be returned to Semaphore for factory conversion if required. No responsibility will be taken by Semaphore for damage caused to boards during modification performed by clients. The circuit board resistors to change are: Ch.1: R81 (or R85+R86); Ch.2: R82 (or R87+R88); Ch.3: R83 (or R89+R90); Ch.1: R84 (or R91+R92).
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IO-5 Wiring Diagram
Analogue Input Examples: 2 wire transmitter
(powered by module)
3 wire transmitter (powered by module)
4 wire transmitter (powered by module)
2 wire transmitter (powered externally)
3 wire transmitter (powered externally)
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4 wire transmitter (powered externally)
Analogue Output Example: Analogue load
Digital Input Examples: Sensing the output form a field contact
Digital Output Examples: Driving external load from digital output
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15. Adaptors and Cables
A range of adaptor and cable accessories are available for the Kingfisher range to allow for communications interfacing. The adaptor plugs universally adapt to RJ45 to allow standard CAT5/6 cabling to be used between RTUs, PLCs and communications devices. Connectivity Example
Reference
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Summary of available adaptors
Part Number ADP-04 ADP-05 ADP-N
ADP-05-N ADP-07 ADP-08
ADP-08 M
ADP-16 ADP-25 ADP-28 ADP-29 ADP-31 RJC-05 RJC-10 RJC-20 RJC-30 RJC-50 RJC-100 RJC-ADP-22B
RJC-ADP-26 RJC-ADP-27 RJC-ADP-30
RJC-45/12 RJC-X-OVER RJC-ETHER-X-
OVER CAB-OPTION-J
CAB-IO-1 CAB-IO-2 CAB-IO-5 CAB-ACR-00 CAB-ACR-AU CAB-ACR-EU CAB-ACR-IN CAB-ACR-UK CAB-ACR-US CAB-FO-PATCH-1 CAB-FO-PATCH-2
Description Maxon and Tait radios (DB9F to RJ45 Adaptor) for 'R' option PC Serial Port (DB9F to RJ45 Adaptor) for 'I' & 'S' options DB9 port saver. Used with ADP-05 for concealed PC serial ports (E.g. Current HP Notebooks) PC Serial Port (DB9F to RJ45 Adaptor) for 'I' & 'S' options DB9 port saver. PSTN modem external 25 pin (DB25M to RJ45 Adaptor) for 'S' options, confirm PSTN pin-outs RJ45 to DB9 Female Converter (Straight Connect) RJ45 to DB9 Male Converter (Straight Connect) for Serial Port to MaxStream External Spread Spectrum Radio Trio "D" and "E" Series Radio (DB9M to RJ45 Adapter) for 'S' options Uni-Op Display Model - MD02R-04-00A5 (DB15M to RJ45 Adapter) for 'S' options Trio "H" series Spread Spectrum Radio (DB9M to RJ45 Adapter) for 'S' options Trio "M" series Radio (Modem fitted) (DB9M to RJ45 Adapter) for 'S' options Trio "M" series Radio (DB9M to RJ45 Adapter) for PC-1 'R' option Cable RJ45 Plug both ends "1:1" - 0.5 meters Cable RJ45 Plug both ends "1:1" - 1.0 meter Cable RJ45 Plug both ends "1:1" - 2.0 meters Cable RJ45 Plug both ends "1:1" - 3.0 meters Cable RJ45 Plug both ends "1:1" - 5.0 meters Cable RJ45 Plug both ends "1:1" - 10.0 meters Wavecom GSM Cable (RJ45 to HD15) for 'S' options, to suit Fastrack Xtend FXT009, and superseded 1205-1306, Supreme 10 Maxon MM-6280IND 3G Cable (RJ45 to DB15) for 'S' options Motorola Satellite Series 9522 L-Band Cable (RJ45 to DB25) for 'S' options Trio "M" series radio Cable (RJ45 to DB15) for 'L' option RJ45 to RJ12 Phone Lead - 2.0m Serial RJ45 to RJ45 cross over cable - 1.5 meters (useful for testing/commissioning) Ethernet RJ45 to RJ45 cross over cable - 2.0 meters
Image Capture Option cable - SMB to BNC female - 2.5m External I/O cable - 1m External I/O cable - 2m External I/O cable - 5m Cable PSO-ACR Power Supply 2.5M (Flying leads) Cable PSO-ACR Power Supply 2.5M (3 Pin 240V AU-NZ Plug) Cable PSO-ACR Power Supply 2.5M (3 Pin 240V EU Plug) Cable PSO-ACR Power Supply 2.5M (3 Pin BA546A 240V Plug) Cable PSO-ACR Power Supply 2.5M (3 Pin 240V UK Plug) Cable PSO-ACR Power Supply 2.5M (3 Pin 240V UK Plug) Patch Cable for A3 Ethernet Option Board (MTRJ to ST) Patch Cable for A3 Ethernet Option Board (MTRJ to SC)
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15.1. RTU Test Cables
RJC-X-Over: Kingfisher PLUS RJ45 to RH45 RS232 Null Modem Cable (serial crossover)
RJ45 to Kingfisher RTU Serial Port
RJ45 to Kingfisher RTU Serial Port
RJC-X-Over-E: Kingfisher PLUS+ RJ45 to RJ45 Ethernet Crossover Cable
RJ45 to Kingfisher RTU Ethernet Port
RJ45 to Kingfisher RTU Ethernet Port
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15.2. Device Cables and Adaptors
ADP-04: PC-1/MC-1 Radio Port to Tait T2010 or Maxon RDM-01 Radio (SD125)
RJ45 to Kingfisher RTU Radio Port
To Tait 2010 or Maxon RDM-01 radio
ADP-05: RTU Serial Port to PC Serial Port (Creates a null modem cable)
To Kingfisher Serial Port
To PC Serial Port
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ADP-07: RTU Serial Port to External PSTN Modem
To Kingfisher Serial Port
To PSTN Modem
ADP-08: RJ45 to DB9 Female Converter (Straight Connect)
(Note: when coupled with an ADP-05 forms a null modem cable DB9 female to DB9 female)
To Kingfisher Serial Port
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To External Device
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ADP-08-M: Serial Port to Digi External Spread Spectrum Radio For Digi XTend-PKG or XStream-PKG, and other 3rd party radios.
To Kingfisher Serial Port
ADP-09: Serial Port to HITECH or Nematron Display Panel
To External Radio
To Kingfisher Serial Port
To Operators Panel
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ADP-16: Serial Port to Trio D-Series Radio or Trio E Series Radio For example TC-450ER or TC-900DR.
To Kingfisher Serial Port
To Trio Radio
RJC-ADP-17: PC-1/MC-1 Radio Port to Trio S- Series Radio
For TC-450SR, TC-900SR or RTU Serial Port to Trio S-Series Radio with 24/48SR modem.
To Kingfisher Serial Port
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To Trio Radio
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RJC-ADP-18: CP-xx Line Option Board to Maxon Analogue Radio (Maxon SD-125)
To Kingfisher Serial Port
To Maxon Radio
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RJC-ADP-20: CP-xx Line Option Board to Trio S Series Analogue Radio For use with TC-450SR or TC-900SR.
To Kingfisher Serial Port
To Maxon Radio
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RJC-ADP-21: CP-xx Line Option Board to Tait T2010 Analogue Radio
To Kingfisher Serial Port
To Tait Radio
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RJC-ADP-22B: Serial Port to Wavecom GSM For use with the WM02-G900, Fastrack, Fastrack Supreme, or Fastrack Xtend. Note: Adds a RTS/DTR link to the previous RJC-ADP-22 cable. Link required for Fastrack Supreme. Link will also work with the older WM02-G900 and Fastrack modems.
To Kingfisher Serial Port
To GSM or GPRS Modem
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RJC-ADP-23: PC-1/MC-1 Radio Port/Serial Port to Trio S- Series (SB) Repeater
To Kingfisher Serial Port
To GSM or GPRS Modem
RJC-ADP-26: Serial Port to Maxon MM-6280IND 3G Data Modem (previously used for the Maxon MM-5100 CDMA Modem)
To Kingfisher Serial Port
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To 3G Data Modem
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RJC-ADP-27: RTU Serial Port to Motorola 9522 Satellite Transceiver
To Kingfisher Serial Port
To Satellite Transceiver
ADP-28: RTU Serial Port to Trio HSeries Spread Spectrum Radio
To Kingfisher Serial Port
To Trio Radio
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ADP-29: Serial Port to Trio M Series Radio (with modem fitted) E.g. MR540
To Kingfisher Serial Port
To Trio Radio
RJC-ADP-30: CP-xx Line Option Board to Trio M Series Analogue Radio (no modem fitted) E.g. MR540
To Kingfisher Serial Port
To Trio Radio
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ADP-31: PC-1/MC-1 Radio Port to Trio M Series Analogue Radio (no modem fitted) E.g. MR540
To Kingfisher Serial Port
To Trio Radio
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CAB-FO-PATCH-1: A3 Ethernet MTRJ Fibre Optic to 2 × ST adaptor cable
To Kingfisher A3 Option Board
To external Device
CAB-FO-PATCH-2: A3 Ethernet MTRJ Fibre Optic to 2 × SC adaptor cable
To Kingfisher A3 Option Board
Maxon Intermax Serial Modem to Kingfisher Serial Port
To external Device
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16. Accessories
Accessories are available that can ease the installation of your RTU. These include rack mounting hardware and battery carrier mounts. MBR-3: 19" Rack Mounting for BA-12
A 12 slot backplane (BA-12) is mounted in a 19 inch rack using two MBR-3 mounting brackets. The MBR-3 brackets replace the surface mount brackets supplied with BA-12 backplanes. Each pair of MBR-3 brackets is supplied with four M4 x 6 mm pan head screws.
Installation Note: The holes in the MBR-3 brackets that are used to attach the brackets to the back of the backplane are drilled oversize to accommodate slight variances in racking equipment. By loosening these screws, pushing the brackets toward the centre of the backplane and then re-tightening the screws, the unit will fit freely into any correctly sized 19-inch rack.
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TEL-RAK-002: 19" Rack Mounting for BA-3/6/40 A four slot backplane (BA-4 or BA-40) or a six slot backplane (BA-6) is mounted in a 19 inch rack using a TEL-RAK-002 mounting bracket. One BA-6 or two BA-4/BA-40 backplanes can be attached to the TEL-RAK-002 using the surface mount brackets supplied with each backplane. The TEL-RAK-002 is supplied with eight M3 x 5 mm screws for attaching the backplane(s).
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Battery Bracket: 7 AH: 7 AH Battery Mounting Bracket When using a 7 AH backup battery, a standard battery holder is available for mounting on an enclosure gear plate. The bracket supports the battery and allows a General Power Outlet (GPO) to be mounted on the front using M3 x 10 mm pan head screws. The battery holder also allows an ISB50LN lightning arrestor to be mounted underneath.
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17. Glossary
AI, AO, DI, DO Byte Comms Current Sinking IO IP Port Processor Module Protocol
RTU
TCP/IP UDP
Analogue Input, Analogue Output, Digital Input and Digital Output respectively A group of 8 bits. Each bit can be a 0 (off) or a 1 (on) allowing up to 256 combinations. Communications
Current is supplied into the RTU's IO terminal.
Input, Output
Internet Protocol. Used for Ethernet communications.
A physical connection or socket on an RTU used for communications
Processor module containing a CPU (central processing unit)
Refers to the format of messages that may be passed to, from and through an RTU in communication with local and remote devices. Communications may use one or more RTU ports. Examples of protocols used within telemetry include Kingfisher, Modbus and DNP3. Acronym for Remote Terminal Unit. Describes a group of processor, communications and IO modules that comprise a device for monitoring and control of equipment in remote locations. Transfer Control Protocol / Internet Protocol. Commonly used for Ethernet communications. User Datagram Protocol.
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18. Appendix
Superseded items are not present in this hardware manual. For information regarding any modules not present in this document please refer to the Superseded Hardware Manual available on MyKingfisher.
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AD2006
Telemetry Module
AD2006 TELEMETRY MODULE QUICKSTART MANUAL
This manual is intended to provide sufficient information for the correct installation of your AD2006 telemetry module. In most cases, your AD2006 module will be delivered pre-configured to your project requirements. For programming information please refer to the MiriMap 2000+ Software on-line help.
PLEASE ENSURE THAT YOU HAVE THE CORRECT POWER SUPPLY VOLTAGE BEFORE POWERING UP THE MODULE.
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AD2006
Ordering Information
There are many variations of the AD2006 telemetry modules available. The following shows the ordering code and details for modules with and without internal data radios. For other radio or modem options please contact Miri Technologies directly.
The following options are not fitted as factory standard and need to be requested when ordering : -
4 Channel Analog Ouput option Ethernet Port option
If you are ordering a module to add to an existing system, please be sure to specify the project when ordering the new module.
ORDERING
Part No. AD2006Tx-aaabb-xx-xx
Add `T' for Ethernet Option Otherwise leave blank
12 - for 12VDC supply. 24 - for 24VDC supply.
N - for no analog output option. A - for analog output option fitted.
L - for low voltage digital inputs 10 - 35V H - for hi voltage digital inputs 70 - 130V
12 - 12.5kHz Channel 25 - 25kHz Channel SS - Spread Spectrum
Radio Type : J02 VHF 138 - 174MHz (12.5KHz only) J51 UHF 450 - 470MHz (12.5KHz only) M50 UHF 395 - 465MHz M51 UHF 450 - 520MHz 90 900MHz Spread Spectrum 24 2.4GHz Spread Spectrum
R - with inbuilt radio E - for external radio
The AD2006 part number is displayed on the rear of each unit together with other relevant information.
AD2006R-M5125-LN-12
Hardware version - Rev. 4
serial no
Tx frequency - 450.650 MHz Rx frequency - 450.650 MHz
special
Brockman Return Water Pumps
10462
Miri Technologies - Perth, West Australia. tel. +61 8 9409 8998 fax. +61 8 9409 9229
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AD2006
Overview
PORT5 RS232 or ETHERNET
PORT4 USB
PORT3 RS485
12V + _ +
_
DOT 1
2 1A
3 2A
4 3A
3B 4A 4B
DIN 1
9
2
3 10
4 11
5 12
6 13
7 14
8 15
C1 16 C2
ALG 1 5
234 678
G G
PTT TEST BUTTON
PROG /RUN SWITCH
POWER SUPPLY
4 DIGITAL OUTPUTS
16 DIGITAL INPUTS
8 ANALOG CHANNELS
PORT1 EXTERNAL
FFSK or RS232
PORT2 RS232
DISPLAY PANEL
pwr
The pwr LED should be on at all times when the unit is powered up.
run
The run LED should flash at 2Hz when the unit is in RUN mode and 4Hz in PROG mode.
fault radio
tx rx
A fault means that the module has received a bad reply to a message. The tx and rx LEDs reflect the PTT and CD status of the internal radio.
tx rx lnk
port 1 port 2 port 3 port 4
The tx and rx LEDs for each port indicate that a valid system message has been sent or received on that port. A link indication means that the slave time-out period for that port has lapsed or the programmed number of retries have failed and communications have been lost.
port 5 DOT
config 12341234
12345678
The first four LEDs indicate that the physical outputs are active. The second four LEDs are programmable status indications.
DIN
These LEDs indicate that a particular input is active.
9 10 11 12 13 14 15 16
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AD2006
Digital I/O
DIGITAL INPUTS
There are two different versions of the AD2006 module with respect to Digital Inputs. There is a low voltage version for nominally 12 or 24 volt inputs, and a high voltage version specifically for 110 volt inputs.
AD2006L - Lo Voltage AD2006H - Hi Voltage
10-35VDC/AC 4k7 Impedance 70-130VAC/DC 27k Impedance
This is not an on-board selectable option so please ensure that you have the correct version of hardware for your application. The digital input voltage is marked on the terminal strip label with the Lo voltage inputs being highlighted in blue and the Hi voltage inputs being highlighted in orange. The digital inputs are supplied in two blocks of 8 inputs each with a separate common terminal. The inputs will accept an AC input voltage or a DC voltage of either polarity .
PULSE COUNTERS
Each Digital Input may be used as a pulse counter up to 5Hz. The first two inputs can be configured as high speed pulse counters up to 5KHz equal (mark space ratio). Where the inputs are used as slow counters (to 5Hz.) the inputs are usually referred to the digital input common. Where the fast pulse counters are used, the inputs are referred to the module 0V supply (ground). They will then accept inputs from common emitter transistors, FETs or reed switches etc. as shown below. The factory default setting is for all inputs to be configured as digital inputs/slow counters. The following jumper settings apply where inputs 1 and 2 are required to be fast counters.
All inputs DINs (factory default) DIN1 - Fast Pulse
DIN2 - Fast Pulse
J27 J30 A
B J28 J29
J27 J30 A
B J28 J29
J27 J30 A
B J28 J29
12V + + _ _
+_
12 VDC supply
DIN
1
9
2
3 10
4 5 6 7 8 C1 11 12 13 14 15 16 C2
S1
S2
Fast pulse input
DIGITAL OUTPUTS Each Digital Output may be individually configured as an isolated relay or common emitter transistor.
LOAD LOAD LOAD LOAD
LOAD LOAD LOAD LOAD
RLY4 RLY3 RLY2 RLY1
With all jumpers J12 - J15 in position A the module is configured for 2 form A and 2 form C relay outputs. (factory default)
RL2
RL4
RL1
RL3
J12 J13 J14 J15 A
B
DOT
1 2 3 4 3B 1A 2A 3A 4A 4B
S1 S2 S3 S4 LOAD - 3 AMPS MAX.
@ 30VDC MAX. or 240VAC
With all jumpers J12 J15 in position B, all outputs are common emitter transistors.
J12 J13 J14 J15 A
B
12V + + _ _
DOT
1 2 3 4 3B 1A 2A 3A 4A 4B
LOAD
100mA MAX.
+
_ @ 30VDC MAX.
S1 S2 S3 S4
12 VDC
supply
++++
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AD2006
Analog Options
The AD2006 module has 8 analog input channels as standard. These are configured from the factory as 4-20mA/1-5V. The following options are available by jumper selection :-
A. 0-20mA/0-5V B. 4-20mA/1-5V C. 0-1V
Whichever option is selected determines the configuration of ALL analog input channels. Channels 1 to 8 are configured for current or voltage inputs via jumpers J35 to J42 respectively. If a jumper is installed in the appropriate location then that channel will operate as a current input. If no jumper is installed, it will operate as a voltage input.
FACTORY DEFAULTS - All channels set to 4-20mA
J26 J25 J35 J36 J37 J38
A B
J39 J40 J41 J42
J16 J20 J4 J10 A B
J24 J22 J5 J9 J11
OTHER OPTIONS
All input channels 0-20mA All input channels 1-5V All input channels 0-5V All input channels 0-1V
J26 J25 J35 J36 J37 J38
A B
J39 J40 J41 J42 J26 J25
J35 J36 J37 J38 A B
J39 J40 J41 J42 J26 J25
J35 J36 J37 J38 A B
J39 J40 J41 J42 J26 J25
J35 J36 J37 J38 A B
J39 J40 J41 J42
POWER SUPPLY MONITOR - Analog Input channel 8 is set by factory default to monitor the supply voltage to the telemetry module. This is particularly useful in solar powered installations. If channel 8 is required as a normal analog input channel then J24 is moved from position A to position B.
VOLTAGE SOURCE FOR FIELD SENSORS - Analog input channel 8 can be configured as a 5V source to power field sensors to a maximum current supply of 20mA. To select this option, install jumpers in J16 position B and J22 position A.
ANALOG OUTPUT OPTION - An analog output board must be installed to utilise this option. This is a factory fitted option. When the analog output option is installed, any of the last four channels can be configured as 4-20mA outputs.
ANALOG OUTPUTS - Channels 5-8 configured as outputs
J26 J25 J35 J36 J37 J38
A B
J39 J40 J41 J42
J16 J20 J4 J10 A B
J42 J22 J5 J9 J11
Channels 5 to 8 are selected as 4-20mA outputs by way of locating jumpers in position A as follows :-
Ch.5 J4 Ch.6 J5 Ch.7 J20 Ch.8 J22 and J16
Note - If channel 8 is configured as an analog output, analog input 8 will still operate as a supply voltage monitor, provided that J24 is selected in position A.
Note - J9, J10 and J11 are not relevant to the analog channel options.
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AD2006
Serial Ports
PORT 1 - EXTERNAL RADIO - FFSK or RS232
Port 1 is intended for connection to an external data radio and provides either FFSK or RS232 options. The FFSK is configurable to 4800 baud. The RS232 option can operate up to 115,200 baud. The on-board selectable options are detailed on the following page of this manual.
PORT 2 & PORT 5 - RS232
Port 2 and Port 5 can both be used for connection to third party devices via RS232. Each port can operate up to 115,200 baud. The on-board selectable options are detailed in the following page of this manual.
NOTE : Port 5 cannot be used as an RS232 port if the Ethernet connection is being used.
PORT 3 - RS485
Port 3 is an RS485 port intended for use as a multidrop serial connection for I/O expansion modules or third party devices. It can run either Miri protocol or Modbus.
PORT 4 - USB-B
This port is intended for use as a programming port.
PORT 5 - Ethernet Option
The Ethernet port is a factory fitted 10/100T option which can run either Modbus TCP or Miri protocols. Note that where the Ethernet port is used, Port 5 cannot be used as an RS232 port.
External Radio Port Pin assignment
1.
n/c
2.
RTS
3.
TX data
4.
PTT
5.
GND
6.
RX data
7.
CTS
8.
CD
External RS232 ports Pin assignment
1.
DTR
2.
RTS
3.
TX data
4.
PTT
5.
GND
6.
RX data
7.
CTS
8.
DSR
External RS485 port Pin assignment
1.
DATA B
2.
DATA A
3.
GND
View looking into ext. radio port.
8 PIN 1
View looking into RS232 ports.
8 PIN 1
View looking into RS485 port.
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AD2006
Radio Communications Options
FACTORY DEFAULTS - Internal radio - 2400 baud.
J8 J49 J1 J18 A B A B A B
INTERNAL RS232
INTERNAL FFSK J34 J33
J2 J6
A
TX LEVEL
VR5
J17
J7
B
AB
A
BA
RX LEVEL
VR6
J3
J50
B
AB
FFSK BAUD RATE OPTIONS - The jumper arrangement shown is the factory default configuration for an internal radio operating at 2400 baud.
Other options are achieved by implementing the following changes to J18, J33, J34.
1200
J18
2400
J18
4800
J18
J34 J33
J34 J33
J34 J33
FFSK EXTERNAL RADIO - To configure the module for an external audio radio, make the following changes to J1, J3, J7, J8, and J9, J10, J11.
J8 J49 J1 J18 A B A B A B
J7
J3
J50
A BA B
AB
J16 J20 J4 J10 A J19
B J42 J22 J5 J9 J11
PTT PUSH BUTTON
J16 J20 J4 J10 A
B J42 J22 J5 J9 J11
RS232 EXTERNAL RADIO CONNECTION - To configure the module for an external RS232 radio port, jumpers J1, J9, J10, J11 should be set up as follows :-
EXTERNAL RADIO
There are a number of radio options available for the AD2006 modules. Some of these use audio (FFSK) modulation, whereas others have an RS232 interface. The above jumper configuration is applicable to both VHF and UHF internal radios. If an audio (FFSK) external radio is to be used with the module, this is implemented using Port1. Ports 2 and 5 are available for RS232 connections.
There is a PTT push button located under the bottom right hand corner of the module. This is intended to be used to check the SWR of antenna installations during commissioning.
J8 J49 J1 J18 A B A B A B
J16 J20 J4 J10 A B
J42 J22 J5 J9 J11
NOTE - The above configuration is the factory default configuration and so it may not be necessary to move any jumpers to implement this mode.
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AD2006
Mounting Detail
272
The AD2006 module is installed by means of the clip in stainless steel mounting bracket supplied with the unit.
Please ensure when mounting the telemetry module that sufficient clearance is left for wiring to and from the unit. Recommended minimum clearances are shown here.
The module is removed by depressing the small tongue at the bottom of the mounting bracket and sliding the unit upwards.
278
90
The terminal blocks are
removable such that the I/O
25
wiring need not be disturbed
when replacing a module in the
field.
202
AD2006
Mounting holes 4.5mm
MOUNTING PLATE
60
60
CL
50
178
50
50
miri AD2006
technologies Wiring Diagram
Internal DC-DC converter
The digital outputs are configurable for relay or solid state format as described in this manual. The relay format is shown here. The relays are isolated - 2 form A , 2 form C.
RL2
RL4
There are 8 Analog input channels which share a common ground. Channels 5 - 8 may be configured as 4-20mA analog outputs by way of a factory installed analog output option.
Fuse 2A 20 x 5mm
RL1
RL3
The digital inputs are optically isolated to 2.5KV. There are two separate groups of 8 inputs each with a separate common. These will both have the same voltage range and can accept either AC or DC source voltages.
12V
+_ +
_
DOT 1
1A
2 2A
3 3A
4
3B 4A 4B
DIN1
2 3 4 5 6 7 8 C1 9 10 11 12 13 14 15 16 C2
ALG 1
2 5
6
3
4 7
G 8
G
+
POWER SUPPLY 10.5 - 16VDC
LOAD LOAD LOAD LOAD
S1 S2 S3 S4
LOAD - 3 AMPS MAX. @ 30VDC MAX. or 250VAC MAX.
NEGATIVE SUPPLY & COAXIAL CONNECTION MUST BE GROUNDED
S1 S2
A1 A2 A3 A4 A5 A6 A7 A8
DIGITAL INPUTS : AD2006 `L' 10 - 35VAC/DC AD2006 `H' 70 - 130VAC/DC
PLEASE ENSURE THAT YOU HAVE THE CORRECT INPUT VOLTAGE BEFORE CONNECTION !
The analog input channels are configurable as 4-20ma /1-5V, 0-20mA / 0-5V or 0-1V.
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Cellular Transit Antenna
The TLA2000 is an ideal antenna solution for GSM data applications in both fixed and mobile situations. Designed to offer true dual band performance the TLA2000 is ready for use with the latest GSM (GPRS) modems. With a high impact resistant vacuum formed ABS radome and neoprene mounting gasket, the TLA2000 can be used for indoor or outdoor applications.
· Applications include public vending machines, ATM kiosks and industrial automotive use
· Designed for use on conductive or nonconductive surfaces
· TLA3000 model incorporates integrated GPS antenna
Typical VSWR response GSM900
2.5
2.4
2.3
2.2
2.1
2.0
1.9
1.8
1.7
1.6
1.5
-35
+35
Typical VSWR response GSM1800
-85
+85
890-960 MHz 1710-1880 MHz
TLA2000 TLA3000
TLA2000/3000
Typical E-Plane response @ 890MHz
Electrical
Model No. Gain dBi Frequency MHz Power W Tuned Bandwidth Tuning
Mechanical
Model No. Construction Diameter mm Height mm Mounting
Cable and Connector
TLA2000/3000 2
890 - 960 / 1710 - 1880 10
Entire specified band @<2.5:1 VSWR Pre-tuned
TLA2000
TLA3000
White Geloy ASA radome
135 61 (including gasket)
M4 hardware (not included)
500mm low loss 9014 RG58 type
Cellular: 5m 9014 RG58 type - FME connector GPS: 5m low loss RG174 type - MCX connector
GPS Specifications
Fo Operation Temperature Storage Temperature System Gain at Fo Impedance Polarization VSWR at Fo Noise Figure at Fo Power Input Power Consumption Power Input Over-Current
1575.42 MHz -40 to +85°C -40 to +100°C 28dBi including cable and filter losses
50 Ohm RHCP 1.5:1 <1.8 dB max. +2.5Vdc to +12Vdc input, Auto Switching 11mA to 13mA (max) Reverse Polarity Short Circuit Shutdown Thermal over-current shutdown >+150°C
www.rfi.com.au
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Data Sheet WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
NP SERIES - NP7-12
Reliability is your Security
Utilizing the latest advance design Oxygen Recombination Technology, Yuasa have applied their 80 years of experience in the lead acid battery field to produce the optimum design of Sealed Lead Acid batteries.
FEATURES
Superb recovery from deep discharge. Electrolyte suspension system. Gas Recombination. Multipurpose: Float or Cyclic use. Usable in any orientation Superior energy density. Lead calcium grids for extended life. Manufactured World wide. Application specific designs.
Technical Features
Sealed Construction
Yuasa's unique construction and sealing technique ensures no electrolyte leakage from case or terminals.
Electrolyte Suspension System
All NP batteries utilize Yuasa's unique electrolyte suspension system incorporating a microfine glass mat to retain the maximum amount of electrolyte in the cells. The electrolyte is retained in the separator material and there is no free electrolyte to escape from the cells. No gels or other contaminants are added.
Control of Gas Generation
The design of Yuasa's NP batteries incorporates the very latest oxygen recombination technology to effectively control the generation of gas during normal use.
Low Maintenance Operation
Due to the perfectly sealed construction and the recombination of gasses within the cell, the battery is almost maintenance free.
Terminals
Terminals
NP batteries are manufactured using a range of terminals which vary in size and type. Please refer to details as shown.
Operation in any Orientation
The combination of sealed construction and Yuasa's unique electrolyte suspension system allows operation in any orientation, with no loss of performance or fear of electrolyte leakage.
Valve Regulated Design
The batteries are equipped with a simple, safe low pressure venting system which releases excess gas and automatically reseals should there be a build up of gas within the battery due to severe overcharge. Note. On no account should the battery be charged in a sealed container.
General Specifications
Layout
Nominal Capacity (Ah)
20hr to 1 .75vpc 30ºC 1 0hr to 1 .75vpc 20ºC 5hr to 1.70vpc 20ºC 1 hr to 1 .60vpc 20ºC Voltage Energy Density (Wh.L.20hr) Specific Energy (Wh.kg.20hr) Int. Resistance (m.Ohms) Maximum discharge (A) Short Circuit current (A) Dimensions (mm) Length Width Height overall Weight (Kg) Terminal Layout Terminal Torque Nm
NP7-12
7 6.4 5.9 4.2 12 91 32 25 40/75 210
151 65 97.5 2.65 A/D 4 -
Q-Pulswe Idw: TMwS1.5y94uasabatteries.coAmctive: 18/04/2016
NP
Page 355 of 1068
Data Sheet WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
NP SERIES - NP7-12
Lead Calcium Grids
The heavy duty lead calcium alloy grids provide an extra margin of performance and life in both cyclic and float applications and give unparalleled recovery from deep discharge.
Long Cycle Service Life
Depending upon the average depth of discharge, over a thousand discharge/charge cycles can be expected.
Float Service Life
The expected service life is five years in float standby applications.
Separators
The use of the special separator material provides a very efficient insulation between plates preventing inter-plate short circuits and prohibiting the shedding of active materials.
Long shelf Life
The extremely low self discharge rate allows the battery to be stored for extended periods up to one year at normal ambient temperatures with no permanent loss of capacity.
Operating Temperature Range
The batteries can be used over a broad temperature range permitting considerable flexibility in system design and location.
Charge 15°C to 50°C Discharge 20°C to 60°C Storage 20°C to 50°C (fully charged battery)
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Yuasa Battery Inc.
2901 Montrose Ave Laureldale, PA 19605 www.yuasabatteries.com
Registered number 1548820
Cat. No. NP7-12 JanuAarcyt0iv8e: 18/04/2016
Distributed by
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Fastrack Supreme User Guide
WA_DEV_Fastrk_UGD_001
Plug and Play Wireless CPU®
FASTRACK Supreme User Guide
Reference: WA_DEV_Fastrk_UGD_001 Revision: 001e Date: 5 june, 2007
Supports Open AT® embedded ANSI C applications
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Fastrack Supreme User Guide
WA_DEV_Fastrk_UGD_001
Document History
Revision 001 001a 001b 001c 001d 001e
Date 9 February, 07 23 February, 2007
21 May, 07 1 Jun, 07 4 Jun, 07 5 Jun, 07
List of revisions First Issue Update DC cable GPIO mapping, add AutoShutDown Add detail of IES, RTC and serial port autoshutdown Change to Quad Band Update label/packaging photo Comment
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Overview
Fastrack Supreme User Guide
WA_DEV_Fastrk_UGD_001
The FASTRACK Supreme 10 and FASTRACK Supreme 20 are discrete, rugged cellular Plug & Play Wireless CPU® offering state-of-the-art GSM/GPRS (and EGPRS for FASTRACK Supreme 20) connectivity for machine to machine applications.
Proven for reliable, stable performance on wireless networks worldwide, Wavecom's latest generation of FASTRACK Supreme continues to deliver rapid time to market and painless integration.
Having comparable size with the previous M1306B generation, and updated with new features, the FASTRACK Supreme offers an Internal Expansion Socket (IES) interface accessible for customer use. Expanding application features is easy without voiding the warrantee of the FASTRACK Supreme by simply plugging in of an Internal Expansion Socket Module (IESM) board.
Fully certified, the quad band 850/900/1800/1900 MHz FASTRACK Supreme 10 offers GPRS Class 10 capability and FASTRACK Supreme 20 offers GPRS/EGPRS Class 10 capability. Both support a powerful open software platform (Open AT®). Open AT® is the world's most comprehensive cellular development environment, which allows embedded standard ANSI C applications to be natively executed directly on the Wireless CPU®.
FASTRACK Supreme is controlled by firmware through a set of AT commands.
This document describes the FASTRACK Supreme and gives information on the following topics:
· general presentation,
· functional description,
· basic services available,
· technical characteristics,
· installing and using the FASTRACK Supreme,
· user-level troubleshooting.
· recommended accessories to be used with the product.
Note:
This document covers the FASTRACK Supreme Plug & Play alone and does not include The programmable capabilities provided via the use of Open AT® Software Suites. The development guide for IESM for expanding the application feature through the IES interface.
For detailed, please refer to the documents shown in the "Reference documents" section.
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RoHS Directive
Fastrack Supreme User Guide
WA_DEV_Fastrk_UGD_001
The FASTRACK Supreme is now compliant with RoHS Directive 2002/95/EC, which sets limits for the use of certain restricted hazardous substances. This directive states that "from 1st July 2006, new electrical and electronic equipment put on the market does not contain lead, mercury, cadmium, hexavalent chromium, polybrominated biphenyls (PBB), and polybrominated diphenyl ethers (PBDE)".
Plug & Plays which are compliant with this directive are identified by the RoHS logo on their label.
Disposing of the product
This electronic product is subject to the EU Directive 2002/96/EC for Waste Electrical and Electronic Equipment (WEEE). As such, this product must not be disposed off at a municipal waste collection point. Please refer to local regulations for directions on how to dispose off this product in an environmental friendly manner.
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Cautions
Fastrack Supreme User Guide
WA_DEV_Fastrk_UGD_001
Information furnished herein by WAVECOM is accurate and reliable. However, no responsibility is assumed for its use. Please read carefully the safety recommendations given in Section 9 for an application based on FASTRACK Supreme Plug & Play.
Trademarks
®, WAVECOM®, Wireless CPU®, Open AT® and certain other trademarks and logos appearing on this document, are filed or registered trademarks of Wavecom S.A. in France or in other countries. All other company and/or product names mentioned may be filed or registered trademarks of their respective owners.
Copyright
This manual is copyrighted by WAVECOM with all rights reserved. No part of this manual may be reproduced in any form without the prior written permission of WAVECOM. No patent liability is assumed with respect to the use of their respective owners.
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Fastrack Supreme User Guide
WA_DEV_Fastrk_UGD_001
Web Site Support
General information about Wavecom and its range of products:
Specific support is available for the FASTRACK Supreme Plug & Play Wireless CPU®: Open AT® Introduction:
Developer community for software and hardware:
www.wavecom.com TBD www.wavecom.com/OpenAT www.wavecom.com/forum
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Contents
Fastrack Supreme User Guide
WA_DEV_Fastrk_UGD_001
DOCUMENT HISTORY ......................................................................................................................................2
OVERVIEW ........................................................................................................................................................3
CAUTIONS .........................................................................................................................................................5
TRADEMARKS ..................................................................................................................................................5
COPYRIGHT ......................................................................................................................................................5
WEB SITE SUPPORT ........................................................................................................................................6
CONTENTS ........................................................................................................................................................7
LIST OF FIGURES ...........................................................................................................................................11
LIST OF TABLES.............................................................................................................................................12
1 REFERENCES .........................................................................................................................................13
1.1 Reference Documents.........................................................................................................................13
1.1.1
Open AT® Software Documentation ..........................................................................................13
1.1.2
AT Software Documentation......................................................................................................13
1.1.3
Firmware Upgrade Documents..................................................................................................13
1.1.4
Delta between M1306B Documents..........................................................................................13
1.1.5
IESM Related Documents .........................................................................................................13
1.2 Abbreviations .......................................................................................................................................14
2 PACKAGING ............................................................................................................................................17
2.1 Contents ..............................................................................................................................................17 2.2 Packaging Box.....................................................................................................................................18 2.3 Production Labelling ............................................................................................................................19
3 GENERAL PRESENTATION ...................................................................................................................20
3.1 Description...........................................................................................................................................20
3.2 External Connections ..........................................................................................................................22
3.2.1
Connectors ................................................................................................................................22
3.2.1.1
Antenna Connector ............................................................................................................22
3.2.1.2
Power Supply Connector ...................................................................................................22
3.2.1.3
Sub HD 15-pin Connector..................................................................................................23
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Fastrack Supreme User Guide
WA_DEV_Fastrk_UGD_001
3.2.1.4
IES Connector....................................................................................................................25
3.2.2
Power supply cable ...................................................................................................................29
4 FEATURES AND SERVICES...................................................................................................................31
4.1 Basic Features and Services...............................................................................................................31
4.2 Additional NEW Features ....................................................................................................................34
4.2.1
Support Additional GSM850/PCS1900 Bands ..........................................................................34
4.2.2
IES Interface for Easy Expansion of Application Features........................................................34
4.2.3
Serial Port Auto Shut Down or Improving Power Consumption ................................................34
4.2.4
Real Time Clock (RTC) for Saving Date and Time ...................................................................34
4.2.5
SIM Card Lock Feature .............................................................................................................35
5 USING THE FASTRACK SUPREME PLUG & PLAY .............................................................................36
5.1 Getting Started.....................................................................................................................................36
5.1.1
Mount the FASTRACK Supreme...............................................................................................36
5.1.2
Set up the FASTRACK Supreme ..............................................................................................36
5.1.3
Check the communication with the FASTRACK Supreme........................................................37
5.1.4
Reset the FASTRACK Supreme ...............................................................................................37
5.2 Specific Recommendations when Using the FASTRACK Supreme on Trucks ..................................38
5.2.1
Recommended Power Supply Connection on Trucks...............................................................38
5.2.2
Technical Constraints on Trucks ...............................................................................................38
5.3 FASTRACK Supreme Operational Status...........................................................................................39
5.4 Echo Function Disabled.......................................................................................................................40
5.5 Verify the Received Signal Strength....................................................................................................41
5.6 Check the Pin Code Status .................................................................................................................41
5.7 Switch between EU/US Band(s)..........................................................................................................41
5.8 Check the Band(s) Selection ...............................................................................................................42
5.9 Verify the FASTRACK Supreme Network Registration .......................................................................43
5.10 Main AT Commands for the Plug & Play .............................................................................................44
5.11 Firmware Upgrade Procedure .............................................................................................................45
6 TROUBLESHOOTING .............................................................................................................................46
6.1 No Communication with the FASTRACK Supreme through the Serial Link .......................................46 6.2 Receiving "ERROR" Message.............................................................................................................46 6.3 Receiving "NO CARRIER" Message ...................................................................................................47
7 FUNCTIONAL DESCRIPTION .................................................................................................................50
7.1 Architecture..........................................................................................................................................50
7.2 EU and US Bands................................................................................................................................51
7.2.1
General Presentation.................................................................................................................51
7.2.2
AT COMMAND for Bands Switch ..............................................................................................51
7.3 Power Supply.......................................................................................................................................51
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7.3.1 7.3.2
Fastrack Supreme User Guide
WA_DEV_Fastrk_UGD_001 General Presentation.................................................................................................................51 Protections.................................................................................................................................51
7.4 RS232 Serial Link ................................................................................................................................51
7.4.1
General Presentation.................................................................................................................51
7.4.2
Autobauding Mode ....................................................................................................................52
7.4.3
Pin Description...........................................................................................................................53
7.4.4
Serial Port Auto shut down Feature ..........................................................................................53
7.5 General Purpose Input/Output (GPIO) ................................................................................................54
7.6 BOOT...................................................................................................................................................54
7.7 RESET.................................................................................................................................................54
7.7.1
General presentation .................................................................................................................54
7.7.2
Reset Sequence ........................................................................................................................55
7.8 Audio....................................................................................................................................................56
7.8.1
Microphone Inputs .....................................................................................................................56
7.8.2
Speaker Outputs........................................................................................................................57
7.9 Real Time Clock (RTC) .......................................................................................................................58
7.10 FLASH LED 58
8 TECHNICAL CHARACTERISTICS..........................................................................................................59
8.1 Mechanical Characteristics..................................................................................................................59
8.2 Electrical Characteristics .....................................................................................................................61
8.2.1
Power Supply.............................................................................................................................61
8.2.2
Power Consumption ..................................................................................................................62
8.2.3
Audio Interface ..........................................................................................................................65
8.2.4
General Purpose Input/Output...................................................................................................66
8.2.5
SIM Interface .............................................................................................................................66
8.2.6
RESET Signal............................................................................................................................66
8.2.7
RF Characteristics .....................................................................................................................67
8.2.7.1
Frequency Ranges.............................................................................................................67
8.2.7.2
RF Performances...............................................................................................................68
8.2.7.3
External Antenna ...............................................................................................................69
8.3 Environmental Characteristics.............................................................................................................69
8.4 Conformity ...........................................................................................................................................72
8.5 Protections...........................................................................................................................................72
8.5.1
Power Supply.............................................................................................................................72
8.5.2
Overvoltage ...............................................................................................................................73
8.5.3
Electrostatic Discharge..............................................................................................................73
8.5.4
Miscellaneous ............................................................................................................................73
9 SAFETY RECOMMENDATIONS .............................................................................................................74
9.1 General Safety.....................................................................................................................................74 9.2 Vehicle Safety......................................................................................................................................74 9.3 Care and Maintenance ........................................................................................................................75 9.4 Your Responsibility ..............................................................................................................................75
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Fastrack Supreme User Guide
WA_DEV_Fastrk_UGD_001 10 RECOMMENDED ACCESSORIES..........................................................................................................76 11 ONLINE SUPPORT ..................................................................................................................................77
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List of Figures
Fastrack Supreme User Guide
WA_DEV_Fastrk_UGD_001
Figure 1: Complete package contents..............................................................................................................17 Figure 2: Packaging box...................................................................................................................................18 Figure 3: Production Label ...............................................................................................................................19 Figure 4: FASTRACK Supreme general description ........................................................................................20 Figure 5: FASTRACK Supreme holding bridles ...............................................................................................21 Figure 6: SMA connector for antenna connection ............................................................................................22 Figure 7: Power supply connector ....................................................................................................................23 Figure 8: Sub HD 15-pin connector ..................................................................................................................24 Figure 9: IES connector for feature expansion.................................................................................................26 Figure 10: Power supply cable .........................................................................................................................29 Figure 11: SIM card lock feature ......................................................................................................................35 Figure 12: FASTRACK Supreme mounting......................................................................................................36 Figure 13: Recommended power supply connection on trucks........................................................................38 Figure 14: Example of electrical connection which may dramatically damage the FASTRACK Supreme ......39 Figure 15: Functional architecture ....................................................................................................................50 Figure 16: RS232 Serial Link signals ...............................................................................................................52 Figure 17: Reset sequence diagram ................................................................................................................56 Figure 18: Dimensioning diagram.....................................................................................................................60
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List of Tables
Fastrack Supreme User Guide
WA_DEV_Fastrk_UGD_001
.
Table 1: Power supply connector pin description.............................................................................................23 Table 2: Sub HD 15-pin connector description.................................................................................................24 Table 3: IES Connector Description .................................................................................................................27 Table 4: Basic features of the FASTRACK Supreme.......................................................................................31 Table 5: FASTRACK Supreme operational status ...........................................................................................40 Table 6: Values of received signal strength .....................................................................................................41 Table 7: AT+CPIN Responses .........................................................................................................................41 Table 8: AT+WMBS Band Selection ................................................................................................................42 Table 9: AT+WMBS Responses.......................................................................................................................42 Table 10: Values of network registration ..........................................................................................................43 Table 11: Main usual AT commands for the Plug & Play .................................................................................44 Table 12: Solutions for no connection with FASTRACK Supreme through serial link .....................................46 Table 13: Solutions for "NO CARRIER" message............................................................................................48 Table 14: Interpretation of extended error code ...............................................................................................49 Table 15: Mechanical characteristics ...............................................................................................................59 Table 16: Electrical characteristics ...................................................................................................................61 Table 17: Effects of power supply defect..........................................................................................................61 Table 18: Power consumption (1*) ...................................................................................................................62 Table 19: Audio parameters caracteristics .......................................................................................................65 Table 20: Microphone inputs internal audio filter characteristics .....................................................................65 Table 21: Recommended characteristics for the microphone: .........................................................................65 Table 22: Recommended characteristics for the speaker: ...............................................................................66 Table 23: Operating conditions.........................................................................................................................66 Table 24: SIM card characteristics ...................................................................................................................66 Table 25: Electrical characteristics ...................................................................................................................66 Table 26: Operating conditions.........................................................................................................................67 Table 27: Frequency ranges.............................................................................................................................67 Table 28: Receiver and transmitter RF performances .....................................................................................68 Table 29: External antenna characteristics ......................................................................................................69 Table 30: Ranges of temperature.....................................................................................................................69 Table 31: Environmental standard constraints .................................................................................................70 Table 32: List of recommended accessories....................................................................................................76
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1 References
Fastrack Supreme User Guide
References
1.1 Reference Documents
For more details, several reference documents may be consulted. The Wavecom reference documents are provided in the Wavecom documents package contrary to the general reference documents, which are not Wavecom owned.
1.1.1 Open AT® Software Documentation [1] Getting started with Open AT® (Ref.WM_ASW_OAT_CTI_001) [2] Open AT® Tutorial (Ref.WM_ASW_OAT_UGD_001) [3] Tools Manual (Ref. WM_ASW_OAT_UGD_003) [4] Open AT® Programming Guide (Ref. TBD) [5] Open AT® Customer Release Note (Ref. WM_ASW_OAT_DVD_00062) Remark: The document above is for Open AT3.12 and FASTRACK Supreme will use new release of Open AT4.21. Reference document not yet available and TBC.
1.1.2 AT Software Documentation [6] AT commands interface Guide for X51 (Ref. WM_ASW_OAT_UGD_00016) [7] Customer Release Note X51 (Ref. WM_ASW_OAT_DVD_00120) Remark: The document above is for X51 and FASTRACK Supreme will use new release of FW6.63. Reference document not yet available and TBC.
1.1.3 Firmware Upgrade Documents [8] Firmware upgrade procedure (Ref. WM_SW_GEN_UGD_001)
1.1.4 Delta between M1306B Documents [9] Delta between M1306B and FASTRACK Supreme (Ref. WA_DEV_Fastrk_UGD_004)
1.1.5 IESM Related Documents [10] IESM Product Technical Specification (Ref. WA_DEV_Fastrk_PTS_001) [11] IESM-GPS+USB User Guide (Ref. WA_DEV_Fastrk_UGD_002) [12] IESM-GPS+USB Installation Guide (Ref. WA_DEV_Fastrk_UGD_003) [13] IESM-IO+USB Installation Guide (Ref. WA_DEV_Fastrk_UGD_005) [14] IESM-IO+USB User Guide (Ref. WA_DEV_Fastrk_UGD_006)
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Fastrack Supreme User Guide
References Note: New versions of software may be available. Wavecom recommends customers to check the web site for the latest documentation.
1.2 Abbreviations
Abbreviation AC ACM AMR AT CLK CMOS CS CTS dB dBc dBi dBm DC DCD DCE DCS DSR DTE DTMF DTR EEPROM EFR E-GSM EMC EMI ESD ETSI FIT FR
Definition Alternating Current Accumulated Call Meter Adaptive Multi-Rate ATtention (prefix for Wireless CPU® commands) CLocK Complementary Metal Oxide Semiconductor Coding Scheme Clear To Send Decibel Decibel relative to the Carrier power Decibel relative to an Isotropic radiator Decibel relative to one milliwatt Direct Current Data Carrier Detect Data Communication Equipment Digital Cellular System Data Set Ready Data Terminal Equipment Dual Tone Multi-Frequency Data Terminal Ready Electrically Erasable Programmable Read-Only Memory Enhanced Full Rate Extended GSM ElectroMagnetic Compatibility ElectroMagnetic Interference ElectroStatic Discharges European Telecommunications Standards Institute Series of connectors (micro-FIT) Full Rate
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Abbreviation FTA GCF GND GPIO GPRS GSM HR I IEC IES IESM IMEI I/O LED MAX ME MIC Micro-Fit MIN MNP MO MS MT NOM O Pa PBCCH PC PCL PDP PIN PLMN PUK RF
Fastrack Supreme User Guide
References Definition Full Type Approval Global Certification Forum GrouND General Purpose Input Output General Packet Radio Service Global System for Mobile communications Half Rate Input International Electrotechnical Commission Internal Expansion Socket Internal Expansion Socket Module International Mobile Equipment Identification Input / Output Light Emitting Diode MAXimum Mobile Equipment MICrophone Family of connectors from Molex MINimum Microcom Networking Protocol Mobile Originated Mobile Station Mobile Terminated NOMinal Output Pascal (for speaker sound pressure measurements) Packet Broadcast Control CHannel Personal Computer Power Control Level Packet Data Protocol Personal Identity Number Public Land Mobile Network Personal Unblocking Key Radio Frequency
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Abbreviation RFI RI RMS RTS RX SIM SMA SMS SNR SPL SPK SRAM TCP/IP TDMA TU TUHigh TX TYP VSWR
Fastrack Supreme User Guide
References Definition Radio Frequency Interference Ring Indicator Root Mean Square Request To Send Receive Subscriber Identification Module SubMiniature version A RF connector Short Message Service Signal-to-Noise Ratio Sound Pressure Level SpeaKer Static RAM Transmission Control Protocol / Internet Protocol Time Division Multiple Access Typical Urban fading profile Typical Urban, High speed fading profile Transmit TYPical Voltage Stationary Wave Ratio
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2 Packaging
Fastrack Supreme User Guide
Packaging
2.1 Contents
The complete package content of the FASTRACK Supreme consists of (see): · one packaging box (A), · one FASTRACK Supreme (B), · two holding bridles (C), · one power supply cable with fuse integrated (D) · a mini notice (E) with: a summary of the main technical features, safety recommendations, EC declaration of conformity.
Figure 1: Complete package contents
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2.2 Packaging Box
Fastrack Supreme User Guide
Packaging
The packaging box is a carton box (see) with the following external dimensions: · width: 54.5 mm, · height: 68 mm, · length: 108 mm.
A packaging label is slicked on the packaging box cover and supports the: · WAVECOM logo, · Product reference (Supreme), · CE marking · 15-digit IMEI code · Open AT® Logo · RoHS logo · WEEE logo
The packaging label dimensions are: · height: 40 mm, · length: 65 mm.
Figure 2: Packaging box
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Fastrack Supreme User Guide
Packaging
2.3 Production Labelling
A production label (see Figure 3) located at the FASTRACK Supreme back side gives the following information:
· product reference (FASTRACK Supreme 10 or FASTRACK Supreme 20), · part number (WM19183), · CE marking, · 15-digit IMEI code, · OpenAT® logo
Figure 3: Production Label
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3 General Presentation
Fastrack Supreme User Guide
General Presentation
3.1 Description
The FASTRACK Supreme description is given in the Figure 4 below.
Micro-Fit connector
Screw for Back Plate Back Plate
SIM card inside SIM connector Lock switch of SIM
connector
IES connector for expanding feature, like GPS, USB, I/O expander... Refer to Section 3.2.1.4
Removed Screw for Back Plate
Sub HD connector
SMA connector
Back Cap GSM LED Indicator
Back Cap with 5 screws
Removed Back Plate
Figure 4: FASTRACK Supreme general description
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Fastrack Supreme User Guide
General Presentation CAUTION: Users are free to remove the back plate for IESM board plug in/unplug without voiding the warrantee of the FASTRACK Supreme. However, the warrantee will be voided if unscrewing any screw of the back cap. In addition, two holding bridles are provided to tighten the FASTRACK Supreme on a support.
Holding bridles Figure 5: FASTRACK Supreme holding bridles
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3.2 External Connections
3.2.1 Connectors
Fastrack Supreme User Guide
General Presentation
3.2.1.1 Antenna Connector The antenna connector is a SMA type connector for a 50 RF connection.
SMA connector for antenna connection
Figure 6: SMA connector for antenna connection
3.2.1.2 Power Supply Connector The power supply connector is a 4-pin Micro FIT connector for:
· external DC Power Supply connection, · GPIOs connection (two General Purpose Input/Output signals available).
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1
2
Fastrack Supreme User Guide
General Presentation
3
4
Figure 7: Power supply connector
Table 1: Power supply connector pin description
Pin # Signal I/O 1 V+BATTERY I
I/O type
Power supply
Description
Battery voltage input: 5.5 V Min. 13.2 V Typ. 32 V Max.
Reset State
Comment High current
2
GND
Power supply
Ground
3
GPIO21 I/O
2V8
General Purpose Input/output Undefined
Not mux
4
GPIO25 I/O
2V8
General Purpose Input/output
Z
Multiplex with INT1
Warning:
Both pin 3 and pin 4 are used by GPIO interface. It is strictly prohibited to connect them to any power supply at the risk of damage to the FASTRACK Supreme.
3.2.1.3 Sub HD 15-pin Connector
The Sub D high density 15-pin connector is used for: · RS232 serial link connection, · Audio lines (microphone and speaker) connection, · BOOT and RESET signal connection.
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Fastrack Supreme User Guide
General Presentation
54321 10 9 8 7 6 15 14 13 12 11
Figure 8: Sub HD 15-pin connector
Pin # 1 2 3
4 5 6 7 8 9
Table 2: Sub HD 15-pin connector description
Signal (CCITT / EIA) CDCD/CT109
CTXD/CT103
BOOT
I/O
I/O type
O STANDARD
RS232
I STANDARD
RS232
I
CMOS
Description
RS232 Data Carrier Detect
RS232 Transmit serial data
Boot
CMIC2P CMIC2N CRXD/CT104 CDSR/CT107 CDTR/CT108-2
GND
I
Analog
I
Analog
O STANDARD
RS232
O STANDARD
RS232
I STANDARD
RS232
-
GND
Microphone positive line Microphone negative line
RS232 Receive serial data
RS232 Data Set Ready
RS232 Data Terminal Ready
Ground
Comment
This signal must not be connected. Its use is strictly reserved to Wavecom or competent retailers.
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Pin # 10 11 12 13 14 15
Signal (CCITT / EIA)
CSPK2P CCTS/CT106
CRTS/CT105
CRI/CT125
RESET CSPK2N
I/O
I/O type
Fastrack Supreme User Guide
General Presentation
Description
Comment
O
Analog
Speaker positive line
O STANDARD RS232
RS232 Clear To Send
I STANDARD RS232
RS232 Request To Send
O STANDARD RS232
RS232 Ring Indicator
I/O
Schmitt
Supreme Plug & Play reset Active low
O
Analog
Speaker negative line
3.2.1.4 IES Connector
The IES connector is a 50 pins board-to-board connector for expanding application features like GPS, USB, I/O expander... Currently there are already 3 IESM boards available for customer to expand the FASTRACK Supreme features immediately. They are:
IESM-GPS+USB+I/O IESM-GPS+USB IESM-USB+I/O
For detail, please refer to Document in Section 1.1.5.
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Fastrack Supreme User Guide
General Presentation For sales and support, please contact Wavecom sales/FAE or your distributor.
Pin 2 Pin 1
Pin 50 Pin 49
Figure 9: IES connector for feature expansion
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Fastrack Supreme User Guide
General Presentation
Pin Number
1 2 3 4 5 6 7 8 9
Signal Name
Nominal
Mux
GND
GND
GPIO4
COL0
GPIO5
COL1
GPIO6
COL2
GPIO7
COL3
VPAD-USB
USB-DP
USB-DM
10
GSM-1V8*
11
GSM-2V8*
12
BOOT
13
~RESET
14
AUX-ADC
15
~SPI1-CS GPIO31
16
SPI1-CLK GPIO32
17
SPI1-I
GPIO30
18
SPI1-IO
GPIO29
19
SPI2-CLK GPIO32
20
SPI2-IO
GPIO33
21
~SPI2-CS GPIO35
22
SPI2-I
GPIO34
23
CT104RXD2
GPIO15
24
CT103-TXD2 GPIO14
25
~CT106CTS2
GPIO16
26
~CT105RTS2
GPIO17
Table 3: IES Connector Description
I/O type
Voltage
I/O*
Reset State
Description
Dealing with unused pins
Ground
Ground
C8
GSM-1V8
I/O
Pull-up
Keypad column 0
NC
C8
GSM-1V8
I/O
Pull-up
Keypad column 1
NC
C8
GSM-1V8
I/O
Pull-up
Keypad column 2
NC
C8
GSM-1V8
I/O
Pull-up
Keypad column 3
NC
VPAD-USB
I
USB Power supply input
NC
VPAD-USB I/O
USB Data
NC
VPAD-USB I/O
GSM-1V8
O
GSM-1V8
O
GSM-1V8
I
C4
GSM-1V8
I/O
A2
Analog
I
C1
GSM-2V8
O
C1
GSM-2V8
O
C1
GSM-2V8
I
C1
GSM-2V8
I/O
C1
GSM-2V8
O
C1
GSM-2V8
I/O
C1
GSM-2V8
O
C1
GSM-2V8
I
C1
GSM-1V8
O
C1
GSM-1V8
I
C1
GSM-1V8
O
C1
GSM-1V8
I
USB Data
NC
1.8V Supply Output (for GPIO pull-up only)
2.8V Supply Output (for GPIO pull-up only)
Not Used
NC
NC
Add a test point / a jumper/ a switch to VCC_1V8 (Pin 10) in case Download Specific mode is used (See product specification for details)
RESET Input
NC or add a test point
Analog to Digital Input
Pull to GND
Z
SPI1 Chip Select
NC
Z
SPI1 Clock
NC
Z
SPI1 Data Input
NC
Z
SPI1 Data Input / Output
NC
Z
SPI2 Clock
NC
Z
SPI2 Data Input / Output
NC
Z
SPI2 Chip Select
NC
Z
SPI2 Data Input
NC
Z
Auxiliary RS232 Receive
Add a test point for firmware upgrade
(TXD2) Pull-up to
Z
Auxiliary RS232 Transmit
VCC_1V8 with 100k and add a test point for
firmware update
Z
Auxiliary RS232 Clear To (CTS2) Add a test point
Send
for firmware update
Z
Auxiliary RS232 Request
(RTS2) Pull-up to
To Send
VCC_1V8 with 100k and
add a test point for
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Pin Number
Signal Name
Nominal
Mux
27
GPIO8
COL4
28
GPIO26
SCL
29
GPIO19
30
GPIO27
SDA
31
GPIO20
32
INT0
GPIO3
33
GPIO23
**
34
GPIO22
**
35
~CT108-2DTR1
GPIO41
36
PCM-SYNC
37
PCM-IN
38
PCM-CLK
39
PCM-OUT
40
AUX-DAC
41
VCC-2V8
42
GND
43
DC-IN
44
DC-IN
45
GND
46
4V
47
4V
48
GND
49
GND
50
GND
I/O type
C8 A1 C1 A1 C1 C1
C1 C1 C1
C5
Fastrack Supreme User Guide
General Presentation
Voltage
I/O*
Reset State
Description
Dealing with unused pins
GSM-1V8
I/O
Pull-up
Keypad column 4
firmware update NC
Open Drain
O
Z
I²C Clock
NC
GSM-2V8
I/O
Z
NC
Open Drain I/O
Z
I²C Data
NC
GSM-2V8
I/O Undefined
GSM-1V8
I
Z
Interruption 0 Input
GSM-2V8
I/O
Z
NC
If INT0 is not used, it should be configured as
GPIO
NC
GSM-2V8 GSM-2V8 GSM-1V8
I/O
Z
I
Z
O Pull-down
Main RS232 Data Terminal Ready
PCM Frame Synchro
NC
(DTR1) Pull-up to VCC_2V8 with 100k
NC
GSM-1V8
I
Pull-up
PCM Data Input
NC
GSM-1V8
O Pull-down
PCM Clock
NC
GSM-1V8
O
Pull-up
PCM Data Output
NC
Analog
O
Digital to Analog Output
NC
VCC_2V8
O
LDO 2.8V Supply Output
NC
DC-IN from 5.5V~32VDC
O
DC-IN from 5.5V~32VDC
O
Ground
DC voltage input through Micro-Fit connector
NC
DC voltage input through Micro-Fit connector
NC
Ground
4V
O
4V
O
4V DC/DC converter Output
NC
4V DC/DC converter Output
NC
Ground
Ground
Ground
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3.2.2 Power supply cable
Fastrack Supreme User Guide
General Presentation
Figure 10: Power supply cable
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Component Micro-Fit connector 4-pin
Cable
Wire
Fastrack Supreme User Guide
General Presentation
Characteristics Part number: MOLEX 43025-0400
Cable length: 1.5 m Core: tinned copper 24 x 0.2 mm Section: 0.75 mm2
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4 Features and Services
Fastrack Supreme User Guide
Features and Services
4.1 Basic Features and Services
Basic features of the FASTRACK Supreme and available services are summarized in the table below.
Table 4: Basic features of the FASTRACK Supreme
Features Open AT®
GSM850 / GSM900
DCS1800 / PCS1900
Open AT® programmable:
Native execution of embedded standard ANSI C applications,
Custom AT command creation,
Custom application library creation, Standalone operation.
Standard
850MHz / 900 MHz.
1800 MHz / 1900MHz
E-GSM compliant.
Output power: class 4 (2W).
Output power: class 1 (1W).
Fully compliant with ETSI GSM phase 2 + Fully compliant with ETSI GSM phase 2 +
small MS.
small MS.
GPRS
Class 10.
PBCCH support.
Coding schemes: CS1 to CS4.
Compliant with SMG31bis.
Embedded TCP/IP stack.
EGPRS
Output power: 0.5W
Output power: 0.4W
(for
Class 10.
FASTRACK Supreme 20
PBCCH support.
only)
Coding schemes: MCS1 to MCS9.
Compliant with SMG31bis.
Embedded TCP/IP stack.
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Features Interfaces
SMS Data
Fax Audio
Fastrack Supreme User Guide
Features and Services
GSM850 / GSM900
DCS1800 / PCS1900
RS232 (V.24/V.28) Serial interface supporting:
Baud rate (bits/s): 300, 600, 1200, 2400, 4800, 9600, 19200, 38400, 57600, 115200, 230400, 460800 and 921600.
Autobauding (bits/s): from 1200 to 921600.
2 General Purpose Input/Output gates (GPIOs) available.
1.8 V / 3 V SIM interface.
AT command set based on V.25ter and GSM 07.05 & 07.07. Open AT® interface for embedded application. Open AT® Plug-In Compatible.
Text & PDU.
Point to point (MT/MO).
Cell broadcast.
Data circuit asynchronous.
Transparent and Non Transparent modes.
Up to 14.400 bits/s.
MNP Class 2 error correction.
V42.bis data compression.
Automatic fax group 3 (class 1 and Class 2).
Echo cancellation
Noise reduction
Telephony.
Emergency calls.
Full Rate, Enhanced Full Rate, Half Rate operation and Adaptive Multi-Rate (FR/EFR/HR/AMR).
Dual Tone Multi Frequency function (DTMF).
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Features
GSM850 / GSM900
GSM supplement services
Call forwarding. Call barring. Multiparty.
Call waiting and call hold.
Calling line identity.
Advice of charge.
USSD
Other
DC power supply
Real Time Clock with calendar
Complete shielding For other detailed technical characteristics, refer to Section 8.
Fastrack Supreme User Guide
Features and Services DCS1800 / PCS1900
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4.2 Additional NEW Features
Fastrack Supreme User Guide
Features and Services
4.2.1 Support Additional GSM850/PCS1900 Bands Apart from GSM900/DCS1800, the FASTRACK Supreme Plug & Play now supports also the GSM850/PCS1900 bands. FASTRACK Supreme is fully compliant to PTCRB and FCC also.
4.2.2 IES Interface for Easy Expansion of Application Features The FASTRACK Supreme Plug & Play offers a 50 pin Internal Expansion Socket (IES) Interface accessible for customer use. It is the additional interface which is easy for customers to expand their application features without voiding the warrantee of the FASTRACK Supreme, by simply plugging in an Internal Expansion Socket Module (IESM) board through the matting connector of the IES interface. Thanks to the flexible IES interface, customers are ready to expand the application features by plugging in the corresponding Internal Expansion Socket Module (IESM) of GPS, I/O expander..., etc. For brief description of the interface, please refer to Section 3.2.1.4. For technical detail, please refer to Document [11] or contact your Wavecom distributor or Wavecom FAE.
4.2.3 Serial Port Auto Shut Down or Improving Power Consumption In order to save power consumption when there is no data communication between the Plug & Play and the DTE, FASTRACK Supreme has now implement the Serial Port Auto Shut Down feature. User can activate or deactivate the Serial Port Auto Shut Down mode by simple AT-command. For detail, please refer to Section 7.3.4.
4.2.4 Real Time Clock (RTC) for Saving Date and Time The FASTRACK Supreme has now implemented the Real Time Clock for saving date and time when the Plug & Play is unplugged from the DC power supply through the DC power cable. For detail, please refer to Section 7.8.
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Fastrack Supreme User Guide
Features and Services 4.2.5 SIM Card Lock Feature The FASTRACK Supreme has now implemented a SIM connector having a carrier with lock. This helps ensuring the user to have proper SIM card insertion and locked before proper use of GSM network.
SIM card is inserted but not locked. GSM network is SIM card is inserted and being locked properly. not ready for use. Only emergency call 112 is GSM network is ready for use. possible.
Figure 11: SIM card lock feature
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Fastrack Supreme User Guide
Using the FASTRACK Supreme Plug & Play
5 Using the FASTRACK Supreme Plug & Play
5.1 Getting Started
5.1.1 Mount the FASTRACK Supreme To mount the FASTRACK Supreme on its support, bind it using the holding bridles as shown in the Figure 12 below.
Figure 12: FASTRACK Supreme mounting
For the drill template, refer to Figure 18.
5.1.2 Set up the FASTRACK Supreme To set up the FASTRACK Supreme, perform the following operations:
· Insert the SIM card into the SIM card holder of the FASTRACK Supreme. · Lock the SIM card by sliding the lever towards the SIM card. · Connect the antenna to the SMA connector. · Connect both sides of the serial and control cable (15-pin Sub HD connector on the FASTRACK
Supreme side). · Connect the power supply cable to the external power supply source. Note: For automotive application, it is recommended to connect the V+BATTERY line of the FASTRACK Supreme directly to the battery positive terminal. · Plug the power supply cable into the FASTRACK Supreme and switch on the external power supply
source. · The FASTRACK Supreme is ready to work. Refer to Section 5.10 for the description of AT
commands used to configure the FASTRACK Supreme.
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Fastrack Supreme User Guide
Using the FASTRACK Supreme Plug & Play 5.1.3 Check the communication with the FASTRACK Supreme To check the communication with the FASTRACK Supreme, do the following operations:
· Connect the RS232 link between the DTE (port COM) and the FASTRACK Supreme (DCE). · Configure the RS232 port of the DTE as follows:
Bits per second: 115.200 bps, Data bits: 8, Parity: None, Stop bits: 1, Flow control: hardware.
· Using a communication software such as a HyperTerminal, enter the AT command. The response of the FASTRACK Supreme must be OK displayed in the HyperTerminal window.
· If the communication cannot be established with the FASTRACK Supreme, do the following: Check the RS232 connection between the DTE and the FASTRACK Supreme (DCE), Check the configuration of the port COM used on the DTE.
· Example of AT commands which can be used after getting started the FASTRACK Supreme:
AT+CGMI: FASTRACK Supreme answer is "WAVECOM MODEM" when serial
link is OK.
AT+CPIN=xxxx: to enter a PIN code xxxx (if activated). AT+CSQ: to verify the received signal strength. AT+CREG?: to verify the registration of the FASTRACK Supreme Plug & Play on
the network.
ATD<phone number>;: to initiate a voice call. ATH: to hang up (end of call).
For further information on these AT commands and their associated parameters, refer to "AT Commands Interface Guide" [6].
5.1.4 Reset the FASTRACK Supreme
To reset the FASTRACK Supreme, a hardware reset signal is available on pin 14 of the Sub HD 15-pin connector (RESET).
The FASTRACK Supreme reset is carried out when this pin is low for at least 200 s.
Warning This signal has to be considered as an emergency reset only. For further details on the FASTRACK Supreme reset, refer to Section 7.7.
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Fastrack Supreme User Guide
Using the FASTRACK Supreme Plug & Play
5.2 Specific Recommendations when Using the FASTRACK Supreme on Trucks
Warning: The power supply connection of the FASTRACK Supreme must NEVER be directly connected to the truck battery. 5.2.1 Recommended Power Supply Connection on Trucks All trucks have a circuit breaker on the exterior of the cabin. The circuit breaker is used for safety reasons: if a fire blazes in the trucks, (for example, on the wiring trunk) the driver may cut the current source to avoid any damage (explosion). The circuit breaker is connected to the truck ground, most often associated with the fuse box. Most of truck circuit breakers do not cut the Positive Supply line of the battery, but cut the ground line of the later.
FASTRACK Suprem e
Figure 13: Recommended power supply connection on trucks
Figure 13 gives the recommended power supply connection where the ground connection of the FASTRACK Supreme is not directly connected to the battery but is connected after the Circuit Breaker (on the truck ground or the fuse box).
5.2.2 Technical Constraints on Trucks
It is highly not recommended to connect directly the power supply on the battery rather than on the circuit breaker. The FASTRACK Supreme may be damaged when starting the truck if the circuit breaker is switched OFF (in this case, the truck ground and the battery ground will be connected through the FASTRACK Supreme as shown in the figure below).
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Fastrack Supreme User Guide
Using the FASTRACK Supreme Plug & Play
FASTRACK Supreme
Figure 14: Example of electrical connection which may dramatically damage the FASTRACK Supreme
Figure 14 gives an example of electrical connection which may dramatically damage the FASTRACK Supreme when its ground connection is directly connected to the battery ground. In this example, when the circuit breaker is switched OFF, the current flows through the FASTRACK Supreme and powers the electrical circuit of the truck (for example, dashboard). Furthermore, when the Starter Engine command will be used, it will destroy the cables or the FASTRACK Supreme. Since the internal tracks are not designed to support high current (up to 60 A when starting the truck), they will be destroyed.
5.3 FASTRACK Supreme Operational Status
The FASTRACK Supreme operational status is given by the red LED status located next to the SIM connector on the FASTRACK Supreme panel. The Table 5 below gives the meaning of the various statuses available.
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Fastrack Supreme User Guide
Using the FASTRACK Supreme Plug & Play Table 5: FASTRACK Supreme operational status
LED Status
LED light activity
FASTRACK Supreme Plug & Play status
ON
LED ON permanent
FASTRACK Supreme is switched ON but
not registered on the network
LED Flashing slowly
FASTRACK Supreme is switched ON and registered on the network, but no communication is in progress (Idle mode)
LED Flashing rapidly
FASTRACK Supreme is switched ON and registered on the network, and a communication is in progress
OFF
LED OFF
FASTRACK Supreme is switched OFF, or Flash LED is disabled* by the user.
* : Flash LED can be disabled by user when in Slow Standby mode in order to save power consumption. For detail, please refer to Section 7.9.
5.4 Echo Function Disabled
If no echo is displayed when entering an AT command, that means: · The "local echo" parameter of your communication software (such as HyperTerminal) is disabled. · The FASTRACK Supreme echo function is disabled.
To enable the FASTRACK Supreme echo function, enter the ATE1.
When sending AT commands to the FASTRACK Supreme by using a communication software, it is recommended:
· to disable the "local echo" parameter of your communication software (such as HyperTerminal),
· to enable the FASTRACK Supreme echo function (ATE1 command).
In a Machine To Machine communication with the FASTRACK Supreme, it is recommended to disable the
FASTRACK Supreme echo function (ATE0 command) in order to avoid useless CPU processing. For further information on ATE0 and ATE1 commands, refer to "AT Commands Interface Guide" [6].
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5.5 Verify the Received Signal Strength
Fastrack Supreme User Guide
Using the FASTRACK Supreme Plug & Play
The FASTRACK Supreme establishes a call only if the received signal is sufficiently strong. To verify the received signal strength, do the following operations:
· Using a communication software such as HyperTerminal, enter the AT command AT+CSQ.
The response returned has the following format:
+CSQ: <rssi>,<ber> with:
· <rssi> = received signal strength indication,
· <ber> = channel bit error rate.
· Verify the <rssi> value returned using the Table 6 below.
Table 6: Values of received signal strength
Value of received signal strength indication (<rssi>)
0 - 10
Interpretation of the received signal strength
Insufficient(*)
11 - 31
Sufficient(*)
32 - 98 99
(*) Based on general observations.
Not defined No measure available
For further information on AT commands, refer to "AT Commands Interface Guide" [6].
5.6 Check the Pin Code Status
To check that the pin code has been entered, use a communication software such as a HyperTerminal, then
enter AT+CPIN? command.
The table below gives the main responses returned:
Table 7: AT+CPIN Responses
AT+CPIN response (*)
+CPIN: READY
Interpretation Code PIN has been entered
+CPIN: SIM PIN
Code PIN has not been entered
(*)For further information on the other possible responses and their meaning, refer to "AT Commands Interface Guide" [6].
5.7 Switch between EU/US Band(s)
To switch between EU/US band(s) for the FASTRACK Supreme, use a communication software such as a
HyperTerminal, then enter AT+WMBS=<band>[,<param>] command.
The table below gives the commands for various band(s) selection:
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Fastrack Supreme User Guide
Using the FASTRACK Supreme Plug & Play Table 8: AT+WMBS Band Selection
AT+WMBS response (*)
AT+WMBS=0,x
Interpretation Select mono band mode 850MHz.
AT+WMBS=1,x AT+WMBS=2,x AT+WMBS=3,x AT+WMBS=4,x AT+WMBS=5,x
Select mono band mode extended 900MHz Select mono band mode 1800MHz Select mono band mode 1900MHz Select dual band mode 850/1900MHz Select dual band mode extended 900MHz/1800MHz
AT+WMBS=6,x
Select dual band mode extended 900MHz/1900MHz
(*)For further information on the other possible responses and their meaning, refer to "AT Commands Interface Guide" [6].
Remark:
x=0 : The Plug & Play will have to be reset to start on specified band(s).
x=1 : The change is effective immediately. This mode is forbidden while in communication and during
Plug & Play initialization. Refer to "AT Commands Interface Guide" [6] for further information on AT commands.
5.8 Check the Band(s) Selection
To check the band selection for the FASTRACK Supreme, use a communication software such as a
HyperTerminal, then enter AT+WMBS? command.
The table below gives the main responses returned:
Table 9: AT+WMBS Responses
AT+WMBS response (*)
+WMBS: 0,x
Interpretation Mono band mode 850MHz is selected
+WMBS: 1,x
Mono band mode extended 900MHz is selected
+WMBS: 2,x
Mono band mode 1800MHz is selected
+WMBS: 3,x
Mono band mode 1900MHz is selected
+WMBS: 4,x
Dual band mode 850/1900MHz are selected
+WMBS: 5,x
Dual band mode extended 900MHz/1800MHz are selected
+WMBS: 6,x
Dual band mode extended 900MHz/1900MHz are selected
(*)For further information on the other possible responses and their meaning, refer to "AT Commands Interface Guide" [6].
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Fastrack Supreme User Guide
Using the FASTRACK Supreme Plug & Play
5.9 Verify the FASTRACK Supreme Network Registration
1. Make sure a valid SIM card has been previously inserted and locked in the FASTRACK Supreme SIM card holder.
2. Using a communication software such as a HyperTerminal, enter the following AT commands:
a. AT+CPIN=xxxx to enter PIN code xxxx.
b. AT+WMBS? To check the current band setting in the Plug & Play
c. AT+WMBS=<Band>[,<param>] To switch band/mode when needed
d. AT+CREG?. To ascertain the registration status.
The format of the returned response is as follows:
+CREG: <mode>,<stat> with:
· <mode> = unsolicited registration message configuration, · <stat> = registration state.
3. Verify the state of registration according the returned value given in the table below.
Table 10: Values of network registration
Returned Value (*)
Network registration
<mode>,<stat>
+CREG: 0,0
No (not registered)
+CREG: 0,1
Yes (registered, home network)
+CREG: 0,5
Yes (registered, roaming)
(*)For further information on the other returned values and their meaning, refer to "AT Commands Interface Guide" [6].
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Fastrack Supreme User Guide
Using the FASTRACK Supreme Plug & Play
If the FASTRACK Supreme is not registered, perform the following procedure: · Check the connection between the FASTRACK Supreme and the antenna. · Verify the signal strength to determine the received signal strength (refer to Section 5.5).
Note: For information on AT command relating to the network registration in GPRS mode, and in particular: CGREG, CGCLASS, CGATT, refer to "AT Commands Interface Guide" [6].
5.10 Main AT Commands for the Plug & Play
The table below lists the main AT commands required for starting the Plug & Play.
For other AT commands available or further information on the AT commands, refer to "AT Commands Interface Guide" [6].
Table 11: Main usual AT commands for the Plug & Play
Description
AT commands
Check for selected AT+WMBS? band(s)
Band(s) switch
AT+WMBS=<Band>
AT+WMBS=<Band>,0
AT+WMBS=<Band>,1
Enter PIN Code
AT+WMBS=<Band> AT+CPIN=xxxx
(xxxx = PIN code)
Network registration checking
AT+CREG?
FASTRACK Supreme Plug & Play response
Comment
+WMBS:<Band>,<ResetFlag> Current selected band
OK
mode is return
OK
Band switch is accepted,
Plug & Play has to be reset
for change to be effective
OK
Band switch is accepted,
Plug & Play has to be reset
for change to be effective
OK
Band switch is accepted
and GSMS stack restarted
+CME ERROR: 3
Band not allowed
OK
PIN Code accepted.
+CME ERROR: 16
Incorrect PIN Code (with +CMEE = 1 mode) (1*)
+CME ERROR: 3
PIN code already entered (with +CMEE = 1 mode) (1*)
+CREG: 0,1
FASTRACK Supreme Plug & Play registered on the network.
+CREG: 0,2
FASTRACK Supreme Plug & Play not registered on the network, registration attempt.
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Description
Receiving an incoming call Initiate a call
Initiate an emergency call Communication loss Hang up
AT commands ATA
Fastrack Supreme User Guide
Using the FASTRACK Supreme Plug & Play
FASTRACK Supreme Plug & Play response
Comment
+CREG: 0,0
FASTRACK Supreme Plug & Play not registered on the network, no registration attempt.
OK
Answer the call.
ATD<phone number>;
OK
(Don't forget the « ; » at the
end for « voice » call)
+CME ERROR: 11
+CME ERROR: 3
ATD112;
OK
(Don't forget the « ; » at the end for « voice » call)
NO CARRIER
Communication established.
PIN code not entered (with +CMEE = 1 mode).
AOC credit exceeded or a communication is already established.
Communication established.
ATH
OK
Store the
AT&W
OK
parameters in
EEPROM
The configuration settings are stored in EEPROM.
(1*) The command "AT+CMEE=1" switch to a mode enabling more complete error diagnostics.
5.11 Firmware Upgrade Procedure
The firmware upgrade procedure is used to update the firmware embedded into the FASTRACK Supreme. That procedure consists in downloading the firmware into internal memories through the RS232 serial link available on the SUB-D 15-pin connector. Refer to "Firmware upgrade procedure" [8] for a detailed description of this procedure.
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6 Troubleshooting
Fastrack Supreme User Guide
Troubleshooting
This section of the document describes possible problems encountered when using the FASTRACK Supreme and their solutions.
To review other troubleshooting information, refer the `FAQs' (Frequently Asked Questions) page at www.wavecom.com or use the following link: http://www.wavecom.com/support/faqs.php
6.1 No Communication with the FASTRACK Supreme through the Serial Link
If the FASTRACK Supreme does not answer to AT commands through the serial link, refer to the table below for possible causes and solutions.
Table 12: Solutions for no connection with FASTRACK Supreme through serial link
If the Supreme returns
Nothing
then ask
Is the FASTRACK Supreme powered correctly?
Is the serial cable connected at both sides?
Does the serial cable follow correctly pin assignment shown in paragraph 3.2.1.2.
Nothing or non- Is the communication program significant characters properly configured on PC?
Is there another program interfering with the communication program (i.e. Conflict on communication port access)
Action
Make sure the external power supply is connected to the FASTRACK Supreme and provides a voltage in the range of 5.5 V to 32 V. Check the serial cable connection
Connect the cable by following pin assignment given in paragraph 3.2.1.1.
Ensure the setting of the communication program is fit to setting of FASTRACK Supreme. FASTRACK Supreme factory setting is:
Data bits = 8 Parity = none Stop bits = 1 Baud = 115 200 bps. Flow control = hardware Close the interfering program.
6.2 Receiving "ERROR" Message
The FASTRACK Supreme returns an "ERROR" message (in reply to an AT command) in the following cases:
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Fastrack Supreme User Guide
Troubleshooting · AT command syntax is incorrect: check the command syntax (refer to "AT Commands Interface
Guide" [6]), · AT command syntax is correct, but transmitted with wrong parameters:
· Enter the AT+CMEE=1 command in order to change the error report method to the verbose
method, which includes the error codes. · Enter again the AT command which previously caused the reception of "ERROR" message in
order to get the Mobile Equipment error code. When the verbose error report method is enabled, the response of the FASTRACK Supreme in case of error is as follows:
· Either +CME ERROR: <error result code>, · Or +CMS ERROR: <error result code>.
Refer to "AT Commands Interface Guide" [6] for error result code description and further details on the AT +CMEE command.
Note: It is strongly recommended to always enable the verbose error report method to get the Mobile
Equipment error code (enter AT +CMEE=1 command).
6.3 Receiving "NO CARRIER" Message
If the FASTRACK Supreme returns a "NO CARRIER" message upon an attempted call (voice or data), then refer to the table below for possible causes and solutions.
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Fastrack Supreme User Guide
Troubleshooting
Table 13: Solutions for "NO CARRIER" message
If the Supreme returns...
"NO CARRIER"
Then ask... Is the received signal strong enough?
Is the FASTRACK Supreme registered on the network?
Is the antenna properly connected?
Is the band selection correction?
"NO CARRIER" (when Is the semicolon (;) entered immediately
trying to issue a voice after the phone number in the AT
communication)
command?
Action...
Refer to section 5.5 to verify the strength of the received signal.
Refer to section 5.9 to verify the registration.
Refer to section 8.2.7.3 for antenna requirements. Refer to Section 7.2 for band switch
Ensure that the semicolon (;) is entered immediately after the phone number in the AT command.
e.g. ATD######;
"NO CARRIER" (when Is the SIM card configured for data / fax trying to issue a data calls? communication)
Configure the SIM card for data / fax calls (Ask your network provider if necessary).
Is the selected bearer type supported by the Ensure that the selected bearer type
called party?
is supported by the called party.
Is the selected bearer type supported by the Ensure that the selected bearer type
network?
is supported by the network.
If no success, try bearer selection type by AT command: AT+CBST=0,0,3
If the FASTRACK Supreme returns a "NO CARRIER" message, you may have the extended error code by
using AT command AT+CEER. Refer to the table below for interpretation of extended error code.
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Fastrack Supreme User Guide
Troubleshooting
Table 14: Interpretation of extended error code
Error Code 1 16 17 18 19 21 22 31 50
Diagnostic Unallocated phone number Normal call clearing User busy No user responding User alerting, no answer Call rejected Number changed Normal, unspecified Requested facility not subscribed
68
ACM equal or greater than ACMmax
252
Call barring on outgoing calls
253
Call barring on incoming calls
3, 6, 8, 29, 34, 38, 41, 42, 43, 44, 47, 49, 57, 58, 63, 65,
69, 70, 79, 254
Network causes
Hint
Check your subscription (data subscription available?). Credit of your pre-paid SIM card expired. See "AT Commands Interface Guide" [6] for further details or call network provider.
Note: For all other codes, and/or details, see AT commands documentation [6].
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7 Functional Description
Fastrack Supreme User Guide
Functional Description
7.1 Architecture
FASTRACK Supreme Plug & Play
BOOT RESET
Microphone
Speaker
SUB HD 15 pins
GPIO-21 GPIO-25
V+BATT
GROUND Micro-FIT
4 pins
RS232 Interface
VCC
Audio Interface
VCC
SMA
Microphone
Internal Quik Wireless CPU®
Q2687
Speaker
Operating Status
DC / DC
VCC
Power
Supply
50 pin IES Interface
SIM card Holder
Figure 15: Functional architecture
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7.2 EU and US Bands
Fastrack Supreme User Guide
Functional Description
7.2.1 General Presentation The FASTRACK Supreme is a quad band Plug & Play. It supports either EU bands (EGSM900/DCS1800) or US bands (GSM850/ PCS1900), depending on the band setting within the Plug & Play. Users are free to switch between EU bands and US bands by simple AT commands when the selected bands are supported.
7.2.2 AT COMMAND for Bands Switch
EU/US band is easily switched/checked by AT command AT+WMBS.
For detail, please refer to Section 5.7 and 5.8.
7.3 Power Supply
7.3.1 General Presentation The FASTRACK Supreme is supplied by an external DC voltage (V+BATTERY) from +5.5 V to +32 V at 2.2 A. Main regulation is made with an internal DC/DC converter in order to supply all the internal functions with a DC voltage. Correct operation of the FASTRACK Supreme in communication mode is not guaranteed if input voltage (V+BATTERY) falls below 5.5 V. Note: The minimum input voltage specified here is at the FASTRACK Supreme input. Be careful of the input voltage decrease caused by the power cable. See paragraph 8.2.1 for more information.
7.3.2 Protections
The FASTRACK Supreme is protected by a 800 mA / 250 V fuse directly bonded on the power supply cable.
The FASTRACK Supreme is also protected against voltage over +32 V. Filtering guarantees:
· EMI/RFI protection in input and output, · Signal smoothing.
7.4 RS232 Serial Link
7.4.1 General Presentation
The RS232 interface performs the voltage level adaptation (V24/CMOS V24/V28) between the internal FASTRACK Supreme Plug & Play (DCE) and the external world (DTE).
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Fastrack Supreme User Guide
Functional Description The RS232 interface is internally protected (by ESD protection) against electrostatic surges on the RS232 lines. Filtering guarantees:
· EMI/RFI protection in input and output, · Signal smoothing. Signals available on the RS232 serial link are: · TX data (CT103/TX), · RX data (CT104/RX), · Request To Send (CT105/RTS), · Clear To Send (CT106/CTS), · Data Terminal Ready (CT108-2/DTR), · Data Set Ready (CT107/DSR), · Data Carrier Detect (CT109/DCD), · Ring Indicator (CT125/RI).
FASTRACK Supreme
(DCE)
CT103 / TX CT104 / RX CT105 / RTS CT106 / CTS CT107 / DSR CT108-2 / DTR CT109 / DCD CT125 / RI
DTE
Figure 16: RS232 Serial Link signals
RS232 interface has been designed to allow flexibility in the use of the serial interface signals. However, the use of TX, RX, CTS and RTS signals is mandatory, which is not the case for DTR, DSR, DCD and RI signals which can be not used.
7.4.2 Autobauding Mode The autobauding mode allows the FASTRACK Supreme to detect the baud rate used by the DTE connected to the RS232 serial link. Autobauding mode is controlled by AT commands. See "AT Commands Interface Guide" [6] for details on this function.
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7.4.3 Pin Description
Fastrack Supreme User Guide
Functional Description
Signal
CTXD/CT103 CRXD/CT104 CRTS/CT105 CCTS/CT106 CDSR/CT107 CDTR/CT108-2 CDCD/CT109
CRI/CT125 CT102/GND
Sub HD connector
I/O
I/O type
Pin number
RS232
STANDARD
Description
2
I
TX
Transmit serial data
6
O
RX
Receive serial data
12
I
RTS
Request To Send
11
O
CTS
Clear To Send
7
O
DSR
Data Set Ready
8
I
DTR
Data Terminal Ready
1
O
DCD
Data Carrier Detect
13
O
RI
Ring Indicator
9
GND
Ground
7.4.4 Serial Port Auto shut down Feature
The UART1 can be shut down when there is no activity between the DTE and the FASTRACK Supreme Plug & Play. This can help for improving power consumption performance.
Serial Port Auto shut down feature is easily controlled by AT command AT+WASR.
AT+WASR=1 for entering the serial port auto shut down mode
AT+WASR=0 for exiting the serial port auto shut down mode
Refer to "AT Commands Interface Guide" [6] for further information on AT commands. CAUTION: GPIO24 is reserved for serial port auto shut down feature. It is prohibited for customer use. Improper access to GPIO24 by customer may lead to unexpected behavior on UART1 performance.
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7.5 General Purpose Input/Output (GPIO)
Fastrack Supreme User Guide
Functional Description
The FASTRACK Supreme provides two General Purpose Input / Output lines available for external use: GPIO21 and GPIO25.
These GPIOs may be controlled by AT commands:
· AT+WIOW for a write access to the GPIO value, when the GPIO is used as an output, · AT+WIOR for a read access to the GPIO value, when the GPIO is used as an input.
Refer to "AT Commands Interface Guide" [6] for further information on AT commands.
After reset, both GPIOs are configured as inputs. The AT+WIOM command has to be used to change this
configuration (refer to "AT Commands Interface Guide" [6] for further details).
Signal
GPIO21 GPIO25
Power Supply connector
(4-pin Micro-Fit)
3
4
Pin description
I/O
I/O Voltage
Reset state
Description
Mulitplex with
I/O
2V8
Undefined General Purpose I/O
No mux
I/O
2V8
Z
General Purpose I/O
INT1
Notes:
· The power supply cable may need to be modified due to the GPIO signals (GPIO21 & GPIO25) available on the 4-pin Micro-FIT connector of the FASTRACK Supreme.
· The previous generation M1306B have GPIO4 and GPIO5 being replaced by GPIO21 and GPIO25 respectively, for which both are of LOW level at reset state.
7.6 BOOT
This signal must not be connected. Its use is strictly reserved to Wavecom or competent retailers. Caution: Previous generation M1306B has BOOT signal of HIGH level at 2.8V. But the FASTRACK Supreme now of 1.8V BOOT instead.
7.7 RESET
7.7.1 General presentation
This signal is used to force a reset procedure by providing low level during at least 200 µs.
This signal must be considered as an emergency reset only. A reset procedure is automatically driven by an internal hardware during the power-up sequence.
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Functional Description
This signal may also be used to provide a reset to an external device. It then behaves as an output. If no external reset is necessary, this input may be left open, if used (emergency reset), it has to be driven either by an open collector or an open drain output:
· RESET pin 14 = 0, for FASTRACK Supreme Reset,
· RESET pin 14 = 1, for normal mode.
Signal RESET
Sub HD 15-Pin connector Pin number
14
Pin description
I/O
I/O type
I/O Open Drain
Voltage 1V8
Description
FASTRACK Supreme Reset
Caution: Previous generation M1306B has RESET signal of HIGH level at 2.8V. But the FASTRACK Supreme now of 1.8V RESET instead.
Additional comments on RESET:
The RESET process is activated either by the external RESET signal or by an internal signal (coming from a RESET generator). This automatic reset is activated at Power-up.
The FASTRACK Supreme remains in RESET mode as long as the RESET signal is held low.
Caution: This signal should be used only for "emergency" reset.
A software reset is always preferred to a hardware reset. Note: See "AT Commands Interface Guide" [6] for further information on software reset.
7.7.2 Reset Sequence
To activate the "emergency" reset sequence, the RESET signal has to be set to low for 200 s minimum.
As soon as the reset is done, the AT interface answers "OK" to the application. For this, the application must
send AT.
If the application manages hardware flow control, the AT command may be sent during the initialization
phase. Another solution is to use the AT+WIND command to get an unsolicited status from the FASTRACK
Supreme.
For further details, refer to AT commands "AT Commands Interface Guide" [6].
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~ RESET
Fastrack Supreme User Guide
Functional Description
STA TE OF TH E W ireless
W ireless CPU
CPU
REA D Y
RESET m od e
IBB+ RF= 2 0 t o 40m A
Rt = M in 1 :2 0 0 s or Typ2 = 40m s
Ct = Typ :34 m s
W ireless CPU
ON
IBB+ RF< 1 2 0 m A w it h ou t loc u p d at e
AT an sw ers " OK"
W ireless CPU REA D Y
SIM an d n etw ork d ep en d en t
Figure 17: Reset sequence diagram
7.8 Audio
Audio interface is a standard one for connecting a phone handset.
Echo cancellation and noise reduction features are also available to improve the audio quality in case of hand-free application.
7.8.1 Microphone Inputs
The microphone inputs are differential ones in order to reject common mode noise and TDMA noise.
They already include the convenient biasing for an electret microphone (0.5 mA and 2 Volts) and are ESD protected.
This electret microphone may be directly connected to these inputs allowing an easy connection to a handset.
The microphone impedance must be around 2 k. AC coupling is already embedded in the Wireless CPU®.
The gain of the microphone inputs is internally adjusted and may be tuned from 30 dB to 51 dB using an AT +VGT command (refer to AT commands documentation [6]).
Signal
CMIC2P CMIC2N
Pin description
Sub D 15-pin Pin #
4
5
I/O I/O type
I
Analog
I
Analog
Description
Microphone positive input Microphone negative input
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Functional Description
7.8.2 Speaker Outputs
This connection is differential to reject common mode noise and TDMA noise.
Speaker outputs are connected to internal push-pull amplifiers and may be loaded down between 32 to 150 Ohms and up to 1 nF (see details in table Speaker gain vs Max output voltage, in "AT Commands Interface Guide" [6]). These outputs may be directly connected to a speaker.
The output power may be adjusted by step of 2 dB. The gain of the speaker outputs is internally adjusted
and may be tuned using an AT +VGR command (refer to AT commands documentation [6]).
Pin description
Signal
Sub D 15-pin Pin #
I/O
I/O type
Description
CSPK2P CSPK2N
10
O
Analog
Speaker positive output
15
O
Analog
Speaker negative output
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Functional Description
7.9 Real Time Clock (RTC)
The FASTRACK Supreme has now implemented the Real Time Clock for saving date and time when the Plug & Play is unplugged from the DC power supply through the DC power cable.
Item
Min
Typical
Max
Charging Time start from fully discharged to fully charged
940 min
RTC Time Period*
Guarantee Non-guarantee
2475 min 5225 min
Remark: The RTC time period is measured from the RTC battery is fully charged before being unplugged from the DC power source.
7.10 FLASH LED
The FASTRACK Supreme has a red LED indicator to show the status of the GSM network. For detail description of the various status, please refer to Section 5.3.
However, during operation mode of Slow Standby, there will be no network registration and so the red LED indicator will always be ON. It is possible for user to deactivate the LED indication during Slow Standby mode, in order to reduce power consumption.
The Flash LED can be deactivated by AT command at+whcnf=1,0 The Flash LED can be activated by AT command at+whcnf=1,1
However, the new setting will be taken into account only after a restart. For detail, please refer to Document[6].
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8 Technical Characteristics
Fastrack Supreme User Guide
Technical Characteristics
8.1 Mechanical Characteristics
Dimensions Overall Dimension
Weight
Volume Housing
Table 15: Mechanical characteristics
73 x 54.5 x 25.5 mm (excluding connectors) 88 x 54.5 x 25.5 mm 80 grams (FASTRACK Supreme only) < 120 grams (FASTRACK Supreme + bridles + power supply cable) 101.5 cm3 Aluminum profiled
The next page gives the dimensioning diagram of the FASTRACK Supreme including the clearance areas to take into account for the FASTRACK Supreme installation.
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Technical Characteristics
Figure 18: Dimensioning diagram
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8.2 Electrical Characteristics
Fastrack Supreme User Guide
Technical Characteristics
8.2.1 Power Supply
Table 16: Electrical characteristics
Operating Voltage ranges 5.5 V to 32 V DC.
Maximum current
480 mA Average at 5.5V. 2.1 A Peak at 5.5 V. (TBC)
Note:
The FASTRACK Supreme is permanently powered once the power supply is connected. The following table describes the consequences of over-voltage and under-voltage with the FASTRACK Supreme.
Warning:
All the input voltages specification described in this Section are at the FASTRACK Supreme input. While powering the FASTRACK Supreme, take into account the input drop caused by the power cable. With the delivered cable, this input drop is around 700 mV at 5.5 V and 220 mV at 32V.
Table 17: Effects of power supply defect
If the voltage
falls below 5.5 V,
is over 32 V (Transient peaks),
Is over 32 V (continuous overvoltage)
then the GSM communication is not guaranteed. the FASTRACK Supreme guarantees its own protection.
the protection of the FASTRACK Supreme is done by the fuse (the supply voltage is disconnected).
The fuse is a 800 mA / 250 V FAST-ACTING 5*20mm. See Section 10 for recommended references.
The following table provides information on power consumption of the FASTRACK Supreme, assuming an operating temperature of +25 °C and using a 3 V SIM card.
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Technical Characteristics
8.2.2 Power Consumption The following table provides information on power consumption of the FASTRACK Supreme, assuming an operating temperature of +25 °C and using a 3 V SIM card.
GSM
GPRS Class 2
I peak I avg I peak I avg I peak I avg I peak I avg
Table 18: Power consumption (1*)
Power Consumption in E-GSM 900/DCS 1800 MHz - GPRS class 10
E-GSM 900
GSM900: During TX bursts @ PCL5 DCS1800 : During TX bursts @ PCL0
@ 5.5V @ 13.2V @ 32V
TBC TBC TBC
GSM900 : Average @ PCL5 DCS1800 : Average @ PCL0
@ 5.5V @ 13.2V @ 32V
TBC TBC TBC
GSM900: During 1TX bursts @ PCL5 DCS1800 : During 1TX bursts @ PCL0
@ 5.5V @ 13.2V @ 32V
TBC TBC TBC
GSM900 : Average 1TX/1RX @PCL5 DCS1800 : Average 1TX/1RX @PCL0
@ 5.5V @ 13.2V @ 32V
TBC TBC TBC
GSM900: During 2TX bursts @ PCL5 (Gamma 3) DCS1800 : During 2TX bursts @ PCL0 (Gamma 2)
@ 5.5V @ 13.2V @ 32V
TBC TBC TBC
GSM900 : Average 2TX/3RX @ PCL5 (Gamma 3) DCS1800 : Average 2TX/3RX @ PCL0 (Gamma 2)
@ 5.5V @ 13.2V @ 32V
TBC TBC TBC
GSM900: During 1TX bursts @ PCL8 (Gamma 6) DCS1800 : During 1TX bursts @ PCL2 (Gamma 5)
@ 5.5V @ 13.2V @ 32V
TBC TBC TBC
GSM900 : Average 1TX/1RX @ PCL8 (Gamma 6) DCS1800 : Average 1TX/1RX @ PCL2 (Gamma 5)
@ 5.5V @ 13.2V @ 32V
TBC TBC TBC
DCS 1800
TBC TBC TBC TBC TBC TBC TBC TBC TBC TBC TBC TBC TBC TBC TBC TBC TBC TBC TBC TBC TBC TBC TBC TBC
GPRS Class 10
EGPRS Class 2
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Technical Characteristics
Power Consumption in E-GSM 900/DCS 1800 MHz - GPRS class 10
E-GSM 900
EGPRS Class 10
I peak
GSM900: During 2TX bursts @ PCL8 (Gamma 6) DCS1800 : During 2TX bursts @ PCL2 (Gamma 5)
@ 5.5V @ 13.2V @ 32V
GSM900 : Average 2TX/3RX @ PCL8 (Gamma 6)
I avg DCS1800 : Average 2TX/3RX @ PCL2 (Gamma 5)
@ 5.5V @ 13.2V @ 32V
I avg in Fast Idle mode Page 9
(2*)
Serial port auto shut down deactivated
@ 5.5V @ 13.2V @ 32V @ 5.5V
Serial port auto shut down activated @ 13.2V
@ 32V
I avg in Slow Idle mode Page 9
(3*)
Serial port auto shut down deactivated
@ 5.5V @ 13.2V @ 32V @ 5.5V
Serial port auto shut down activated @ 13.2V
@ 32V
I avg in Fast Standby mode
(4*)
Serial port auto shut down deactivated
@ 5.5V @ 13.2V @ 32V @ 5.5V
Serial port auto shut down activated @ 13.2V
@ 32V
TBC TBC TBC
TBC TBC TBC
33 TBC TBC
17 TBC TBC
23 TBC TBC
5 TBC TBC
52 TBC TBC
35 TBC TBC
DCS 1800
TBC TBC TBC TBC TBC TBC TBC TBC TBC TBC TBC TBC TBC TBC TBC TBC TBC TBC TBC TBC TBC TBC TBC TBC
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Technical Characteristics
Power Consumption in E-GSM 900/DCS 1800 MHz - GPRS class 10
E-GSM 900
I avg in Slow Standby mode
(with FLASH LED activated) (4*)
Serial port auto shut down deactivated
@ 5.5V @ 13.2V @ 32V
@ 5.5V
Serial port auto shut down activated @ 13.2V
@ 32V
24 TBC TBC
8 TBC TBC
I avg in Slow Standby mode
(with FLASH LED deactivated) (4*)
Serial port auto shut down deactivated
@ 5.5V @ 13.2V @ 32V
@ 5.5V
Serial port auto shut down activated @ 13.2V
@ 32V
TBC TBC TBC
4 TBC TBC
DCS 1800
TBC TBC TBC TBC TBC TBC TBC TBC TBC TBC TBC TBC
(1*):The power consumption might vary by 5 % over the whole operating temperature range (-20 °C to +55 °C). (2*): In this Mode, the RF function is active and the FASTRACK Supreme synchronized with the network, but there is no communication. (3*): In this Mode, the RF function is disabled, but regularly activated to keep the synchronization with the network. This Mode works only when the DTE send AT command to shut down the serial link by software approach (DTE turns DTR in inactive state). (4*): In this Mode, the RF function is disabled, and there is no synchronization with the network.
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Technical Characteristics
8.2.3 Audio Interface The audio interface is available through the Sub HD 15-pin connector.
Table 19: Audio parameters caracteristics
Audio parameters
Min Typ Max
Microphone input current @2 V/2 k
0.5
Absolute microphone input voltage
100
Speaker output current 150 //1 nF
16
Absolute speaker impedance
32
50
Impedance of the speaker amplifier output in
1
differential mode
Unit
Comments
mA
mVpp AC voltage
mA
+/-10 %
Table 20: Microphone inputs internal audio filter characteristics
Frequency 0-150 Hz 150-180 Hz 180-200 Hz 200-3700 Hz >4000 Hz
< -22 dB < -11 dB < -3 dB 0 dB < -60 dB
Gain
Table 21: Recommended characteristics for the microphone:
Feature
Value
Type
Electret 2 V / 0.5 mA
Impedance
Z = 2 k
Sensitivity
-40 dB to 50 dB
SNR
> 50 dB
Frequency response
compatible with the GSM specifications
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Technical Characteristics
Table 22: Recommended characteristics for the speaker:
Feature
Value
Type
10 mW, electro-magnetic
Impedance
Z = 32 to 50
Sensitivity
110 dB SPL min. (0 dB = 20 µPa)
Frequency response
compatible with the GSM specifications
8.2.4 General Purpose Input/Output Both GPIO21 and GPIO25 may be interfaced with a component that comply with 3 Volts CMOS levels.
Table 23: Operating conditions
Parameter
I/O type
Min
Typ
Max
VIL
CMOS
VIH
CMOS
VOL
CMOS
VOH
CMOS
IOH
IOL Clamping diodes are present on I/O pads.
1.96 V 2.4 V
0.84 V
0.4 V
4mA -4mA
Condition
IOL = -4 mA IOH = 4 mA
8.2.5 SIM Interface SIM card
Table 24: SIM card characteristics 1.8V / 3 V
8.2.6 RESET Signal
Table 25: Electrical characteristics
Parameter
Input Impedance ( R )* Input Impedance ( C ) *Internal pull-up
Min
Typ
Max
Unit
330K
k
10n
nF
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Technical Characteristics
Table 26: Operating conditions
Parameter
Minimum
Typ
Maximum Unit
~RESET time (Rt) 1
200
µs
~RESET time (Rt) 2 at power up only
20
40
100
ms
Cancellation time (Ct)
34
ms
VH VIL VIH
* VH: Hysterisis Voltage
0.57 0
1.33
V
0.57
V
V
1 This reset time is the minimum to be carried out on the ~RESET signal when the power supply is already stabilized.
2 This reset time is internally carried out by the Wireless CPU power supply supervisor only when the Wireless CPU power supplies are powered ON.
8.2.7 RF Characteristics
8.2.7.1 Frequency Ranges
Table 27: Frequency ranges
Characteristic Frequency TX Frequency RX
GSM 850 824 to 849 MHz 869 to 894 MHz
E-GSM 900 880 to 915 MHz 925 to 960 MHz
DCS 1800 1710 to 1785 MHz 1805 to 1880 MHz
PCS 1900 1850 to 1910 MHz 1930 to 1990 MHz
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Technical Characteristics 8.2.7.2 RF Performances RF performances are compliant with the ETSI recommendation GSM 05.05. The RF performances for receiver and transmitter are given in the table below.
Table 28: Receiver and transmitter RF performances
Receiver
E-GSM900/GSM850 Reference Sensitivity
-104 dBm Static & TUHigh
DCS1800/PCS1900 Reference Sensitivity
-102 dBm Static & TUHigh
Selectivity @ 200 kHz
> +9 dBc
Selectivity @ 400 kHz
> +41 dBc
Linear dynamic range
63 dB
Co-channel rejection
>= 9 dBc
Transmitter
Maximum output power (E-GSM 900/GSM850) at ambient temperature
33 dBm +/- 2 dB
Maximum output power (DCS1800/PCS1900) at ambient temperature
30 dBm +/- 2 dB
Minimum output power (E-GSM 900/GSM850) at ambient temperature
5 dBm +/- 5 dB
Minimum output power (DCS1800/PCS1900) at ambient temperature
0 dBm +/- 5 dB
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Technical Characteristics
8.2.7.3 External Antenna The external antenna is connected to the FASTRACK Supreme via the SMA connector. The external antenna must fulfill the characteristics listed in the table below.
Table 29: External antenna characteristics
Antenna frequency range
Quad-band GSM 850/GSM900/DCS1800/PCS1900 MHz
Impedance
50 Ohms nominal
DC impedance
0 Ohm
Gain (antenna + cable)
0 dBi
VSWR (antenna + cable)
2
Note: Refer to Section 10 for recommended antenna.
8.3 Environmental Characteristics
The FASTRACK Supreme Plug & Play is compliant with the following operating class. To ensure the proper operation of the FASTRACK Supreme, the temperature of the environment must be within a specific range as described in the table below.
Table 30: Ranges of temperature
Conditions Operating / Class A Operating / Class B
Storage
Temperature range -20 °C to +55°C -30 °C to +85°C -40 °C to +85°C
Function Status Classification:
Class A:
The FASTRACK Supreme remains fully functional, meeting GSM performance criteria in accordance with ETSI requirements, across the specified temperature range.
Class B:
The FASTRACK Supreme remains fully functional, across the specified temperature range. Some GSM parameters may occasionally deviate from the ETSI/PTCRB specified requirements and this deviation does not affect the ability of the FASTRACK Supreme to connect to the cellular network and function fully, as it does within the Class A range.
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Technical Characteristics
The detailed climatic and mechanics standard environmental constraints applicable to the FASTRACK Supreme are listed in the table below:
Environmental Tests
Table 31: Environmental standard constraints
Environmental Classes
(IEC TR 60721-4)
(IEC 60721-3)
Tests
Standards
Storage (IEC 60721-3-1)
Class IE13
Transportation (IEC 60721-3-2)
Class IE23
Operation
Stationary (IEC 60721-3-3)
Class IE35
Non-Stationary (IEC 60721-3-7)
Class IE73
Cold
Dry heat
Change of temperature
IEC 60068-2-1 : Ab/Ad
IEC 60068-2-2 : Bb/Bd
IEC 60068-2-14 : Na/Nb
Damp heat
IEC 60068-2-56 : Cb
Damp heat, cyclic
60068-2-30 : Db Variant 1 or 2
Vibration (sinusoidal)
IEC 60068-2-6 : Fc
Vibration (random)
IEC 60068-2-64 : Fh
Shock (half-sine)
IEC 60068-2-27 : Ea
Bump Free fall
IEC 60068-2-29 : Eb ISO 4180-2
Drop and topple IEC 60068-2-31 : Ec
-25°C, 16 h
+70°C, 16 h
-33°C to ambient 2 cycles, t1=3 h
1 °C.min-1 +30°C, 93% RH
96 h +40°C, 90% to
100% RH One cycle Variant 2 1-200 Hz
2 m.s-2 0,75 mm 3 axes 10 sweep cycles
-
-
-
-
-
-40°C, 16 h
-5°C, 16 h
+70°C, 16 h
+55°C, 16 h
-40°C to ambient 5 cycles, t1=3 h
t2<3 min
+40°C, 93% RH 96 h minimum
+55°C, 90% to 100% RH Two cycles Variant 2
1-500 Hz 10 m.s-2 3,5 mm 3 axes 10 sweep cycles 10-100 Hz / 1,0 m2.s-3 100-200 Hz / -3 dB.octave-1 200-2000 Hz / 0,5 m2.s-3 3 axes 30 min
-
250 m.s-2 6 ms
50 bumps vertical direction
Two falls in each specified attitude
-5°C to ambient 2 cycles, t1=3 h
0,5 °C.min-1 +30°C, 93% RH, 96
h +30°C, 90% to 100%
RH Two cycles Variant 2 1-150 Hz
2 m.s-2 0,75 mm 3 axes 5 sweep cycles
50 m.s-2
6 ms 3 shocks 6 directions
-
-
One drop on relevant corner
One topple about each bottom
edge
-
-5°C, 16 h
+55°C, 16 h
-5°C to ambient 5 cycles, t1=3 h
t2<3 min +30°C, 93% RH, 96 h
+40°C, 90% to 100% RH Two cycles Variant 1
1-500 Hz 10 m.s-2 3,5 mm 3 axes 10 sweep cycles
150 m.s-2
11 ms 3 shocks 6 directions
-
2 falls in each specified attitude
0,025 m (<1kg) One drop on each relevant
corner One topple on each of 4
bottom edges
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Notes:
Short description of Class IE13 (For more information see standard IEC 60721-3-1)
"Locations without controlled temperature and humidity, where heating may be used to raise low temperatures, locations in buildings providing minimal protection against daily variations of external climate, prone to receiving rainfall from carrying wind". Short description of Class IE23 (For more information, see standard IEC 60721-3-2)
"Transportation in unventilated compartments and in conditions without protection against bad weather, in all sorts of trucks and trailers in areas of well developed road network, in trains equipped with buffers specially designed to reduce shocks and by boat". Short description of Class IE35 (For more information see standard IEC 60721-3-3)
"Locations with no control on heat or humidity where heating may be used to raise low temperatures, to places inside a building to avoid extremely high temperatures, to places such as hallways, building staircases, cellars, certain workshops, equipment stations without surveillance". Short description of Class IE73 (For more information see standard IEC 60721-3-7)
"Transfer to places where neither temperature nor humidity are controlled but where heating may be used to raise low temperatures, to places exposed to water droplets, products can be subjected to ice formation, these conditions are found in hallways and building staircases, garages, certain workshops, factory building and places for industrial processes and hardware stations without surveillance".
Warning: The specification in the above table applies to the FASTRACK Supreme product only. Customers are advised to verify that the environmental specification of the SIM Card used is compliant with the FASTRACK Supreme environmental specifications. Any application must be qualified by the customer with the SIM Card in storage, transportation and operation.
The use of standard SIM cards may drastically reduce the environmental conditions in which the Product can be used. These cards are particularly sensible to humidity and temperature changes. These conditions may produce oxidation of the SIM card metallic layers and cause, in the long term, electrical discontinuities. This is particularly true in left alone applications, where no frequent extraction/insertion of the SIM card is performed.
In case of mobility when the application is moved through different environments with temperature variations, some condensation may appear. These events have a negative impact on the SIM and may favor oxidation.
If the use of standard SIM card, with exposition to the environmental conditions described above, can not be avoided, special care must be taken in the integration of the final application in order to minimize the impact of these conditions. The solutions that may be proposed are:
· Lubrication of the SIM card to protect the SIM Contact from oxidation. · Putting the FASTRACK Supreme Plug & Play in a waterproof enclosure with desiccant bags.
Lubrication of the SIM card had been tested by Wavecom (using Tutela Fluid 43EM from MOLYDUVAL) and gives very good results. If waterproof enclosure with a desiccant solution is used, check with your desiccant retailer the quantity that must be used according to the enclosure dimensions. Ensure humidity has been removed before sealing the enclosure. Any solution selected must be qualified by the customer on the final application. To minimize oxidation problem on the SIM card, its manipulation must be done with the greatest precautions. In particular, the metallic contacts of the card must never be touched with bare fingers or any matter which
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Technical Characteristics
may contain polluted materials liable to produce oxidation (such as, e.g. substances including chlorine). In case a cleaning of the Card is necessary, a dry cloth must be used (never use any chemical substance).
8.4 Conformity
The complete product complies with the essential requirements of article 3 of R&TTE 1999/5/EC Directive and satisfied the following standards:
Domain Safety standard Efficient use of the radio frequency spectrum
EMC
Global Certification Forum Certification Criteria PTCRB FCC IC
Applicable standard EN 60950 (ed.1999) EN 301 419-(v 4.1.1) EN 301 511 (V 7.0.1) EN 301 4891 (edition 2002) EN 301 489-7 (edition 2002) GCF-CC V3.13.0
8.5 Protections
8.5.1 Power Supply
The FASTRACK Supreme is protected by a 800 mA / 250 V fuse directly bonded on the power supply cable. The model of fuse used is: FSD 800 mA / 250 V FAST-ACTING.
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Technical Characteristics
8.5.2 Overvoltage The FASTRACK Supreme is protected against voltage over +32 V. When input voltages exceed +32 V, the supply voltage is disconnected in order to protect the internal electronic components from an overvoltage.
8.5.3 Electrostatic Discharge The FASTRACK Supreme withstands ESD according to IEC 1000-4-2 requirements for all accessible parts of the FASTRACK Supreme except the RF part:
· 8 kV of air discharge, · 4 kV of contact discharge.
8.5.4 Miscellaneous Filtering guarantees:
· EMI/RFI protection in input and output, · Signal smoothing.
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9 Safety recommendations
Fastrack Supreme User Guide
Safety recommendations
9.1 General Safety
It is important to follow any special regulations regarding the use of radio equipment due in particular to the possibility of radio frequency (RF) interference. Please follow the safety advice given below carefully. Switch OFF your Wireless CPU®:
· When in an aircraft. The use of cellular telephones in an aircraft may endanger the operation of the aircraft, disrupt the cellular network and is illegal. Failure to observe this instruction may lead to suspension or denial of cellular telephone services to the offender, or legal action or both,
· When at a refueling point,
· When in any area with a potentially explosive atmosphere which could cause an explosion or fire,
· In hospitals and any other place where medical equipment may be in use.
Respect restrictions on the use of radio equipment in:
· Fuel depots,
· Chemical plants,
· Places where blasting operations are in progress,
· Any other area where signalization reminds that the use of cellular telephone is forbidden or dangerous.
· Any other area where you would normally be advised to turn off your vehicle engine.
There may be a hazard associated with the operation of your FASTRACK Supreme Plug & Play close to inadequately protected personal medical devices such as hearing aids and pacemakers. Consult the manufacturers of the medical device to determine if it is adequately protected.
Operation of your FASTRACK Supreme Plug & Play close to other electronic equipment may also cause interference if the equipment is inadequately protected. Observe any warning signs and manufacturers' recommendations.
The FASTRACK Supreme Plug & Play is designed for and intended to be used in "fixed" and "mobile" applications: "Fixed" means that the device is physically secured at one location and is not able to be easily moved
to another location. "Mobile" means that the device is designed to be used in other than fixed locations and generally in
such a way that a separation distance of at least 20 cm (8 inches) is normally maintained between the transmitter's antenna and the body of the user or nearby persons.
The FASTRACK Supreme Plug & Play is not designed for and intended to be used in portable applications (within 20 cm or 8 inches of the body of the user) and such uses are strictly prohibited.
9.2 Vehicle Safety
Do not use your FASTRACK Supreme Plug & Play while driving, unless equipped with a correctly installed vehicle kit allowing 'Hands-Free' Operation.
Respect national regulations on the use of cellular telephones in vehicles. Road safety always comes first.
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Safety recommendations If incorrectly installed in a vehicle, the operation of FASTRACK Supreme Plug & Play telephone could interfere with the correct functioning of vehicle electronics. To avoid such problems, make sure that the installation has been performed by a qualified personnel. Verification of the protection of vehicle electronics should form part of the installation. The use of an alert device to operate a vehicle's lights or horn on public roads is not permitted.
9.3 Care and Maintenance
Your FASTRACK Supreme Plug & Play is the product of advanced engineering, design and craftsmanship and should be treated with care. The suggestion below will help you to enjoy this product for many years. Do not expose the FASTRACK Supreme Plug & Play to any extreme environment where the temperature or humidity is high. Do not use or store the FASTRACK Supreme Plug & Play in dusty or dirty areas. Its moving parts (SIM holder for example) can be damaged. Do not attempt to disassemble the Wireless CPU®. There are no user serviceable parts inside. Do not expose the FASTRACK Supreme Plug & Play to water, rain or spilt beverages. It is not waterproof. Do not abuse your FASTRACK Supreme Plug & Play by dropping, knocking, or violently shaking it. Rough handling can damage it. Do not place the FASTRACK Supreme Plug & Play alongside computer discs, credit or travel cards or other magnetic media. The information contained on discs or cards may be affected by the Wireless CPU®. The use of third party equipment or accessories, not made or authorized by Wavecom may invalidate the warranty of the Wireless CPU®. Do contact an authorized Service Center in the unlikely event of a fault in the Wireless CPU®.
9.4 Your Responsibility
This FASTRACK Supreme Plug & Play is under your responsibility. Please treat it with care respecting all local regulations. It is not a toy. Therefore, keep it in a safe place at all times and out of the reach of children. Try to remember your Unlock and PIN codes. Become familiar with and use the security features to block unauthorized use and theft.
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10 Recommended Accessories
Fastrack Supreme User Guide
Recommended Accessories
Accessories recommended by Wavecom for the FASTRACK Supreme are given in the table below.
Table 32: List of recommended accessories
Designation
Part number
1140.26
Quad-band antenna
MA112VX00
MCA1890 MH/PB/SMA m
SMA/FME adaptor
Antenna
Power adaptor (Europe) EGSTDW P2 EF9W3 24W
Out:12 V - 2A
In: 100 to 240 V 50/60 Hz 550 mA
Mounted with micro-fit connector
Fuse
F800L250V
Supplier ALLGON MAT Equipement HIRSCHMANN PROCOM
EGSTDW (for power adaptor) MOLEX (for micro-fit connector)*
Shanghai Fullness
IESM GPS + USB
M13SUE01
WAVECOM
IESM IO + USB
M13SUE02
WAVECOM
IESM IO + USB + GPS M13SUE03 * Information not available for this preliminary version.
WAVECOM
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11 Online Support
Fastrack Supreme User Guide
Online Support
Wavecom provides an extensive range on online support which includes the following areas of Wavecom's wireless expertise:
· the latest version of this document · new versions of our Operating System user guides · comprehensive support for Open AT® · regulatory certifications · carrier certifications · application notes To gain access to this support, simply visit our web site at www.wavecom.com or click on the desire link in Page. Privileged access via user login is provided to Wavecom authorized distributors.
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VpCI®-110 Emitter, Patented
· Switching equipment · Fuse boxes and power boxes · Medical equipment · Electrical wireways and terminal boxes · Scientific and measuring instruments · Telecommunications equipment · Remote electronics devices · Tool-boxes, parts-storage, and other containers
holding metals
PRODUCT DESCRIPTION Cortec® VpCI-110 emitters are designed to provide corrosion protection for metal components and parts enclosed in non-ventilated control boxes, cabinets, or tool boxes up to 10 cubic feet (283 liters) in volume. The Vapor phase Corrosion Inhibitor (VpCI) emits vapors which form a molecular layer on internal metal surfaces to protect critical, complex, and expensive electronic equipment and other metal components during operation, shipping, or storage. VpCI-110 is a small foam emitter through which corrosion inhibitors are slowly released, and moisture and air pollutants can enter to be absorbed. It provides long-term protection against corrosion even in the presence of adverse conditions including salt, moisture, airborne contaminants, H2S, SO2, NH3, and others.
TYPICAL APPLICATIONS VpCI-110 can be effectively used for:
· Operations, packaging, and storage electrical equipment
· Marine navigation and communication electronic equipment
· Aerospace electrical controls · Electric motors
FEATURES · Economical to use · Provides continuous protection for up to 24 months
during operation and/or shutdown · Effective in polluted and humid environments · Does not interfere with electrical, optical, or
mechanical performance · Multimetal protection · Quick and easy installation · Non-toxic and safe to handle · Compact and space-saving · Free of nitrites, halogens, and phosphates · No spraying, wiping, or dipping required · Low VOC values · Meets Southern California Clean Air Act and other
National and local regulations · Self-stick back · Self-stick date label · Accepted by FDA for corrosion protection of electrical
and electronic equipment within food processing plants · Canadian Food Inspection Agency acceptance for indirect food contact · NSN 6850-01-456-2971 · Conforms to MIL I-22110C · Federal Standard 101, Ardec Technical Report 9905, Picatinny Arsenal, New Jersey, USA
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METHOD OF APPLICATION VpCI-110 is extremely simple and convenient to install. The device should be installed at the earliest possible time. Simply select a space within enclosure where corrosion protection would be useful. Verify the surface is clean and free of debris. Peel off the protective peel strip from the bottom of the device and attach it to the clean surface.
VpCI-110 emitters can be installed in any position. For volumes greater than 10 cubic feet (283 liters), use more than one device. If the enclosure is not totally airtight, or if the access doors are opened frequently, replace the VpCI-110 device more often than every 2 years. After periods of heavy maintenance replace the device. For additional protection spray the enclosure very lightly with ElectriCorr® VpCI-238 or VpCI -239.
SPECIFICATIONS Packaging
Protection
Standard Size
12 individually wrapped emitters per carton up to 10 ft3 (283 liters) per device Foam device with adhesive backing 2.5" D x 2" H (6.4 cm D x 5 cm H)
FOR INDUSTRIAL USE ONLY KEEP OUT OF REACH OF CHILDREN KEEP CONTAINER TIGHTLY SEALED NOT FOR INTERNAL CONSUMPTION CONSULT MATERIAL SAFETY DATA SHEET FOR MORE INFORMATION
LIMITED WARRANTY
All statements, technical information and recommendations contained herein are based on tests Cortec Corporation believes to be reliable, but the accuracy or completeness thereof is not guaranteed.
Cortec Corporation warrants Cortec® products will be free from defects when shipped to customer. Cortec Corporation's obligation under this warranty shall be limited to replacement of product that proves to be defective. To obtain replacement product under this warranty, the customer must notify Cortec Corporation of the claimed defect within six months after shipment of product to customer. All freight charges for replacement products shall be paid by customer.
Cortec Corporation shall have no liability for any injury, loss or damage arising out of the use of or the inability to use the products.
BEFORE USING, USER SHALL DETERMINE THE SUITABILITY OF THE PRODUCT FOR ITS INTENDED USE, AND USER ASSUMES ALL RISK AND LIABILITY WHATSOEVER IN CONNECTION THEREWITH. No representation or recommendation not contained herein shall have any force or effect unless in a written document signed by an officer of Cortec Corporation.
THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, EXPRESS, IMPLIED OR STATUTORY, INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE. IN NO CASE SHALL CORTEC CORPORATION BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
Distributed by:
4119 White Bear Parkway, St. Paul, MN 55110 USA Phone (651) 429-1100, Fax (651) 429-1122 Toll Free (800) 4-CORTEC, E-mail info@cortecvci.com Internet http://www.CortecVCI.com
printed on recycled paper
100% post consumer
Revised 3/3/09. Cortec Corporation 2001-2009. All rights reserved. Supersedes: 5/31/06
ElectriCorr® and Cortec® are trademarks of Cortec Corporation
© 2009, Cortec Corporation. All Rights Reserved. Copying of these materials in any form
without the written authorization of Cortec Corporation is strictly prohibited.
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1.7. TERMINALS, LINKS & OTHER ACCESSORIES PHOENIX CONTACT TCP 10A (0712314) + UK 6-FSI/C (3118203) 10A Miniature Thermal Circuit Breakers PHOENIX CONTACT TCP 4A (0712259) + UK 6-FSI/C (3118203) 4A Miniature Thermal Circuit Breakers PHOENIX CONTACT TCP 2A (0712217) + UK 6-FSI/C (3118203) 2A Miniature Thermal Circuit Breakers PHOENIX CONTACT PIT 2,5 (3209510) Through Terminals (Grey) PHOENIX CONTACT D-ST 2,5 (3030417) Through Terminal Endplate PHOENIX CONTACT PIT 2,5-MT (3210156) Disconnect Terminals (Grey) PHOENIX CONTACT D-PIT 2,5-MT (3211003) Disconnect Terminals Endplate PHOENIX CONTACT UBE (0800310) Group Marker Carrier PHOENIX CONTACT PS-5 (3030983) Test Plug Adapter PHOENIX CONTACT SZS 0.6x3.5 (1205053) Screw Driver PHOENIX CONTACT FBS 20-5 (3030226) Plug-In Bridge PHOENIX CONTACT ZB 5 CUS (0824962) Terminal Numbers WEIDMULLER (8611320000) Adapter MAXON MA.2025 Ethernet Router MAXON C3LA30-BD170F Antenna LUMIFA LF1B-C35-2THWW4 Switchboard LED
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CLIPSAL NEUTRAL-ACTIVE-METER LINKS
CLIPSAL NEUTRAL / ACTIVE / METER LINKS
Clipsal Links are produced from Impact Resistant materials to prevent cracking in transit or during installation.
The transparent covers enable you to check wiring and locate the sealing screw at a glance. The sealing screw (nylon with brass insert) resists stripping. Voltage and amperage ratings are clearly marked on both the cover and brass bar.
All links are available with black or red covers and bases for neutral, active or meter applications as required by local authorities.
T-Type - 500 Volt 140 Ampere L4T35
500V 140A 4 Hole Neutral Link with two screws per tunnel. Black base and cover.
L4T35R 500V 140A 4 Hole Active Link. Red base and cover. Dimensions: 65 x 46 x 43mm. Mounting centres: 28mm. 1 tunnel 8.7mm diameter accommodate 1 x 25mm2 cable. 3 tunnels 7.7mm diameter accommodate 1 x 25mm2 cable. Certificate of Suitability No. CS2252N.
L4T35R
Mini Links with Cover
500V 100A 2 screws per tunnel.
L5 500V 100A 5 Hole Neutral Link with two screws per tunnel. Black base and cover.
L5R 500V 100A 5 Hole Active Link. Red base and cover.
Dimensions: 65 x 46 x 43mm. Mounting centres: 46mm. 3 tunnels, 6.3mm diameter accommodate 1 x 16mm2. 2 tunnels, 5.8mm diameter accommodate 1 x 16mm2.
L5BW 500V 110A 5 Hole Back Wiring Neutral Link with two screws per tunnel. Black base and cover.
L5BWR 500V 110A 5 Hole Back Wiring Active Link. Red base and cover.
Dimensions: 65 x 46 x 43mm. Mounting centres: 46mm. 5 tunnels, 7mm diameter accommodate 1 x 25mm2. Transparent black cover, with cut outs.
L6R 500V 100A 6 Hole Active Link. Red base and cover.
Dimensions: 65 x 46 x 43mm. Mounting centres: 46mm. 3 tunnels, 6.3mm diameter accommodate 1 x 16mm2 cable. 3 tunnels, 5.8mm diameter accommodate 1 x 16mm2 cable.
L6/25 500V 110A 6 Hole Neutral Link with 2 screws per tunnel. Black base and cover.
L6/25R 500V 110A 6 Hole Active Link. Red base and cover.
Dimensions: 65 x 46 x 43mm. Mounting centres: 46mm. 2 tunnels, 7.5mm diameter accommodate 2 x 25mm2 cable. 1 tunnel, 5.5mm diameter accommodates 1 x 16mm2 cable. 3 tunnels, 4.7mm diameter accommodate 3 x 10mm2 cable. Transparent black cover with cut-outs.
L7 500V 100A 7 Hole Neutral Link with two screws per tunnel. Black base and cover.
L6
500V 100A 6 Hole Neutral Link with
21
two screws per tunnel. Black base
and cover.
L7
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2 Pumps
SUPPLIER:
MODEL: kW RATING: VOLTAGE:
Grundfos 30 Blanck Street Ormeau QLD 4208
Ph: (07) 5540 6700 Fax: (07) 5540 6710
MOB-QUU-3xCRNE 45-2 BOOSTER
7.5kW
415V
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GRUNDFOS INSTRUCTIONS
BoosterpaQ Hydro MPC
Installation and operating instructions
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LIMITED WARRANTY
Products manufactured by GRUNDFOS PUMPS CORPORATION (Grundfos) are warranted to the original user only to be free of defects in material and workmanship for a period of 24 months from date of installation, but not more than 30 months from date of manufacture. Grundfos' liability under this warranty shall be limited to repairing or replacing at Grundfos' option, without charge, F.O.B. Grundfos' factory or authorized service station, any product of Grundfos' manufacture. Grundfos will not be liable for any costs of removal, installation, transportation, or any other charges which may arise in connection with a warranty claim. Products which are sold but not manufactured by Grundfos are subject to the warranty provided by the manufacturer of said products and not by Grundfos' warranty. Grundfos will not be liable for damage or wear to products caused by abnormal operating conditions, accident, abuse, misuse, unauthorized alteration or repair, or if the product was not installed in accordance with Grundfos' printed installation and operating instructions.
To obtain service under this warranty, the defective product must be returned to the distributor or dealer of Grundfos' products from which it was purchased together with proof of purchase and installation date, failure date, and supporting installation data. Unless otherwise provided, the distributor or dealer will contact Grundfos or an authorized service station for instructions. Any defective product to be returned to Grundfos or a service station must be sent freight prepaid; documentation supporting the warranty claim and/or a Return Material Authorization must be included if so instructed.
GRUNDFOS WILL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, LOSSES, OR EXPENSES ARISING FROM INSTALLATION, USE, OR ANY OTHER CAUSES. THERE ARE NO EXPRESS OR IMPLIED WARRANTIES, INCLUDING MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, WHICH EXTEND BEYOND THOSE WARRANTIES DESCRIBED OR REFERRED TO ABOVE.
Some jurisdictions do not allow the exclusion or limitation of incidental or consequential damages and some jurisdictions do not allow limit actions on how long implied warranties may last. Therefore, the above limitations or exclusions may not apply to you. This warranty gives you specific legal rights and you may also have other rights which vary from jurisdiction to jurisdiction.
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CONTENTS
1. Symbols used in this document
2. Scope of these instructions
3. Product description
4. Nameplate
5. Software label
6. Type key 6.1 Examples of control variants
7. 7.1 7.1.1 7.1.2 7.1.3 7.1.4 7.1.5 7.2 7.3
Installation Mechanical installation Location Pipework Foundation Vibration dampers Expansion joints Electrical installation Start-up
8. Control panel 8.1 Display (pos. 1) 8.1.1 Menu line 8.1.2 Top line 8.1.3 Graphical illustration 8.1.4 Scroll bar 8.1.5 Bottom line 8.2 Buttons and indicator lights 8.2.1 Arrow to the right (pos. 2) 8.2.2 Help (pos. 3) 8.2.3 Up and down (pos. 4 and 5) 8.2.4 Plus and minus (pos. 6 and 7) 8.2.5 Esc (pos. 8) 8.2.6 Home (pos. 9) 8.2.7 Ok (pos. 10) 8.2.8 Indicator lights (pos. 11 and 12) 8.2.9 Contrast (pos. 13) 8.2.10 Back light
9. 9.1 9.2 9.3 9.4 9.4.1 9.4.2 9.4.3 9.4.4 9.4.5 9.4.6 9.4.7 9.4.8 9.5 9.5.1 9.5.2 9.5.3 9.5.4 9.5.5 9.5.6
9.6 9.6.1 9.6.2 9.6.3 9.7 9.7.1 9.7.2 9.7.3 9.7.4 9.7.5
Functions Tree of functions Overview Description of functions Status (1) Current alarms (3.1) System (1.2) Operating mode (1.2.1) Setpoint (1.2.2) Setpoint influence (1.2.3) Measured values (1.2.4) Analog inputs (1.2.5) Pump 1...6 (1.3 to 1.8) Operation (2) Operation (2) System operating mode (2.1.1) Control mode (2.1.2) Setpoints (2.1.3) Individual pump control (2.1.4) Setting of individual operating mode (2.1.4.1 to 2.1.4.6) Alarm (3) Alarm status (3) Current alarms (3.1) Alarm log (3.2) Settings (4) Primary controller (4.1) PI controller (4.1.1) Alternative setpoints (4.1.2) Alternative setpoints 2 to 7 (4.1.2.1 to 4.1.2.7) External setpoint influence (4.1.3)
Page
4
4
4
5
5
6 6
9 9 9 9 9 9 9 10 10
12 12 12 12 12 12 12 13 13 13 13 13 13 13 13 13 13 13
14 14 17 19 19 19 19 20 20 20 21 21 21 21 22 22 23 25 25
26 27 27 32 32 32 33 33 33 34 34
9.7.6 Setting of influence function (4.1.3.2)
35
9.7.7 Primary sensor (4.1.4)
35
9.7.8 Clock program (4.1.6)
36
9.7.9 Proportional pressure (4.1.7)
36
9.7.10 S-system configuration (4.1.8)
37
9.7.11 Pump cascade control (4.2)
37
9.7.12 Min. time between start/stop (4.2.1)
38
9.7.13 Max. number of starts/hour (4.2.1)
38
9.7.14 Standby pumps (4.2.3)
38
9.7.15 Forced pump changeover (4.2.4)
39
9.7.16 Pump test run (4.2.5)
39
9.7.17 Pilot pump (4.2.6)
40
9.7.18 Pump stop attempt (4.2.7)
40
9.7.19 Pump start and stop speed (4.2.8)
41
9.7.20 Min. performance (4.2.9)
41
9.7.21 Compensation for pump start-up time (4.2.10)
42
9.7.22 Secondary functions (4.3)
42
9.7.23 Stop function (4.3.1)
42
9.7.24 Soft pressure build-up (4.3.3)
44
9.7.25 Emergency run (4.3.5)
45
9.7.26 Digital inputs (4.3.7)
45
9.7.27 Functions of digital inputs (4.3.7.1)
46
9.7.28 Analog inputs (4.3.8)
46
9.7.29 Analog inputs (4.3.8.1 to 4.3.8.7)
47
9.7.30 Analog inputs and measured value
(4.3.8.1.1 to 4.3.8.7.1)
47
9.7.31 Digital outputs (4.3.9)
48
9.7.32 Functions of digital outputs (4.3.9.1 to 4.3.9.16)
48
9.7.33 Min., max. and user-defined duty (4.3.14)
49
9.7.34 Min. duty (4.3.14.1)
49
9.7.35 Max. duty (4.3.14.2)
49
9.7.36 User-defined duty (4.3.14.3)
50
9.7.37 Pump curve data (4.3.19)
50
9.7.38 Control source (4.3.20)
51
9.7.39 Fixed inlet pressure (4.3.22)
52
9.7.40 Flow estimation (4.3.23)
52
9.7.41 Monitoring functions (4.4)
52
9.7.42 Dry-running protection (4.4.1)
53
9.7.43 Dry-running protection with pressure/level switch
(4.4.1.1)
53
9.7.44 Dry-running protection with pressure transmitter
(4.4.1.2)
54
9.7.45 Dry-running protection with level transmitter (4.4.1.3) 54
9.7.46 Min. pressure (4.4.2)
55
9.7.47 Max. pressure (4.4.3)
55
9.7.48 External fault (4.4.4)
56
9.7.49 Limit 1 and 2 exceeded (4.4.5 and 4.4.6)
56
9.7.50 Pumps outside duty range (4.4.7)
57
9.7.51 Pressure relief (4.4.8)
57
9.7.52 Functions, CU 351 (4.5)
58
9.7.53 Display language (4.5.1)
58
9.7.54 Display units (4.5.2)
59
9.7.55 Date and time (4.5.3)
60
9.7.56 Passwords (4.5.4)
60
9.7.57 Ethernet (4.5.5)
60
9.7.58 GENIbus number (4.5.6)
61
9.7.59 Software status (4.5.9)
61
9.8 Data communication
62
9.8.1 Ethernet
62
9.8.2 GENIbus
64
10. External variable frequency drive
65
10.1 VLT 2800
65
10.2 Danfoss VLT 8000 factory settings
66
10.3 Danfoss VLT 8000 extended menu programming
66
10.4 Danfoss VLT 8000 factory settings
67
10.5 Danfoss VLT 8000 extended menu programming
67
10.6 Baldor Smart motor settings
68
10.7 VLT FC 202
69
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11. Fault finding chart
70
12. Maintenance
71
12.1 Pumps
71
12.2 Motor bearings
71
12.3 CU 351
71
13. Frost protection
71
14. Taking out of operation
71
15. Technical data
71
15.1 Pressure
71
15.2 Temperature
72
15.3 Relative humidity
72
15.4 Sound pressure
72
16. Electrical data
72
17. Related documents
72
18. Disposal
72
Warning
Prior to installation, read these installation and operating instructions. Installation and operation must comply with local regulations and accepted codes of good practice.
1. Symbols used in this document
Warning
If these safety instructions are not observed, it may result in personal injury!
If these safety instructions are not observed, it Caution may result in malfunction or damage to the
equipment!
Note
Notes or instructions that make the job easier and ensure safe operation.
2. Scope of these instructions
These installation and operating instructions apply to Grundfos Hydro MPC booster systems. Hydro MPC is a range of factory-assembled booster systems, ready for installation and operation.
3. Product description
As standard, Hydro MPC booster systems consist of two to six CR(E) pumps coupled in parallel and mounted on a common base frame with all the necessary fittings and a control panel.
Note
A diaphragm tank is required in most installations.
1
9
8 2
7 3
6
5
4
Fig. 1 Hydro MPC booster system
Pos.
1 2 3 4 5 6 7 8 9
Description
Control panel Nameplate Suction manifold (stainless steel) Isolating valve Base frame (stainless steel) Non-return valve Discharge manifold (stainless steel) Pressure transmitter/pressure gauge Pump
Quantity
1 1 1 2 per pump 1 1 per pump 1 12 2 - 6
TM03 1171 1205
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Hydro MPC booster systems are divided into seven groups based on control variant:
Control variant
Description
-E -ED -ES -EF -EDF
-F -S
Two to six CRE pumps
Two CRE pumps and up to four constant speed CR pumps
One CRE pump and up to five constant speed CR pumps
Two to six CR pumps connected to external variable frequency drives (VFD)
Two CR pumps connected to external variable frequency drives and up to four constant speed CR pumps
Up to six CR pumps connected to an external variable frequency drive. The speed-controlled operation alternates between the pumps.
Two to six constant speed CR pumps
See also section 6.1 Examples of control variants.
Hydro MPC booster systems always includes applicationoptimised software for setting the booster system to the application in question.
4. Nameplate
The nameplate of the booster system is fitted on the base frame. See position 2 in fig. 1.
Pos. Description
1 Type designation 2 Model 3 Serial number 4 Supply voltage 5 Maximum operating pressure in PSI 6 Liquid temperature in °F 7 Maximum flow rate in GPM 8 Minimum head in feet 9 Number of fixed speed and/or auxiliary pumps 10 Motor power in HP for fixed speed pumps 11 Nominal voltage in volts for fixed speed pumps 12 Number of E-pumps 13 Motor power in HP for E-pumps
14 Nominal voltage in volts for E-pumps
15 Number of pilot pumps
16 Motor power in HP for pilot pump
17 Nominal voltage in volts for pilot pump
18 Order number
1924
Options
25 Enclosure type
26 Weight in lbs
27 Approval marks
28 Production location & date code
5. Software label
The software label is placed on the back of the CU 351 controller.
1. Control MPC 1
2. C-MPC options 2
3. Hydro MPC 3
4. H-MPC options 4
5. Pump data 5
TM03 1741 3105 TM03 1742 3105
Fig. 2 Nameplate
CONFIGURATION STEPS - PLEASE FOLLOW THE NUMBERS
Fig. 3 Software label
96586126
Pos.
1 2 3 4 5
Description
Control MPC - GSC file number Control MPC options - GSC file numbers Hydro MPC - GSC file number Hydro MPC options - GSC file numbers Pump data - GSC file numbers
Note
A GSC (Grundfos Standard Configuration) file is a configuration data file.
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6. Type key
Example
Hydro MPC -ED 2 CRE 5-10 1 CR 5-10
3x460 V, 60Hz
Type range
Subgroups: Pumps with integrated variable frequency drive: -E, -ED, -ES Pumps with external VFD: -EF, -EDF, -F Constant speed pumps (start/stop): -S Number of pumps with integrated variable frequency drive and pump type Number of constant speed pumps and pump type Supply voltage, frequency
6.1 Examples of control variants
Booster systems with motors that include an integrated variable frequency drive (CRE)
Hydro MPC-E
Hydro MPC booster system with three CRE pumps.
Hydro MPC-ED
Hydro MPC booster system with two CRE pumps and one constant speed CR pump.
Hydro MPC-ES
Hydro MPC booster system with one CRE pump and two constant speed CR pumps.
TM03 0996 0905
TM03 0994 0905
TM03 0993 0905
PT
PT
PT
One CRE pump in operation.
H
One CRE pump in operation.
H
One CRE pump in operation.
H
TM00 7995 2296
TM00 7995 2296
TM00 7995 2296
Hset
Hset
Hset
Three CRE pumps in operation.
H
Q
Q
Q
Two CRE pumps and one constant speed One CRE pump and two constant speed CR
CR pump in operation.
pumps in operation.
H
H
TM00 7998 2296
TM03 0814 0505
TM00 7996 2296
Hset
Hset
Hset
Q
Q
Q
· The MPC-E system maintains a constant · The MPC-ED system maintains a constant · The MPC-ES system maintains a constant
pressure through continuous adjustment pressure through continuous adjustment pressure through continuous adjustment
of the speed of the pumps.
of the speed of two CRE pumps, while the of the speed of the CRE pump. The other
· The system performance is adjusted to
CR pump is constant speed.
pumps are cut in/out according to demand
the demand through cutting in/out the
· One CRE pump always starts first. If the
to achieve a performance corresponding
required number of pumps and through
pressure cannot be maintained by the
to the consumption.
parallel control of the pumps in operation. pump, the second CRE pump will be cut · The CRE pump always starts first. If the
· Pump changeover is automatic and
in. If the two CRE pumps cannot maintain pressure cannot be maintained by the
depends on load, operating hours and
the pressure, the CR pump will be cut in. pump, one or both CR pumps will be cut
fault.
· Pump changeover is automatic and
in.
· All pumps in operation will run at equal
depends on load, operating hours and · Changeover among the constant speed
speed.
fault.
pumps is automatic and depends on load,
operating hours and fault.
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Booster systems with motors connected to external variable frequency drive (VFD)
Hydro MPC-EF
Hydro MPC booster system with three CR pumps connected to external variable frequency drives in the control panel.
Hydro MPC-EDF
Hydro MPC booster system with two CR pumps connected to external frequency converters in the control cabinet and one constant speed CR pump.
Hydro MPC-F
Hydro MPC booster system with three CR pumps connected to an external frequency converter in the control cabinet. The speed-controlled operation alternates between the pumps.
TM03 1265 1505
TM03 0997 0905
TM03 0995 0905
PT
PT
PT
One CR pump in operation.
H
One CR pump connected to an external variable frequency drive in operation.
H
One CR pump connected to an external variable frequency drive in operation.
H
TM00 7995 2296
TM00 7995 2296
TM00 7995 2296
Hset
Three CR pumps in operation.
H
Hset
Hset
Q
Q
Q
Two CR pumps connected to external
One CR pump connected to an external
variable frequency drives and one constant variable frequency drive and two constant
speed CR pump in operation.
speed CR pumps in operation.
H
H
TM00 7998 2296
TM03 0814 0505
TM00 7996 2296
Hset
Hset
Hset
Q
Q
Q
· The MPC-EF system maintains a constant · The MPC-EDF system maintains a
· The MPC-F system maintains a constant
pressure through continuous adjustment constant pressure through continuous
pressure through continuous adjustment
of the speed of the pumps.
adjustment of the speed of two CR pumps of the speed of the CR pump connected to
· The system performance is adjusted to the demand through cutting in/out the required number of pumps and through
connected to external variable frequency drives, while the third CR pump is constant speed.
the external variable frequency drive. The speed-controlled operation alternates between the pumps.
parallel control of the pumps in operation. · One CR pump connected to an external · One CR pump connected to the external
· Pump changeover is automatic and depends on load, operating hours and fault.
· All pumps in operation will run at equal speed.
variable frequency drive always starts
variable frequency drive always starts
first. If the pressure cannot be maintained first. If the pressure cannot be maintained
by the pump, the second CR pump
by the pump, one or two constant speed
connected to an external variable
CR pumps will be cut in.
frequency drive will be cut in. If the
· Pump changeover is automatic and
pressure cannot be maintained by the two depends on load, operating hours and
pumps, the constant speed CR pump will fault.
be cut in.
· Pump changeover is automatic and
depends on load, operating hours and
fault.
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TM03 0999 0905
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Booster system with constant speed pumps (on/off) Hydro MPC-S
Hydro MPC booster system with three constant speed CR pumps.
PT
One constant speed CR pump in operation.
H
Hstop Hset
Q
Three constant speed CR pumps in operation.
H
Hstop Hset
Q
· Hydro MPC-S maintains a pressure differential through cutting in/out the required number of pumps.
· The operating range of the pumps will lie between Hset and Hstop (cut-out pressure).
· Pump changeover is automatic and depends on load, operating hours and fault.
TM03 9204 3607
TM03 9203 3607
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7. Installation
Warning Installation and operation must comply with local regulations and accepted codes of good practice.
Before installation check that · the booster system corresponds to the one ordered. · no visible parts have been damaged.
7.1 Mechanical installation
7.1.1 Location The booster system must be installed in a well ventilated room to ensure sufficient cooling of the motors and control panel.
Note
Hydro MPC is not designed for outdoor installation unless protected and must not be exposed to direct sunlight.
The booster system must have a 3 feet clearance in front and on the two sides for inspection and dismantling.
7.1.2 Pipework
Arrows on the pump base show the direction of flow of water through the pump.
The pipework connected to the booster system must be of adequate size. The pipes are connected to the manifolds of the booster system. Either end can be used. Apply sealing compound to the unused end of the manifold and fit the screw cap. For manifolds with flanges, fit a blanking flange with gasket.
To achieve optimum operation and minimise noise and vibration, it may be necessary to consider vibration dampening of the booster system.
Noise and vibration are generated by the rotations in the motor and pump and by the flow in pipework and fittings. The effect on the environment is subjective and depends on correct installation and the state of the other parts of the system.
If booster system is to be installed where first customer on the line is close to the booster system, it is advisable to fit expansion joints on the suction and discharge pipes to prevent vibration being transmitted through the pipework.
All nuts should be checked and re-tightened if necessary prior to start-up. The pipes must be fastened to parts of the building to ensure that they cannot move or be twisted.
7.1.3 Foundation
The booster system should be positioned on an even and solid surface, for instance a concrete floor or foundation. If the booster system is not fitted with machine shoes, it must be bolted to the floor or foundation.
Note
As a rule the weight of a concrete foundation should be 1.5 x the weight of the booster system.
7.1.4 Vibration dampers
To prevent the transmission of vibrations to buildings, it imay be necessary to isolate the booster system foundation from building parts by means of vibration dampers.
The right damper varies from installation to installation, and a wrong damper may increase the vibration level. Vibration dampers should therefore be sized by the supplier of vibration dampers. If the booster system is installed on a base frame with vibration dampers, expansion joints should always be fitted on the manifolds. This is important to prevent the booster system from "hanging" in the pipework.
7.1.5 Expansion joints
Expansion joints are installed to · absorb expansions/contractions in the pipework caused by
changing liquid temperature · reduce mechanical strains in connection with pressure surges
in the pipework · isolate mechanical structure-borne noise in the pipework
(only rubber bellows expansion joints).
Note
Expansion joints must not be installed to compensate for inaccuracies in the pipework such as center displacement of flanges.
Fit expansion joints at a distance of minimum 1 to 1 1/2 times the nominal flange diameter from the manifold on the suction as well as on the discharge side. This prevents the development of turbulence in the expansion joints, resulting in better suction conditions and a minimum pressure loss on the pressure side. At high water velocities (> 10 ft/sec) it is advisable to install larger expansion joints corresponding to the pipework.
TM03 2154 3805 TM02 4981 1902 - TM02 4979 1902
1
1
2
2
Fig. 4
3
3
Sketch showing the position of expansion joints, pipe supports and machine shoes
Pos. Description
1 Expansion joint
2
Pipe support and good location for system isolation valve (not shown)
3 Machine shoe
Note
Expansion joints, pipe supports and machine shoes shown in the figure above are not supplied with a standard booster system.
Fig. 5 Examples of rubber bellows expansion joints without and with limit rods
Expansion joints with limit rods can be used to minimise the forces caused by the expansion joints. Expansion joints with limit rods are always recommended for flanges larger than 6 inches. The pipework should be anchored so that it does not stress the expansion joints and the pump. Follow the supplier's instructions and pass them on to advisers or pipe installers.
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7.2 Electrical installation
Warning
The electrical installation should be carried out by an authorized person in accordance with local regulations and the relevant wiring diagram.
· The electrical installation of the booster system must comply with enclosure class IP54.
· Make sure that the booster system is suitable for the electricity supply to which it is connected.
· Make sure that the wire cross-section corresponds to the specifications in the wiring diagram.
The connection of the electrical supply, transmitters and external monitoring equipment must be carried out by an authorized electrician in accordance with the NEC, local regulations and the BoosterpaQ wiring diagram.
Ensure that the Hydro MPC controls and the pumps are suitable for the electricity supply on which they will be used (see Technical Data). Please read the wiring diagram carefully. According to the NEC, if the motors cannot be seen from the control panel, they must be fitted with a disconnect switch.
Any BoosterpaQ that utilizes a variable frequency drive (E, ED, ES, EF, EDF, F) should be connected to an electrical supply with all phase lines electrically symmetrical with respect to ground. A "four wire wye" electrical supply with line impedance between 0.5% - 3% is recommended. If a variable frequency drive is connected to a delta transformer or if line impedance is not within the recommended 0.5% - 3%, the drive may not operate correctly and may not provide optimum performance (excessive faults, erratic behavior, or complete failure). Ask your power company or electrician to determine what type of electrical supply is present. Generator supplied power must meet public utility power quality standards.
7.3 Start-up
1. Have a qualified person check for proper power supply and plumbing connections. Make sure the main power is off.
2. Check that the air pre-charge in the diaphragm tank is 0.7 times the required discharge pressure set-point (0.9 times for MPC-S systems). System pressure must not be applied to the tank connection during the tank precharge process. If water is supplied to the tank from the system, close the tank valve and bleed off the pressure in the tank before the pressurizing process.
Prime the system as follows
3. Suction pressure system (pumps are flooded at least as high as the highest part of the pumps)
close all discharge manifold pump isolation valves and open all inlet manifold pump isolation valves
open the vent plug on top of each pump. It is a small hex head screw in a large vent plug. Air and water will escape from the pump through a small hole in the large vent plug. When the air is out and water is flowing steadily, tighten the small hex head screw on the vent plug to stop the flow.
Note
If you are filling an empty piping system, do not allow the pumps to run with the discharge valves wide open as cavitation may occur.
4. Suction lift system (the water source is below the pumps or does not flood the pumps to the highest point on the pumps).
close all discharge manifold pump isolation valves and open all inlet manifold pump isolation valves
for suction lift applications, a foot valve must be placed on the inlet piping at the water source (tank, etc). If there is a fill point above the highest point of the pumps, you may fill the system from this point. If there is no fill point above the highest point of the pumps, remove the large vent plug on each pump. Fill each pump until the water is up to the vent plug, then replace the vent plugs.
5. Ensure all circuit breakers are in the "on" position.
6. Make sure the discharge manifold pump isolation valves are closed. Switch on main power.
Caution The pumps may start at this time.
7. At this time "Start-up wizard" may now be ran. Step 8 can be skipped upon completion of "Start-up wizard". If "Start-up wizard" could not be ran or already ran proceed to step 8.
8. Run the "Start-up wizard" again by performing the following: Move top line display to "Settings". If prompted for password enter "6814", next move down to "Functions, CU 351" and press the "OK" button. Now move down to "Run wizard again" and press the "OK" button.
9. Vent the system by opening the vent plug on each pump (as in Step 3, while the pump is running starting in step 18 of the "Start-up wizard".). Venting with the pumps running ensures all air is removed from the suction piping. Do not run the system with the discharge manifold pump isolation valves closed more than five minutes to prevent over-heating of the pump liquid.
10.As pumps stop, check pump rotation. Repeat as necessary. If the area is dark, a flashlight may be required, or remove a coupling guard on each pump for better visibility. Disconnect the main power when removing coupling guards. Warning
Do not touch the couplings while the pumps are turning as injury may result. Replace all coupling guards after the rotation check. Disconnect main power when removing and replacing coupling guards (or open service disconnect switches if this option was supplied).
If the rotation is incorrect on any 3 phase pumps, switch any 2 of the 3 power main wires supplied to the control panel (L1, L2, L3). If that doesn't correct the rotation, call your Grundfos representative.
Note
If you are filling an empty piping system, do not allow the pumps to run with the discharge valves wide open as cavitation may occur.
11.Upon completion of venting pumps and checking for correct rotation you are now ready to bring the BoosterpaQ into normal operation. With the discharge manifold isolation valves still closed, partially open each pump discharge isolation valve to allow water to enter into the discharge piping of the BoosterpaQ. Continue the process of filling the discharge piping until discharge piping pressure is approximately at the desired Setpoint pressure of the BoosterpaQ.
12.Open the discharge manifold isolation valves for each pump completely. System is now ready for operation.
It may be necessary to clear alarms in the fault log. Follow the steps in paragraph sections 9.6 to clear alarms.
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8. Control panel
8.1 Display (pos. 1)
The control panel in the front cover of the control cabinet features
a display, a number of buttons and two indicator lights. The
A
control panel enables manual setting and monitoring of the
B
performance of the Hydro MPC.
2
CU 351
3
1
5
4
6
7 8 9
10
11
Fig. 6 Control panel
13
12
Key
Pos.
1 2 3 4 5 6 7 8 9 10 11 12 13
Description
Display Arrow to the right Help Up Down Plus Minus Esc Home Ok Indicator light, operation (green) Indicator light, fault (red) Contrast
TM03 1304 1705 TM03 8947 4807
D
C
Fig. 7 Display design
8.1.1 Menu line The menu line (A) is illustrated in fig. 7. The display has four main menus:
Status:
Indication of system status
Operation:
Change of operating parameters such as setpoint (password option)
Alarm:
Alarm log for fault finding
Settings: Change of settings (password option)
8.1.2 Top line The top line (B) is illustrated in fig. 7. The top line shows · the display number and title (left side) · the selected menu (left side) · the symbol in case of alarm (right side) · the symbol if the service language has been selected (right
side).
8.1.3 Graphical illustration The graphical illustration (D) may show a status, an indication or other elements, depending on the position in the menu structure. The illustration may show the entire system or part of it as well as various settings.
8.1.4 Scroll bar If the list of illustration elements exceeds the display, the symbols
and will appear in the scroll bar to the right. Use the and buttons to move up and down in the list.
8.1.5 Bottom line The bottom line (C) shows the date and time.
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8.2 Buttons and indicator lights
The buttons (pos. 2 to 10 in fig. 6) on the CU 351 are active when they are illuminated.
8.2.1 Arrow to the right (pos. 2)
Press the button to move to the next menu in the menu structure. If you press when the Settings menu is highlighted, you go to the Status menu.
8.2.2 Help (pos. 3)
When the button is illuminated, a help text applying to the current display will appear if the button is pressed.
Close the text by pressing the button.
8.2.3 Up and down (pos. 4 and 5)
Press the and buttons to move up and down in lists.
A text can be selected when it is in a box.
If a text is marked and the button is pressed, the text above will be marked instead. If the button is pressed, the text below will be marked.
If the button is pressed in the last line in the list, the first line will be marked.
If the button is pressed in the first line in the list, the last line will be marked.
8.2.4 Plus and minus (pos. 6 and 7)
Use the
and buttons to increase and reduce values.
A value is activated when the button is pressed.
8.2.5 Esc (pos. 8)
Use the button to go one display back in the menu.
If a value has been changed and the button is pressed, the new value will not be saved. For further information, see section 8.2.7 Ok (pos. 10).
If the button is pressed before the button, the new value will be saved. For further information, see section 8.2.7 Ok (pos. 10).
8.2.6 Home (pos. 9)
Press the
button to return to the Status menu.
8.2.7 Ok (pos. 10)
Use the
button as an enter button.
The
button is also used to start the setting of a value.
If a value has been changed and the new value will be activated.
button is pressed, the
8.2.8 Indicator lights (pos. 11 and 12)
The Hydro MPC control panel incorporates a green and red indicator light.
The green indicator light is on when the Hydro MPC is in operation.It is flashing if the Hydro MPC has been set to stop.
The red indicator light is on if there is an alarm or a warning. The fault can be identified from the alarm list.
8.2.9 Contrast (pos. 13)
The contrast in the display can be changed by means of the button:
1. Press .
2. Adjust the contrast with
and .
8.2.10 Back light
If no button is touched for 15 minutes, the back light of the panel will be dimmed, and the first display in the Status menu will appear. Press any button to re-activate the back light.
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9. Functions 9.1 Tree of functions
1. Status
1 Status 3.1 Current alarms 3.1.1 Current alarms 1.2 System 1.2.1 Operating mode 1.2.2 Setpoint 1.2.3 Setpoint influence 1.2.4 Measured values 1.2.5 Analog inputs 1.3 Pump 1 1.4 Pump 2 1.5 Pump 3 1.6 Pump 4 1.7 Pump 5 1.8 Pump 6
2. Operation
3. Alarm
2 Operation 2.1 Further settings 2.1.1 System operating mode 2.1.2 Control mode 2.1.3 Setpoints 2.1.4 Individual pump control 2.1.4. Pump 1...6
3 Alarm status
3.1 Current alarms 3.2 Alarm log
Continued on page 15
Key to the four main menus, Status, Operation, Alarm and Settings
Status
The Status menu shows alarms and the status of system and pumps. Note: No settings can be made in this menu.
Operation
In the Operation menu, the most basic parameters can be set, such as setpoint, operating mode, control mode and individual pump control.
Alarm
The Alarm menu gives an overview of alarms and warnings. Alarms and warnings can be reset in this menu.
Settings
In the Settings menu, it is possible to set various functions: · Primary controller
Setting of alternative setpoints, external setpoint influence, primary sensor, clock program, proportional pressure and S-system configuration. · Pump cascade control Setting of min. time between start/stop, max. number of starts/hour, number of standby pumps, forced pump changeover, pump test run, pilot pump, pump stop attempt, pump start and stop speed, min. performance and compensation for pump start-up time. · Secondary functions Setting of stop function, soft pressure build-up, digital and analog inputs, digital outputs, emergency run, min., max. and user-defined duty, pump curve data, flow estimation, control source and fixed inlet pressure. · Monitoring functions Setting of dry-running protection, min. and max. pressure, external fault, limit 1 and 2 exceeded, pumps outside duty range and pressure relief. · Functions, CU 351 Selection of service language, main language and units. Setting of date and time, passwords, Ethernet connection, GENIbus number and software status.
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Continued from page 16
4. Settings
4.1 Primary controller
4.1.1
PI controller
4.1.2
Alternative setpoints
4.1.3
4.1.2.1 Alternative setpoints 2...7 External setpoint influence
4.1.3.1 Set the influence function 4.1.3.2
Setting of influence function
4.1.4 4.1.6 4.1.7 4.1.8
Primary sensor Clock program Proportional pressure S-system configuration
4.2 Pump cascade control
4.2.1
Min. time between start/stop Max. number of starts/hour
4.2.3
Standby pumps
4.2.4 4.2.5 4.2.6 4.2.7
Forced pump changeover Pump test run Pilot pump Pump stop attempt
4.2.8
Pump start and stop speed
4.2.9
Min. performance
4.2.10 Compensation for pump start-up time
4.3 Secondary functions
4.3.1
Stop function
4.3.3 4.3.5 4.3.7
4.3.1.1
Stop parameters
Soft pressure build-up
Emergency run
Digital inputs
4.3.8
Function, DI1..DI3 (CU 351), [10, 12, 14] Function, DI1..DI9 (IO 351-41), [10...46] Function, DI1..DI9 (IO 351-42), [10...46] Analog inputs
Setting, analog input AI1..AI3 (CU 351), [51, 54, 57] Function, AI1...AI3 (CU 351), [51, 54, 57]
Setting, AI1..AI2 (IO 351-41), [57, 60]
Function, AI1..AI2 (IO 351-41), [57, 60]
Setting, AI1..AI2 (IO 351-42), [57, 60]
Function, AI1..A2 (IO 351-42), [57, 60]
4.3.9
Digital outputs
Function, DO1 and DO2 (CU 351), [71, 74]
Function, DO1...DO7 (IO 351-41), [77...88]
Function, DO1...DO7 (IO 351-42), [77...88]
4.3.14 Min., max. and user-defined duty
4.3.14.1
Min. duty
4.3.14.2
Max. duty
4.3.14.3
User-defined duty
4.3.19 Pump curve data
4.3.23
Flow estimation
4.3.20 Control source
4.3.22 Fixed inlet pressure
4.3.23 Flow estimation
4.4 Monitoring functions
4.4.1
Dry-running protection
4.4.1.1
Pressure/level switch
4.4.1.2
Measurement, inlet pressure
4.4.1.3
Measurement, tank level
4.4.2
Min. pressure
4.4.3
Max. pressure
4.4.4
External fault
4.4.5
Limit 1 exceeded
4.4.6
Limit 2 exceeded
4.4.7
Pumps outside duty range
4.4.8
Pressure relief
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Continued from page 16
4. Settings
4.5 Functions, CU 351 Change language to service language (GB) Run wizard again
4.5.1 4.5.2
Display language Display units
4.5.2.1 4.5.2.2
Units for pressure Units for differential pressure
4.5.2.3 4.5.2.4 4.5.2.5 4.5.2.6
Units for head Units for level Units for flow rate Units for volume
4.5.2.7 4.5.2.8 4.5.2.9 4.5.2.10
Units for specific energy Units for temperature Units for power Units for energy
4.5.3 4.5.4 4.5.5 4.5.6 4.5.9
Date and time Password Ethernet GENIbus number Software status
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9.2 Overview
Section Display and display number
9.4 Status (1)
9.4.1
Current alarms (3.1)
9.4.2
System (1.2)
9.4.3
Operating mode (1.2.1)
9.4.4
Setpoint (1.2.2)
9.4.5
Setpoint influence (1.2.3)
9.4.6
Measured values (1.2.4)
9.4.7
Analog inputs (1.2.5)
9.4.8
Pump 1...6 (1.3 to 1.8)
9.5 Operation (2)
9.5.1
Operation (2)
9.5.2
System operating mode (2.1.1)
9.5.3
Control mode (2.1.2)
9.5.4
Setpoints (2.1.3)
9.5.5
Individual pump control (2.1.4)
9.5.6
Setting of individual operating mode (2.1.4.1 to 2.1.4.6)
9.6 Alarm (3)
9.6.1
Alarm status (3)
9.6.2
Current alarms (3.1)
9.6.3
Alarm log (3.2)
9.7 Settings (4)
9.7.1
Primary controller (4.1)
9.7.2
PI controller (4.1.1)
9.7.3
Alternative setpoints (4.1.2)
9.7.4
Alternative setpoints 2 to 7 (4.1.2.1 to 4.1.2.7)
9.7.5
External setpoint influence (4.1.3)
9.7.6
Setting of influence function (4.1.3.2)
9.7.7
Primary sensor (4.1.4)
9.7.8
Clock program (4.1.6)
9.7.9
Proportional pressure (4.1.7)
9.7.10
S-system configuration (4.1.8)
9.7.11
Pump cascade control (4.2)
9.7.12
Min. time between start/stop (4.2.1)
9.7.13
Max. number of starts/hour (4.2.1)
9.7.14
Standby pumps (4.2.3)
9.7.15
Forced pump changeover (4.2.4)
9.7.16
Pump test run (4.2.5)
9.7.17
Pilot pump (4.2.6)
9.7.18
Pump stop attempt (4.2.7)
9.7.19
Pump start and stop speed (4.2.8)
9.7.20
Min. performance (4.2.9)
9.7.21
Compensation for pump start-up time (4.2.10)
9.7.22
Secondary functions (4.3)
9.7.23
Stop function (4.3.1)
9.7.24
Soft pressure build-up (4.3.3)
9.7.25
Emergency run (4.3.5)
9.7.26
Digital inputs (4.3.7)
9.7.27
Functions of digital inputs (4.3.7.1)
9.7.28
Analog inputs (4.3.8)
9.7.29
Analog inputs (4.3.8.1 to 4.3.8.7)
9.7.30
Analog inputs and measured value (4.3.8.1.1 to 4.3.8.7.1)
9.7.31
Digital outputs (4.3.9)
9.7.32
Functions of digital outputs (4.3.9.1 to 4.3.9.16)
9.7.33
Min., max. and user-defined duty (4.3.14)
9.7.34
Min. duty (4.3.14.1)
See page
19 19 19 20 20 20 21 21 21 21 22 22 23 25 25 26 27 27 32 32 32 33 33 33 34 34 35 35 36 36 37 37 38 38 38 39 39 40 40 41 41 42 42 42 44 45 45 46 46 47 47 48 48 49 49
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Section
9.7.35 9.7.36 9.7.37 9.7.38 9.7.39 9.7.40 9.7.41 9.7.42 9.7.43 9.7.44 9.7.45 9.7.46 9.7.47 9.7.48 9.7.49 9.7.51 9.7.52 9.7.53 9.7.54 9.7.55 9.7.56 9.7.57 9.7.58 9.7.59
Display and display number
Max. duty (4.3.14.2) User-defined duty (4.3.14.3) Pump curve data (4.3.19) Control source (4.3.20) Fixed inlet pressure (4.3.22) Flow estimation (4.3.23) Monitoring functions (4.4) Dry-running protection (4.4.1) Dry-running protection with pressure/level switch (4.4.1.1) Dry-running protection with pressure transmitter (4.4.1.2) Dry-running protection with level transmitter (4.4.1.3) Min. pressure (4.4.2) Max. pressure (4.4.3) External fault (4.4.4) Limit 1 and 2 exceeded (4.4.5 and 4.4.6) Pressure relief (4.4.8) Functions, CU 351 (4.5) Display language (4.5.1) Display units (4.5.2) Date and time (4.5.3) Passwords (4.5.4) Ethernet (4.5.5) GENIbus number (4.5.6) Software status (4.5.9)
See page
49 50 50 51 52 52 52 53 53 54 54 55 55 56 56 57 58 58 59 60 60 60 61 61
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TM03 2293 4807
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9.3 Description of functions
The description of functions is based on the four main menus of the CU 351 control unit: Status, Operation, Alarm and Settings. The functions apply to all control variants unless otherwise stated.
9.4 Status (1)
The first status display is shown below. This display is shown when the Hydro MPC is switched on, and it appears when the buttons of the control panel have not been touched for 15 minutes.
F
G H
9.4.1 Current alarms (3.1)
E
A
Fig. 9 Current alarms
Description I
In this display, current unreset alarms and warnings are shown.
C
For further information, see sections 9.6.2 Current alarms (3.1)
D
B
and 9.6.3 Alarm log (3.2).
9.4.2 System (1.2)
TM03 8947 4807
Fig. 8 Status
Description
No settings can be made in this menu.
The current value (process value, PV) of the control parameter, usually the discharge pressure, is shown in the upper right corner (G) together with the selected setpoint (SP) (H).
The upper half of the display (A) shows a graphic illustration of the Hydro MPC booster system and part of the system. The selected measuring parameters are shown with sensor symbol and current value.
In the middle of the display, an information field (I) is shown if any incidents occur.
The lower display half (B) shows
· the latest current alarm, if any, and the fault cause together with the fault code in brackets
· system status with current operating mode and control source
· pump status with current operating mode and manual/auto.
Note
If a fault has occurred, the symbol will be shown in the alarm line (C) together with the cause and fault code, for instance Limit 2 exceeded (191).
If the fault is related to one of the pumps, the symbol will also be shown in front of the status line (D) of the pump in question. At the same time, the symbol will be flashing instead of the pump symbol (E). The symbol will be shown to the right in the top line of the display (F). As long as a fault is present, this symbol will be shown in the top line of all displays.
To open a menu line, mark the line with .
or , and press
The display makes it possible to open status displays showing
· current alarms
· system status
· status of each pump.
Fig. 10 System
Description This display shows the current operational state of the Hydro MPC booster system. It is possible to go to subdisplays showing details. The display makes it possible to open specific displays about · operating mode · setpoint · setpoint influence · measured values · analog inputs.
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9.4.3 Operating mode (1.2.1)
9.4.4 Setpoint (1.2.2)
TM03 2272 4807
TM03 2273 4807
Fig. 11 Operating mode
Description Here the operating mode of the Hydro MPC booster system is shown as well as from where the Hydro MPC is controlled.
Operating modes Hydro MPC has six operating modes: 1. Normal
The booster system adapts its performance to the requirement. 2. Max. The pumps run at a constant high speed. Normally, all pumps run at maximum speed. 3. User-defined The pumps run at a constant speed set by the user. Usually it is a performance between Max. and Min. 4. Min. The pumps run at a constant low speed. Normally, one pump is running at a speed of 70 %. 5. Stop All pumps have been stopped. 6. Emergency run The pumps run according to the setting made in the display Emergency run (4.3.5). The performance required in the operating modes Max., Min., User-defined and Emergency run can be set in the Settings menu. See sections 9.7.33 Min., max. and user-defined duty (4.3.14) and 9.7.25 Emergency run (4.3.5). The current operating mode can be controlled from four different sources: Fault, External signal, CU 351 and Bus.
Control source Hydro MPC can be set to remote control via an external bus (option). In this case, a setpoint and an operating mode must be set via the bus. In the Settings menu, it is possible to select whether the CU 351 or the external bus is to be the control source. The status of this setting is shown in the display Operating mode.
Fig. 12 Setpoint Description This display shows the selected setpoint and whether it comes from the CU 351 or an external bus. The display also shows all seven possible setpoints from CU 351 (for closed- and open-loop control). At the same time, the selected setpoint is shown. As it is a status display, no settings can be made. Setpoints can be changed in the Operation menu. 9.4.5 Setpoint influence (1.2.3)
Fig. 13 Setpoint influence Description The selected setpoint can be influenced by parameters. The parameters are shown as percentage from 0 to 100 % or as a pressure measured in bar. They can only reduce the setpoint, as the influence in percentage divided with 100 is multiplied with the selected setpoint:
Setpointcurrent(SP) = Setpointselected × Infl.(1) × Infl.(2) × ...
The display shows the parameters influencing the selected setpoint and the percentage or value of influence. Some of the possible parameters can be set in the display External setpoint influence (4.1.3). The parameter low flow boost is set as an on/off band as a percentage of the setpoint set in the display Stop function (4.3.1). The parameter is set as a percentage in the display Proportional pressure (4.1.7). Finally the resulting current setpoint (SP) is shown.
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9.4.6 Measured values (1.2.4)
9.4.8 Pump 1...6 (1.3 to 1.8)
TM03 2268 4807
TM03 2270 4807
Fig. 14 Measured values
Description
This display gives a general status of all measured and calculated parameters.
Note
The lines "Power consumption" and "Energy consumption" are only shown in Hydro MPC-E booster systems.
9.4.7 Analog inputs (1.2.5)
TM03 8949 4807
Fig. 15 Analog inputs
Description The display shows an overview of the analog inputs and the current measured values of each input. See sections 9.7.28 Analog inputs (4.3.8), 9.7.29 Analog inputs (4.3.8.1 to 4.3.8.7) and 9.7.30 Analog inputs and measured value (4.3.8.1.1 to 4.3.8.7.1).
Fig. 16 Pump 1
Description This display shows the operational state of the individual pumps. The pumps may have different operating modes: · Auto
Together with the other pumps in automatic operation, the pump is controlled by the PI controller which ensures that the booster system delivers the required performance (pressure). · Manual The pump is not controlled by the PI controller. In manual operation, the pump has one of the following operating modes: Max.
The pump runs at a set maximum speed. (This operating mode can only be selected for variable-speed pumps.) Normal The pump runs at a set speed. Min. The pump runs at a set minimum speed. (This operating mode can only be selected for variable-speed pumps.) Stop The pump has been forced to stop. Besides information about the operating mode, it is possible to read various parameters in the status display, such as these: · speed (only 0 or 100 % are shown for mains-operated pumps) · power consumption (only CR(I)E pumps) · energy consumption (only CR(I)E pumps) · operating hours.
9.5 Operation (2)
In this menu, the most basic parameters can be set, such as setpoint, operating mode, control mode and forced control of pumps.
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9.5.1 Operation (2)
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Factory setting The setpoint is a value suitable for the Hydro MPC booster system in question. The factory setting may have been changed in the start-up menu. 9.5.2 System operating mode (2.1.1)
A
B
C
TM03 8950 4807 TM03 8951 4807
Fig. 17 Operation
Description
The column shows the setting range. In closed-loop control, it corresponds to the range of the primary sensor, here 0-16 bar. In open-loop control, the setting range is 0-100 %.
At the left hand of the column, the selected setpoint 1 (A) is shown, i.e. the value set in the display. At the right hand of the column, the current setpoint (B) is shown, i.e. the setpoint acting as reference for the PI controller. If no kind of external setpoint influence has been selected, the two values will be identical. The current measured value (discharge pressure) is shown as the grey part of the column (C). See sections 9.7.5 External setpoint influence (4.1.3) and 9.7.6 Setting of influence function (4.1.3.2).
Below the display is a menu line for setting of setpoint 1 and selection of operating mode, including the operating modes Normal and Stop. It is possible to select further settings: system operating mode, control mode, setpoints for closed and open loop as well as individual pump control.
Setting range
Setpoint:
Closed-loop control: Open-loop control:
Measuring range of the primary sensor 0-100 %
Setting via control panel
Setpoint:
1. Mark the Operation menu with .
2. Mark Setpoint 1 with or . Set the value with or .
3. Save with .
Operating mode:
1. Mark the Operation menu with .
2. Mark operating mode Normal or Stop with or . Save
with .
Further settings:
1. Mark the Operation menu with .
2. Mark Further settings with
or
, and press
.
3. Select one of the settings below with :
or , and press
· system operating mode (see section 9.5.2)
· control mode (see section 9.5.3)
· setpoints (see section 9.5.4)
· individual pump control (see section 9.5.6).
Fig. 18 System operating mode
Description
Hydro MPC can be set to six different operating modes. Normal is the typical setting. See section 9.4.3 Operating mode (1.2.1).
The performance of the operating modes Max., Min., Userdefined and Emergency run can be set in the Settings menu.
In the display shown, it is possible to go directly to the Settings menu in order to set the pump performance or the setpoint.
Setting range
It is possible to select the operating modes Normal, Max., Min., User-defined, Stop and Emergency run.
Setting via control panel
1. Mark the Operation menu with .
2. Mark Further settings with
or
, and press
.
3. Mark System operating mode with .
or , and press
4. Select the desired operating mode by marking one of the lines
with check boxes with or , and press .
5. In order to set the performance in min., max., user-defined duty or emergency run, mark the desired line at the bottom of the display, and press . See sections 9.7.33 Min., max. and user-defined duty (4.3.14) and 9.7.25 Emergency run (4.3.5).
Factory setting Normal.
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9.5.3 Control mode (2.1.2)
Open loop
In open-loop control, the pumps run at a fixed speed. The pump speed is calculated from the performance set by the user (0-100 %). The pump performance in percentage is proportional with the flow rate.
Open-loop control is usually used when the booster system is controlled by an external controller which controls the performance via an external signal. The external controller could for instance be a building management system connected to the Hydro MPC. In such cases, the Hydro MPC is like an actuator. See figs 22 and 23.
TM03 2283 4807
TM03 2232 3905
Fig. 19 Control mode
Description There are two control modes, namely closed and open loop. Examples:
Closed loop The typical control mode is closed loop where the built-in PI controller ensures that the booster system delivers the discharge pressure required (setpoint). The performance is based on the setpoint set for closed loop. See figs 20 and 21.
Fig. 22 Booster system with external controller (open loop) Flow rate [gpm]
TM03 2391 3607
Fig. 20 Booster system controlled by built-in PI controller (closed loop)
P [bar]
Setpoint
Time [sec]
Fig. 21 Regulation curve for closed loop
Setting via control panel
1. Mark the Operation menu with .
2. Mark Further settings with
or
, and press
.
3. Mark Control mode with
or
, and press
.
4. Select Closed loop with or , and press .
5. Set the setpoint. See sections 9.5.4 Setpoints (2.1.3) and 9.5.1 Operation (2).
TM03 2390 4105
TM03 2231 3905
0 5
Input [%] from external controller
Fig. 23 Regulation curve for open loop
Flow rate [gpm]
100
75
Flow rate
Pump 1
50
Pump 2
Pump 3
Pump 4
25
5
50 70.7 86.6 100 Input [%] from
external controller
Fig. 24 Regulation curve for Hydro MPC-E in open loop
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Flow rate [gpm]
100 75 50 25
Flow rate Pump 1 Pump 2 Pump 3 Pump 4
5
50 70.7 86.6 100 Input [%] from
external controller
Fig. 25 Regulation curve for Hydro MPC-ED in open loop
Flow rate [gpm]
100
75
Flow rate
Pump 1
50
Pump 2
Pump 3
Pump 4
25
5
50 70.7 86.6 100 Input [%] from
external controller
Fig. 26 Regulation curve for Hydro MPC-ES in open loop
Flow rate [gpm]
100
75
Flow rate
50
Pump 1
Pump 2
Pump 3
25
Pump 4
Input [%] from
5
50 70.7 86.6 100
external controller
Fig. 27 Regulation curve for Hydro MPC-S in open loop
TM03 9974 4807
TM03 9975 4807
TM03 9976 4807
Correlating open loop input setpoint percentage with number of pumps in operation. Example: MPC system with (4) pumps
· Setpoint 0% to 5% = All pumps stopped One pump operation from setpoint from 5% to (1-pump/4pumps) = 50% · Two pump operation from 50% to (2-pump/4-pumps) =
70.7% · Three pump operation from 70.7% to (3-pumps/4-pumps) =
86.6%
· Four pump operation from 86.6% to 100%
For staging pumps off the cut-out is 2% less then cut-in. Example: staging from 4-pump to 3-pump operation will occur at 84.6% reference signal.
Setting range These settings must be made in connection with open loop: · stop of the Hydro MPC booster system · selection of control mode Open loop · setting of setpoint 1, open loop · setting of external setpoint influence · selection of operating mode Normal.
Setting via control panel
To set an external control source to control the Hydro MPC booster system, proceed as follows:
1. Mark the Operation menu with .
2. Mark the operating mode Stop with or , and press . The check mark in the right box shows that the operation
has been stopped.
3. Mark Further settings with or , and press .
4. Mark Control mode with or , and press .
5. Select Open loop with or , and press .
6. Return by pressing
twice.
7. Mark Set setpoint 1, open loop with or .
8. Set the setpoint to 100 % with , and save with .
9. Mark the Settings menu with .
10.Mark Primary controller with or , and press .
11.Mark External setpoint influence with .
or , and press
12.Mark Go to setting of analog input with press .
or , and
13.Select the analog input with or , and press .
14.Select the range of the analog input with or , and press . The selection is indicated by a check mark.
15.Mark Measured input value with or , and press . Now the display 4.3.8.1.1 appears.
16.Select 0-100 % signal with or , and press .
17.Press
to return to display 4.3.8.1.
18.Set the minimum sensor value with .
or , and save with
19.Set the maximum sensor value with .
or , and save with
20.Return by pressing
twice.
21.Mark Input value to be influenced by with press .
or , and
22.Mark 0-100 % signal with or , and press .
23.Return with .
24.Mark Set the influence function with or , and press . For details, see section 9.7.6 Setting of influence
function (4.1.3.2).
25.Mark the menu line for number of points with press .
or , and
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26.Select the required number of points with save with .
or , and
27.Mark External input value (point 1) with or .
28.Set the value of the external input value with save with .
or , and
29.Mark Reduce setpoint to (point 1) with or .
30.Set the value as a percentage with .
or , and save with
31.Repeat 27 to 31 for all chosen points.
32.Return with .
33.Mark Filter time with or , set the time in seconds with or , and save with .
34.Mark Activated with or , and press . The check mark in the right box shows that the function has been activated.
35.Return by pressing
twice.
36.Mark the Operation menu with .
37.Mark the operating mode Normal with or , and press . The check mark in the right box shows that the operation
is normal. The booster system can now be controlled by an external controller.
Factory setting Closed-loop control.
9.5.4 Setpoints (2.1.3)
Fig. 28 Setpoints
Description In addition to the primary setpoint 1 (shown in the display 2 in the Operation menu), six alternative setpoints can be set for closedloop control. It is furthermore possible to set seven setpoints for open-loop control. As described in sections 9.7.3 Alternative setpoints (4.1.2) and 9.7.4 Alternative setpoints 2 to 7 (4.1.2.1 to 4.1.2.7), it is possible to activate one of the alternative setpoints by means of external contacts.
Setting range The setting range of setpoints for closed-loop control depends on the range of the primary sensor. See section 9.7.7 Primary sensor (4.1.4). In open loop control, the setting range is 0 - 100 %.
Setting via control panel 1. Mark the Operation menu with . 2. Mark Further settings with or , and press . 3. Mark Setpoints with or , and press . 4. Select the setpoint with or .
TM03 8952 4807 TM03 8953 4807
5. Set the setpoint with
or , and press .
Factory setting Setpoint 1 for closed-loop control is a value suitable for the Hydro MPC in question. The alternative setpoints for closed-loop control are 3 bar. All setpoints for open-loop control are 70 %.
9.5.5 Individual pump control (2.1.4)
Fig. 29 Individual pump control
Description It is possible to change the operating mode from automatic operation to one of the manual operating modes. Auto The pumps are controlled by the PI controller, ensuring that the booster system delivers the required performance (pressure). Manual The pump is not controlled by the PI controller, but set to one of the following manual operating modes: · Max.
The pump runs at a set maximum speed. (This operating mode can only be selected for variable-speed pumps.) · Normal The pump runs at a set speed. · Min. The pump runs at a set minimum speed. (This operating mode can only be selected for variable-speed pumps.) · Stop The pump has been forced to stop. Pumps in manual operation are not part of the normal pump cascade and speed control. The manual pumps are a "disturbance" of the normal control of Hydro MPC. If one or more pumps are in manual operation, Hydro MPC may not be able to deliver the set performance. There are two displays for the function. In the first display, the pump to be set is selected, and in the next display, the operating mode is selected.
Setting range All pumps can be selected.
Setting via control panel 1. Mark the Operation menu with . 2. Mark Further settings with or , and press . 3. Mark Individual pump control with or , and press
. 4. Select the pump with or , and press .
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual 9.5.6 Setting of individual operating mode (2.1.4.1 to 2.1.4.6)
TM03 8954 4807
Fig. 30 Setting of individual operating mode
Description
This display is shown for the individual pumps and makes it possible to set an operating mode.
Setting range
It is possible to select Auto or Manual as well as the operating mode of the pump for manual operation - Max., Normal, Min. or Stop. For mains-operated pumps only Normal or Stop can be selected.
Setting via control panel
1. Mark the Operation menu with .
2. Mark Individual pump control with or , and press
.
3. Select the pump with or , and press .
4. Mark Auto or Manual with or , and press .
5. Manual: Select the operating mode with press .
or , and
6. Normal: Mark Setpoint with
or
.
Set the speed of the variable-speed pump with
and press .
or ,
Factory setting Auto.
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TM03 2291 4807
Warning( )/alarm( ) Change of operating mode to Reset of alarm Restart Set in the Settings menu Alarm code
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
9.6 Alarm (3)
The Alarm menu gives an overview of alarms and warnings. In this menu, it is possible to reset alarms and to see the alarm log.
9.6.1 Alarm status (3)
Fault
Fig. 31 Alarm status
Description
A fault in the Hydro MPC booster system or one of the components monitored can cause an alarm or a warning . Besides the fault signal via the alarm/warning signal relay and the red indicator light on the CU 351, an alarm can also cause a change of operating mode, for instance from Normal to Stop. A warning only causes a fault indication.
The table shows the possible causes of fault together with an alarm code number, and whether they result in an alarm or a warning. It also shows to what operating mode the booster system changes in case of alarm, and whether restart of the booster system and reset of the alarm is manual or automatic.
The table also shows that the reaction to some of the fault causes mentioned can be set in the Settings menu. See sections 9.7.24 Soft pressure build-up (4.3.3) and 9.7.41 Monitoring functions (4.4) to 9.7.51 Pressure relief (4.4.8).
Water shortage Water shortage Pressure high
Pressure low
Pressure relief Alarm, all pumps
External fault
Dissimilar sensor signals Fault, primary sensor Fault, sensor Communication fault Phase failure Undervoltage, pump Overvoltage, pump
Overload, pump
Overtemperature, pump Other fault, pump
Internal fault, CU 351
Internal fault, IO 351 VFD not ready Fault, Ethernet Limit 1 exceeded Limit 2 exceeded Pressure build-up fault Pumps outside duty range Pilot pump fault
Auto
206
Stop Man/auto X 214
Stop Auto
210
Stop
Auto Man
X 211
Auto X 219
Stop Auto
203
Auto
X
3
Stop Man
Auto
204
Stop Auto
89
Auto
88
Auto
10
Auto
2
Auto
7, 40, 42, 73
Auto
32
Auto Auto
48, 50, 51, 54
64, 65, 67
Auto
76, 83
72,
Auto
83,
157
Stop Auto
83, 157
Auto
213
Auto
231, 232
Man/auto X 190
Man/auto X 191
Man/auto X 215
Man/auto X 208
Auto
216
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Alarm (3) continued
MPC alarm indication "Protocol description" 1. Phase failure, pump
2. Undervoltage
Alarm code
2
7
3. Undervoltage, pump
40
4. Undervoltage, pump 42
5. Undervoltage, pump 73
6. Overvoltage, pump
32
7. Overload, associated
device
48
8. Overload, associated device
50
9. Overload, associated
device
51
10. Overload, associated device 54
11. Over temperature, pump 65
12. Over temperature, pump
67
Associated device and device no. Pump 1-6
Pump 1-6
Pump 1-6 Pump 1-6 Pump 1-6 Pump 1-6 Pump 1-6
Pump 1-6
Pump 1-6 Pump 1-6 Pump 1-6 Pump 1-6
Description/cause
Remedy
-
1. Check that all three
power supply phases are
within a 15 V window.
HSD = hardware shutdown.
There has been a fault,
and the permissible
number of restarts for the 1. Restore power supply.
fault type has been
exceeded.
2. Replace terminal box.
a) Fault in power supply.
a) Terminal box defective.
a) Power supply voltage 1. Bring voltage back to
is too low at start.
prescribed level.
a)
Faulty power supply at the time of staging on a pump.
1. Restore proper power supply.
a) Low supply voltage.
b) Power supply failure 1. Restore proper power
while motor is
supply.
running.
a) Supply voltage is too 1. Bring voltage back to
high at start.
prescribed level.
a) Heavy overload has caused software shutdown (SSD).
1. Check and possibly reduce load.
a) MPF = motor
protection function.
The built-in motor 1. Check and possibly
protection has
reduce load/improve
detected a sustained cooling.
overload (MPF 60
sec. limit)>
a) Heavy overload (Imax. very high). Pump blocked at start.
1. Unblock the pump.
a) The built-in motor
protection has
1. Check and possibly
detected a transitory reduce load/improve
overload (MPF 3 sec. cooling
limit).
a) PTC sensor in the motor has signalled over temperature.
1. Check and possibly reduce load/improve cooling.
a) Terminal box has indicated over temperature.
1. Check and possibly reduce load/improve cooling. (Temperature during operation can be read via PC Tool Eproducts.)
Reset Alarm/warning type1 Action type2
Auto
Warning
Auto
Warning
Auto Auto
Warning Warning
Auto
Warning
Auto Auto
Warning Warning
Auto
Warning
Auto
Warning
Auto
Warning
Auto
Warning
Auto
Warning
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MPC alarm indication "Protocol description" 13. Other fault, associated
device
14. Limit 1 exceeded
15. Limit 2 exceeded
16. Pressure relief 17. Pressure build-up fault
18. Pumps outside duty range
19. Pilot pump fault
Alarm code
76
190 191 219 215 208 216
Associated device and device no.
Pump 1-6
Measured parameter Measured parameter
System
System
System Pilot pump
Description/cause
Remedy
Reset Alarm/warning type1 Action type2
Try to reset the fault:
1. Switch off the supply power.
a) Internal communication error has occurred in the pump.
2. Wait until all diodes are out.
3. Switch on the supply power.
If this does not remedy the fault, replace the terminal box.
a) The measured parameter has exceeded the limit set.
1. Remove the cause of the fault.
a) The measured parameter has exceeded the limit set.
1. Remove the cause of the fault.
a)
The monitored pressure could not be reduced sufficiently.
1. Reduce the pressure to below the limit.
a) The pressure set
cannot be reached within the configured
1. Check limit and pipes.
time.
a) The pump is running outside the defined 1. Check the system. range.
a) Pilot pump fault
1. Check wires. 2. Check the pump.
Auto
Auto/ manual
Auto/ manual
Auto
Auto/ manual Auto/ manual
Auto
Warning
Alarm/warning Stop/
unchanged
Alarm/warning Stop/
unchanged
Warning Unchanged
Alarm/warning Stop/
unchanged
Warning Unchanged
Warning
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MPC alarm indication "Protocol description"
Alarm code
Associated device and device no.
Description/cause
Remedy
Reset Alarm/warning type1 Action type2
20. Water shortage, level 1 *Water shortage, level 1 206
a) The pre-pressure (or the level in the feed tank) is below its programmable warning limit.
Auto
Warning Unchanged
21. Water shortage, level 2 *Water shortage, level 2
214
a) The pre-pressure (or
the level in the feed
tank) is below its
1. Check the actual and the
programmable
corresponding settings. Auto/
warning limit.
2. Check the sensor/switch, Manual
b) The pre-pressure
wiring and input
switch detect water
according to the wiring
shortage.
diagram.
Alarm Stop
Warning Unchanged
22. Discharge pressure high
*Pressure above max.
210
pressure
23. Discharge pressure low
*Pressure below min.
211
pressure
System
a) The system pressure 3. Check the sensor/switch.
Alarm
is above the
Auto/ Fast stop (over
programmable highpressure alarm limit.
Manual rule min. seq. time)
a) The system pressure is below the programmable lowpressure alarm limit.
Auto/ Manual
Alarm/Warning Stop/
Unchanged
24. All pumps in alarm *All pumps in alarm
203
a) All pumps, set to Auto, is stopped on account of pump alarm
Troubleshoot according to the alarm message/code: 1. System
2. Pumps installed Use fault fault finding for the pump.
Auto
Alarm Stop
b) Pumps are not indicating alarm
Check the Genibus wires eg. connection, polarisation.
25. External fault signal *External fault signal
003
a) External fault digital input activated.
1. Check the external signal source.
2. Check the digital input according to the wiring diagram
Auto/ Manual
Alarm/Warning Stop/
Unchanged
26. Inconsistency between sensors *Inconsistency between sensors
a) Primary feedback 1. Check the wiring and
Primary
sensor value
input according to the
204
sensor and/or redundant
(pressure) is inconsistent with
wiring diagram. 2. Check the sensor output
sensor
redundant feedback
according to the
sensor value.
measured value.
Auto
Warning Unchanged
27. Primary sensor *Closed loop feedback sensor signal fault
089
Primary sensor
a) A fault in the sensor assigned to the feed back control is detected.
1. Check the wiring and input according to the wiring diagram.
2. Check the sensor output according to the measured value.
Alarm Stop
b) Error in the settings Check the primary sensor of the sensor which is settings assigned to the regulator.
Auto
28. Sensor fault *General (measurement) sensor signal fault 088
CU 351 IO 351 as IO module
a) The signal
1. Check the wiring and
(ex. 4-20 mA) from
input according to the
one of the analog
wiring diagram.
sensors is outside the 2. Check the sensor output
selected signal
according to the
range.
measured value
Warning Unchanged
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MPC alarm indication "Protocol description"
Alarm code
29. CU 351 internal fault *Real time clock out of 157 order
30. Ethernet fault
*Ethernet: No address
231
from DHCP server
31. Ethernet fault *Ethernet: Auto disabled 232 due to misuse
32. FLASH parameter
verification error *FLASH parameter
083
verification error
33. IO 351 internal fault *Hardware fault type 2 080
34. VFD not ready *VFD not ready 213
35. Communication fault *Pump communication fault
010
36. Device alarms
From device
Associated device and device no.
CU 351
IO 351 Pump 1-6 CU 351
Pump 1-6 IO 351
Pump 1-6
Description/cause
Remedy
a) The real-time clock in Replace the CU 351 CU 351 is out of order.
a) No address from DHCP server
1. Communication error.
2. Please contact the
a) Auto-disabled due to misuse
system integrator.
a) Verification error in CU 351 FLASH memory
Replace the CU 351
a) IO 351 pump module See current alarms and
hardware fault
identify the faulty IO 351
b) IO 351 I/O module hardware fault
module from the alarm message and replace the module.
1. Check for VFD alarm
a) The VFD signal relay
do not release the 2. Check the wiring and
VFD for operation
input according to the
wiring diagram.
See actual alarms and
identify the faulty device
from the alarm message.
a) No GeniBus
1. Check power supply
communication with a device connected to CU 351
2.
Check GeniBus cable connection
3. Check, with R100, that
the device GeniBus no. is
correct.
See actual alarms and
identify the faulty device
a)
The device is in alarm
from the alarm message. 1. Fault find according to
the service instruction for
the device.
Reset type1
Auto
Alarm/warning Action type2
Warning Unchanged
1) Reset type is either fixed as "Auto acknowledge" (Auto) or can be programmed to be Auto or manual ackknowledge (Auto/Man)*. 2) Programmable action types:
- Go to operating mode "Stop" (no delay (<0.5 s) between pump disconnections). - Go to operating mode "Min". - Go to operating mode "User-defined". - Go to operating mode "Max". - Set pumps in source mode "Local". - No action (warning only)
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9.6.2 Current alarms (3.1)
Description Here warnings and alarms are shown. For every warning or alarm, the following is shown: · Whether it is a warning or an alarm . · Where the fault occurred. System, Pump 1, Pump 2, etc. · In case of input-related faults, the input is shown. · What the cause of the fault is, and the alarm code in brackets:
Water shortage (214), Max. pressure (210), etc. · When the fault occurred: Date and time. · When the fault disappeared: Date and time. If the fault still
exists, date and time are shown as --...--. The latest warning/alarm is shown at the top of the display.
9.7 Settings (4)
TM03 2293 4807 TM03 2294 4807
Fig. 32 Current alarms Description This submenu shows the following: · Warnings caused by faults that still exist. · Warnings caused by faults that have disappeared, but the
warning requires manual reset. · Alarms caused by faults that still exist. · Alarms caused by faults that have disappeared, but the
alarm requires manual reset. All warnings and alarms with automatic reset are automatically removed from the menu when the fault has disappeared. Alarms requiring manual reset are reset in this display by pressing . An alarm cannot be reset until the fault has disappeared. For every warning or alarm, the following is shown: · Whether it is a warning or an alarm . · Where the fault occurred: System, Pump 1, Pump 2, etc. · In case of input-related faults, the input is shown. · What the cause of the fault is, and the alarm code in brackets:
Water shortage (214), Max. pressure (210), etc. · When the fault occurred: Date and time. · When the fault disappeared: Date and time. If the fault still
exists, date and time are shown as --...--. The latest warning/alarm is shown at the top of the display. 9.6.3 Alarm log (3.2) The alarm log can store up to 24 warnings and alarms.
Fig. 33 Alarm log
TM03 2292 4807
Fig. 34 Settings
In the Settings menu, it is possible to set the following functions:
· Primary controller Setting of PI controller, alternative setpoints, external setpoint influence, primary sensor, clock program, proportional pressure and S-system configuration.
· Pump cascade control Setting of min. time between start/stop, max. number of starts/ hour, number of standby pumps, forced pump changeover, pump test run, pilot pump, pump stop attempt, pump start and stop speed, min. performance and compensation for pump start-up time.
· Secondary functions Setting of stop function, soft pressure build-up, digital and analog inputs, digital outputs, emergency run, min., max. and user-defined duty, pump curve data, flow estimation, control source and fixed inlet pressure.
· Monitoring functions Setting of dry-running protection, min. and max. pressure, external fault, limit 1 and 2 exceeded, pumps outside duty range and pressure relief.
· Functions, CU 351 Selection of service language, main language and units. Setting of time and date, passwords, Ethernet connection, GENIbus number and software status.
Usually, all these functions are set correctly when the Hydro MPC is switched on. It is only necessary to make settings in this menu if the functionality is to be expanded with for instance alternative setpoints or setpoint influence, or if the settings of the CU 351 are to be adjusted.
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9.7.1 Primary controller (4.1)
Fig. 35 Primary controller Description In this menu section, it is possible to set the functions related to the primary controller. It is only necessary to make settings in this menu if the functionality is to be expanded with for instance alternative setpoints, external setpoint influence, clock program or proportional pressure. The following menus can be selected: · PI controller · Alternative setpoints · External setpoint influence · Primary sensor · Clock program · Proportional pressure · S-system configuration. 9.7.2 PI controller (4.1.1)
TM03 8955 4807
Setting range
· Gain Kp: 30 to 30. Note: For inverse control, set Kp to a negative value.
· Integral time Ti: 0.1 to 3600 seconds.
Setting via control panel
1. Mark the Settings menu with .
2. Mark Primary controller with or , and press .
3. Mark PI controller with or , and press .
4. Select the gain (Kp) with or . Set the value with or , and save with .
Note: Usually it is not necessary to adjust Kp.
5. Select the integral time (Ti) with or , and press .
or . Set the time with
Factory setting · Kp: 0.5 · Ti: 1 second
9.7.3 Alternative setpoints (4.1.2)
TM03 2383 4807
Fig. 37 Alternative setpoints
Description This function makes it possible to select up to six setpoints (No 2 to 7) as alternatives to the primary setpoint (No 1). The primary setpoint (No 1) is set in the Operation menu. Every alternative setpoint can be addressed manually to a separate digital input (DI). When the contact of the input is closed, the alternative setpoint applies. If more than one alternative setpoint has been selected and they are activated at the same time, the CU 351 selects the setpoint with the lowest number.
Setting range · Six setpoints, No 2 to 7.
TM03 2387 4807
Fig. 36 PI controller
Description Hydro MPC includes a standard PI controller which ensures that the pressure is stable and corresponds to the setpoint. It is possible to adjust the PI controller if a faster or slower reaction to changes of consumption is required. A faster reaction is obtained if Kp is increased and Ti is reduced. A slower reaction is obtained if Kp is reduced and Ti is increased.
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Factory setting No alternative setpoints have been selected. 9.7.4 Alternative setpoints 2 to 7 (4.1.2.1 to 4.1.2.7)
TM03 2384 4807
Fig. 38 Alternative setpoints 2 to 7
For each alternative setpoint, select the digital input to activate the setpoint.
It is possible to set a setpoint for closed loop and for open loop.
Setting via control panel
1. Mark the Settings menu with .
2. Mark Primary controller with or , and press .
3. Mark Alternative setpoints with or , and press .
4. Select the alternative setpoint with .
or , and press
5. Mark Go to setting of digital input with or , and press . Now the display Digital inputs (4.3.7) appears. Set the input and return with .
6. Mark the menu line of the setpoint (closed or open loop) with or .
7. Set the required setpoint with
or , and save with .
Set both setpoints if Hydro MPC is to be controlled both in
open and closed loop.
Factory setting No alternative setpoints have been set.
9.7.5 External setpoint influence (4.1.3)
TM03 8956 4807
Fig. 39 External setpoint influence
Description
This function makes it possible to adapt the setpoint by letting measuring parameters influence the setpoint. Typically an analog signal from a flow or temperature transmitter, or a similar transmitter.
As an example, the setpoint can be adapted to parameters that can influence the discharge pressure or temperature of the system. The parameters which influence the performance of the booster system are shown as a percentage from 0 to 100 %. They can only reduce the setpoint, as the influence as a percentage divided with 100 is multiplied with the setpoint:
Setpointcurrent(SP) = Setpointselected × Infl.(1) × Infl.(2) × ...
The influence values can be set individually.
A low-pass filter ensures smoothing of the measured value which influences the setpoint. This results in stable setpoint changes.
Setting range The following parameters can be selected. · 0-100 % signal · Inlet pressure · Discharge pressure · External pressure · Differential pressure, pump · Differential pressure, external · Flow rate · Tank level, discharge side · Tank level, suction side · Flow pipe temperature · Return pipe temperature · Ambient temperature · Return pipe temperature, external · Differential temperature.
Setting via control panel
1. Mark the Settings menu with .
2. Mark Primary controller with or , and press .
3. Mark External setpoint influence with .
or , and press
4. Mark Input value to be influenced by with press . Now a list of available parameters appear.
or , and
5. Mark the parameter which is to influence the setpoint with or , and press .
6. Return with .
7. Mark Set the influence function with or , and press . For details, see section 9.7.6 Setting of influence
function (4.1.3.2).
8. Mark the menu line for number of points with press .
or , and
9. Select the required number of points with save with .
or , and
10.Mark External input value (point 1) with or .
11.Set the value of the external input value with save with .
or , and
12.Mark Reduce setpoint to (point 1) with or .
13.Set the value as a percentage with .
or , and save with
14.Repeat points 8 to 13 for all desired parameters.
15.Return with .
16.Mark Filter time with or , set the time in seconds with or , and save with .
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17.Mark Activated with or , and press . The check mark in the right box shows that the function has been activated.
Factory setting Setpoint influence is not activated.
9.7.6 Setting of influence function (4.1.3.2)
5. Mark the menu line for number of points with press .
or , and
6. Select the required number of points with save with .
or , and
7. Mark External input value (point 1) with or .
8. Set the value of the external input value with save with .
or , and
9. Mark Reduce setpoint to (point 1) with or .
10.Set the value as a percentage with
or , and save with
.
11.Repeat points 7 to 10 for all desired parameters.
Factory setting External setpoint influence is not activated.
9.7.7 Primary sensor (4.1.4)
TM03 2389 4807
Fig. 40 Setting of influence function
Description In this menu, you select the relation between the measuring parameter which is to influence the setpoint and the desired influence as a percentage. The relation is set by entering values in a table with maximum eight points by means of the control panel. Example with four points:
Setpoint influence [%]
TM03 1691 4807
4 100
80
60
3
2
40
20
1
Q [m³/h] 50
Fig. 41 Relation between setpoint influence and flow rate
The control unit of the Hydro MPC draws straight lines between
the points. A horizontal line is drawn from the minimum value of the relevant sensor (0 m3/h in the example) to the first point. This
is also the case from the last point to the sensor's maximum value (example 50 m3/h).
Setting range
Two to eight points can be selected. Each point contains the relation between the value of the parameter which is to influence the setpoint and the influence of the value.
Setting via control panel 1. Mark the Settings menu with . 2. Mark Primary controller with or 3. Mark External setpoint influence with
. 4. Mark Set the influence function with
.
, and press . or , and press
or , and press
Fig. 42 Primary sensor
Description In this display, select the control parameter of Hydro MPC and the sensor to measure the value. Usually, the control parameter is the discharge pressure which is measured by a sensor fitted on the discharge manifold and connected to analog input AI1 of the CU 351. If another control parameter is selected, the sensor must be connected to AI3 (CU 351) which is then set to one of the chosen parameters listed below.
Setting range · Discharge pressure (factory setting) · Differential pressure, external · Differential pressure, pump · Series 2000, differential pressure · External pressure · Differential pressure, inlet · Differential pressure, outlet · Flow rate · Series 2000, flow rate · Flow pipe temperature · Return pipe temperature · Differential temperature · Ambient temperature · Return pipe temperature, external · 0-100 % signal · Not used.
TM03 8958 4807
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From factory the discharge pressure sensor is connected to AI1 (CU 351). If one of the above parameters is selected, the sensor in question must be connected to AI3 (CU 351) and set in order to function as the primary sensor.
Setting via control panel
1. Mark the Settings menu with .
2. Mark Primary controller with or , and press .
3. Mark Primary sensor with or , and press .
4. Mark Go to setting of analog input with or , and press . Now the display Analog inputs (4.3.8) appears. Select the analog input (AI) for the primary sensor, and set the parameters for this sensor. Return to display Primary sensor (4.1.4) with .
5. Select the control parameter for the primary sensor with or , and press .
Note
If the primary parameter is discharge pressure, AI1 (CU 351) must be set to this parameter.
If the primary parameter is external pressure or flow rate, AI3 (CU 351) must be set to this parameter.
Factory setting
The primary parameter is discharge pressure. The sensor is connected to AI1 (CU 351).
9.7.8 Clock program (4.1.6)
5. Mark operating mode Normal or Stop with or , and
press
. (If Stop is selected, point 7 is skipped.)
6. Mark Setpoint, closed loop with or
pressure with
or , and save with
. Set the .
7. Mark Time (hours, minutes) with or .
8. Set the time with
or , and save with .
9. Mark day of week on which the settings are to be activated
with or , and press
.
10.Mark Activated with or , and press
.
11.Return with .
12.Mark Activated with or , and press
. The check
mark in the right box shows that the function has been
activated.
13.Repeat points 4 to 11 if several events are to be activated. Note: Up to ten events can be set.
Factory setting The function is deactivated.
9.7.9 Proportional pressure (4.1.7)
TM03 8959 4807
TM03 8990 4807
Fig. 43 Clock program
Description With this function, it is possible to set setpoints and day and time for their activation. It is also possible to set day and time for stop of the Hydro MPC system. If the clock program is deactivated, the setpoint of the program will remain active.
Setting range · Activation of the function. · Activation and setting of event.
Setting via control panel 1. Mark the Settings menu with . 2. Mark Primary controller with or , and press . 3. Mark Clock program with or , and press . 4. Mark event 1 with or , and press .
Fig. 44 Proportional pressure
Description The function can only be activated in pressure-controlled systems and automatically adapts the setpoint set to the current flow rate. The adaptation can be linear or square. See fig. 45.
TM03 8960 4807
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Hset
Pump curve Setpoint Resultant setpoint, linear Resultant setpoint, square
Starting point of proportional pressure control (Influence at 0 flow = x % of Hset)
Fig. 45 Proportional pressure
The function has these purposes: · to compensate for pressure losses · to reduce the energy consumption · to increase the comfort for the user.
Setting range · Activation of the function. · Selection of control mode. · Setting of setpoint influence.
Setting via control panel
1. Mark the Settings menu with .
2. Mark Primary controller with or , and press .
3. Mark Proportional pressure with or , and press .
4. Mark Activated with or , and press
. The check
mark in the right box shows that the function has been
activated.
5. Mark Adaptation, linear or square with press .
or , and
6. Mark Influence at 0 flow with or or , and save with .
. Set the value with
Factory setting The function is deactivated.
9.7.10 S-system configuration (4.1.8)
TM03 8524 1807 TM03 9205 3607 - TM03 9205 3607
Description
The function makes it possible to invert the control of mainsoperated pumps (Hydro MPC-S). That is to set whether pumps are to be started or stopped depending on the current value.
A start/stop band must be set in order to use this function. See fig. 47.
Normal control: A pump is stopped when the current value becomes higher than Hset + start/stop band. And a pump is started when the current value becomes lower than Hset. See fig. 47.
Inverse control: A pump is started when the current value becomes higher than Hset + start/stop band. And a pump is stopped when the current value becomes lower than Hset. See fig. 47.
Normal control H [m]
Inverse control H [m]
Pump stops
Pump starts
Start/stop band
Hset Pump starts
Start/stop band
Hset Pump stops
Time [sec]
Time [sec]
Fig. 47 Normal and inverse control
Setting range · Selection of configuration (normal or inverse control). · Setting of start/stop band.
Setting via control panel
1. Mark the Settings menu with .
2. Mark Primary controller with or , and press .
3. Mark S-system configuration with .
or , and press
4. Mark Inverse with or , and press .
5. Mark Start/stop band with or . Set the value with or , and save with .
Factory setting Normal.
9.7.11 Pump cascade control (4.2)
TM03 8961 4807 TM03 8962 4807
Fig. 46 S-system configuration Q-Pulse Id: TMS1594
Fig. 48 Pump cascade control
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In this menu section, it is possible to set the functions connected to pump cascade control. The following menus can be selected: · Min. time between start/stop · Max. number of starts/hour · Standby pumps · Forced pump changeover · Pump test run · Pilot pump · Pump stop attempt · Pump start and stop speed · Min. performance · Compensation for pump start-up time.
9.7.12 Min. time between start/stop (4.2.1)
9.7.13 Max. number of starts/hour (4.2.1)
TM03 2367 4807 TM03 2367 4807
Fig. 49 Min. time between start/stop
Description
This function ensures a delay between the starting/stopping of one pump and the starting/stopping of another pump.
The purpose is to prevent hunting when pumps start and stop continuously.
Setting range From 1 to 3600 seconds.
Setting via control panel
1. Mark the Settings menu with .
2. Mark Pump cascade control with or .
3. Mark Min. time between start/stop with press .
4. Mark Min. time between start/stop with press .
5. Set the required minimum time with or .
, and press or , and or , and , and save with
Factory setting Minimum time between start/stop of pumps:
Hydro MPC-E and -EF: 1 second
Other variants:
5 seconds
Fig. 50 Max. number of starts/hour
Description
This function limits the number of pump starts and stops per hour for the complete system. It reduces noise emission and improves the comfort of booster systems with mains-operated pumps.
Each time a pump starts or stops, the CU 351 calculates when the next pump is allowed to start/stop in order not to exceed the permissible number of starts per hour.
The function always allows pumps to be started to meet the requirement, but pump stops will be delayed, if needed, in order not to exceed the permissible number of starts per hour.
The time between pump starts must be between the minimum time between start/stop, see section 9.7.12, and 3600/n, n being the set number of starts per hour.
Setting range 1 to 1000 starts per hour.
Setting via control panel
1. Mark the Settings menu with .
2. Mark Pump cascade control with .
or , and press
3. Mark Max. number of starts/hour with .
or , and press
4. Mark Max. number of starts/hour with or , and press
.
5. Set the permissible number of starts per hour with and save with .
or ,
Factory setting
Hydro MPC-E and -EF: 200 starts per hour
Other variants:
100 starts per hour
Note
This function has no influence on Stop function (4.3.1).
9.7.14 Standby pumps (4.2.3)
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Fig. 51 Standby pumps
Description
This function makes it possible to limit the maximum performance of the Hydro MPC, by selecting one or more pumps as standby pumps.
If a three-pump system has one standby pump, maximum two pumps are allowed to be in operation at a time.
If one of the two pumps in operation has a fault and is stopped, the standby pump will be started. The performance of the booster system is thus not reduced.
The status as standby pump alternates between all pumps.
Setting range
The number of possible standby pumps in a Hydro MPC booster system is equal to the total number of pumps in the system minus 1.
Setting via control panel
1. Mark the Settings menu with .
2. Mark Pump cascade control with .
or , and press
3. Mark Standby pumps with or , and press .
4. Select the number of standby pumps with save with .
or , and
Factory setting
The number of standby pumps is set to 0, i.e. function is deactivated.
9.7.15 Forced pump changeover (4.2.4)
TM03 2366 4807
Description
This function ensures that the pumps run for the same number of operating hours.
In certain applications, the requirement remains constant for long periods and does not require all pumps to run. In such situations, pump changeover does not take place naturally, and forced pump changeover may thus be required.
Once every 24 hours, the CU 351 checks if any pump running has a larger number of operating hours than pumps that are stopped. If this is the case, the pump will be stopped and replaced by a pump with a lower number of operating hours.
Setting range
The function can be activated/deactivated. The hour of the day at which the changeover is to take place can be set.
Setting via control panel
1. Mark the Settings menu with .
2. Mark Pump cascade control with .
or , and press
3. Mark Forced pump changeover with .
or , and press
4. Mark Activated with or , and press . The check mark in the right box shows that the function has been activated.
5. Mark Time for changeover with , and press .
6. Set the time with
or , and save with .
Factory setting The function is activated. The time is set to 03:00.
9.7.16 Pump test run (4.2.5)
TM03 2365 4807 TM03 2364 4807
Fig. 52 Forced pump changeover
Fig. 53 Pump test run
Description This function is primarily used in situations where the forced pump changeover is deactivated, and/or if the Hydro MPC is set to operating mode Stop, for instance in a period when the system is not needed. In such situations, it is important to test the pumps regularly. The function ensures that · pumps do not seize up during a long standstill due to deposits
from the pumped liquid. · the pumped liquid does not decay in the pump. · trapped air is removed from the pump. The pumps start automatically one by one and run for five seconds.
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Note
Pumps in the operating mode Manual are not included in the test run. If there is an alarm, the test run will not be carried out.
Setting range · Not used. · Once every 24 hours. · Once every 48 hours. · Once a week.
Setting via control panel 1. Mark the Settings menu with . 2. Mark Pump cascade control with
. 3. Mark Pump test run with or 4. Select the interval with or . 5. Activate the function with .
or , and press , and press .
Factory setting Test runs are set to once every 24 hours.
9.7.17 Pilot pump (4.2.6)
Setting via control panel
1. Mark the Settings menu with .
2. Mark Pump cascade control with .
or , and press
3. Mark Pilot pump with or , and press .
4. Mark Go to setting of digital output with press .
or , and
5. Select a digital output with or , and press .
6. Mark Pilot pump control with .
or , and save with
7. Return by pressing
twice.
8. Mark Go to setting of digital input with press .
or , and
9. Select a digital input or , and press .
10.Mark Pilot pump fault with or , and save with .
Factory setting The function is deactivated.
9.7.18 Pump stop attempt (4.2.7)
TM03 8963 4807 TM03 8964 4807
Fig. 54 Pilot pump
Description
The function controls a pilot pump via a digital output. The pilot pump takes over the operation from the main pumps in periods when the consumption is so small that the stop function of the main pumps is activated. See section 9.7.23 Stop function (4.3.1).
Via a digital input, the operational state of the pilot pump is monitored, i.e. whether it is operational or in a fault condition.
The purpose is to
· save energy
· reduce the number of operating hours of the main pumps.
If the pilot pump cannot keep the pressure by itself, one or more main pumps are started. If only one main pump is started and runs on/off operation, the pilot pump remains cut in. If one or more main pumps run continuously, the pilot pump is cut out.
Note
If the setpoint of the main pumps is changed, the setpoint of the pilot pump must be changed too.
Setting range · See section 9.7.31 Digital outputs (4.3.9). · See section 9.7.26 Digital inputs (4.3.7).
Fig. 55 Pump stop attempt
Description
The function makes it possible to set automatic stop attempts of a pump when several pumps are running. It ensures that the optimum number of pumps is always running, in terms of energy consumption. At the same time, the purpose is to avoid disturbances in connection with automatic stop of pumps.
Stop attempts can either take place with a fixed interval set under Interval between stop attempts or by self learning. If self learning is selected, the interval between stop attempts will be increased if repeated attempts to stop the pump fail.
Setting via control panel
1. Mark the Settings menu with .
2. Mark Pump cascade control with .
or , and press
3. Mark Pump stop attempt with or , and press .
4. Mark Self learning or Fixed interval with
or
, and
press .
5. If Fixed interval is selected:
6. Mark Interval between stop attempts with or .
7. Set the interval with
or , and save with .
8. Mark Activated with or , and press
. The check
mark in the right box shows that the function has been
activated.
Factory setting The function is activated.
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9.7.19 Pump start and stop speed (4.2.8)
Description
The function controls the starting and stopping of pumps. There are two options:
1. Use calculated speed This function ensures that the optimum number of pumps is always running at a desired duty point, in terms of energy consumption. The CU 351 calculates the required number of pumps and their speed. This requires that the differential pressure of the pump is measured by a differential pressure sensor or separate pressure sensors on the inlet and discharge side. When calculated speed has been selected, the CU 351 ignores the percentages set.
2. Use fixed speed The pumps are started and stopped at speeds set by the user.
1. Use calculated speed
Setting via control panel
1. Mark the Settings menu with .
2. Mark Pump cascade control with .
or , and press
3. Mark Pump start and stop speed with .
or , and press
4. Mark Use fixed speed with or , and press .
5. Mark Start of next pump at: 1->2 with or , and press
.
6. Set the speed as percentage with
or , and save with
. Set the other pumps in the same way.
7. Mark Instant pump stop at: 1->0 with .
or , and press
8. Set the speed as percentage with
or , and save with
. Set the other pumps in the same way.
Factory setting The function is set to calculated speed.
9.7.20 Min. performance (4.2.9)
TM03 8966 4807
TM03 8967 4807
Fig. 56 Calculated pump start and stop speed
Setting via control panel 1. Mark the Settings menu with . 2. Mark Pump cascade control with or
. 3. Mark Pump start and stop speed with
. 4. Mark Use calculated speed with or
, and press or , and press
, and press .
2. Use fixed speed
Fig. 58 Min. performance
Description
This function ensures circulation in a system. Note that the stop function, if activated, can influence this function. See section 9.7.23 Stop function (4.3.1). Examples:
· If 0 or 1 pump has been selected as a minimum, the stop function can stop the pump if there is no or a very small consumption.
· If two or more pumps have been selected as a minimum, the stop function is not active.
Setting via control panel
1. Mark the Settings menu with .
2. Mark Pump cascade control with .
or , and press
3. Mark Min. performance with or , and press .
4. Set Number of pumps with
or , and save with .
5. Mark Speed with or and save with .
. Set the speed with
or ,
Factory setting
The number of pumps is set to 1. The speed in closed loop is set to 25 %.
TM03 8965 4807
Fig. 57 Fixed pump start and stop speed
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9.7.21 Compensation for pump start-up time (4.2.10)
The display makes it possible to open specific displays regarding: · Stop function (4.3.1) · Soft pressure build-up (4.3.3) · Digital inputs (4.3.7) · Analog inputs (4.3.8) · Digital outputs (4.3.9) · Emergency run (4.3.5) · Min., max. and user-defined duty (4.3.14) · Pump curve data (4.3.19) · Flow estimation (4.3.23) · Control source (4.3.20) · Fixed inlet pressure (4.3.22).
9.7.23 Stop function (4.3.1)
TM03 8968 4807
Fig. 59 Compensation for pump start-up time
Description
The function is used for the system types -ES, -ED, -F and -EDF.
The purpose is to avoid disturbances when a mains-operated pump with fixed speed is started. The function compensates for the time it takes a mains-operated pump to reach its full performance after start. The start-up time of the mains-operated pump must be known.
Setting via control panel
1. Mark the Settings menu with .
2. Mark Pump cascade control with or , and press
.
3. Mark Compensation for pump start-up time with or , and press .
4. Set the start-up time with
or , and save with .
Factory setting The start-up time is set to 0 seconds.
9.7.22 Secondary functions (4.3)
Fig. 61 Stop function
Description This function makes it possible to stop the last pump if there is no or a very small consumption. The purpose is to · save energy · prevent heating of shaft seal faces due to increased
mechanical friction as a result of reduced cooling by the pumped liquid · prevent heating of the pumped liquid. The description of the stop function applies to all Hydro MPC booster systems with variable-speed pumps. Hydro MPC-S will have on/off control of all pumps as described in section 6.1 Examples of control variants.
H
TM03 2355 4807
TM03 8969 4807
TM03 1692 2705
Hset
On/off band
Fig. 60 Secondary functions
Description
Qmin
Q
Functions that are secondary in relation to the normal operation of the Hydro MPC booster system can be set in this display.
On/off Normal operation control
Secondary functions are functions that offer additional functionality.
Fig. 62 On/off band
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When the stop function is activated, the operation of Hydro MPC is continuously monitored to detect a low flow rate. When the CU 351 detects no or a low flow rate (Q < Qmin), it changes from constant-pressure operation to on/off control of the last pump in operation.
Before stopping, the pump increases the pressure to a value corresponding to Hset + 0.5 x on/off band. The pump is restarted when the pressure is Hset 0.5 x on/off band. See fig. 63.
[psi]
Stop
A
B
A: Normal operation B: Pressure boosting C: Stop
C
B
C
Start
Stop = Hset + 0.5 x on/off band Start = Hset 0.5 x on/off band
Time [sec]
Fig. 63 On/off operation
The flow rate is estimated by the CU 351 when the pump is in the stop period. As long as the flow rate is lower than Qmin, the pump will run on/off. If the flow rate is increased to above Qmin, the pump returns to normal operation, Hset. Hset is equal to the current setpoint. See section 9.4.4 Setpoint (1.2.2).
Detection of low flow rate
Low flow rate can be detected by means of
· direct flow measurement with a flowmeter or flow switch
· estimation of flow rate by measurement of current pressure and speed.
If the booster system is not connected to a flowmeter or flow switch, the stop function will use the estimating function.
If the detection of low flow rate is based on flow estimation, a diaphragm tank of a certain size and with a certain precharge pressure is required.
Diaphragm tank size
Pump type
CR(E) 3 CR(E) 5 CR(E) 10 CR(E) 15 CR(E) 20 CR(E) 32 CR(E) 45 CR(E) 64 CR 90
Recommended diaphragm tank size [gallons]
-E
4.4 4.4 10.2 34 34 44 86 132
-
-ED
4.4 4.4 10.2 34 34 44 86 132
-
-ES
4.4 4.4 10.2 34 34 44 86 132
-
-EF
4.4 4.4 10.2 34 34 44 86 132 132
-EDF
4.4 4.4 10.2 34 34 44 86 132 132
-F
4.4 4.4 10.2 34 34 44 86 132 132
-S
20 34 62 211 211 317 528 1056 1056
Precharge pressure Hydro MPC-E, -ED, -ES, -EF, -EDF and -F: 0.7 x setpoint. Hydro MPC-S: 0.9 x setpoint.
TM03 9292 4807 TM03 9966 4807
During each flow estimation (every 2 minutes), the estimating function will disturb the discharge pressure by ±10 % of the setpoint. If this disturbance is not acceptable, the stop function must be based on direct flow measurement with a flowmeter or flow switch.
The minimum flow rate can be set, i.e. the flow rate at which the booster system changes to on/off control of the last pump in operation.
If both a flowmeter and a flow switch are connected, the changeover to on/off control is determined by the unit first indicating low flow rate.
Setting range
On/off band: Min. flow rate:
5 to 30 %
2 to 50 % of the nominal flow rate (Qnom) of one of the pumps. (Can only be set if direct flow measurement by means of flowmeter has been selected.)
Setting via control panel
System without flow switch or flowmeter
1. Mark the Settings menu with .
2. Mark Secondary functions with or , and press .
3. Mark Stop function with or , and press .
4. Mark Activated with or , and press . The activation is indicated by a check mark in the box.
5. Mark On/off band with or .
6. Set the on/off band with
or , and save with .
7. Mark Go to setting of flow stop parameters with and press . Now the display below is shown.
or ,
Fig. 64 Stop parameters
8. Select one of the stop parameters with or , and save with . If Customised settings are selected, the parameters shown in fig. 65 must be set. See examples below.
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1. Mark Go to setting of analog input with or , and press . Now the display Analog inputs (4.3.8) appears.
2. Select the analog input where the flowmeter is connected, and set up the input for the flowmeter by selecting Flow rate.
3. Return to Stop function by pressing twice.
4. Mark Stop limit with or .
5. Set the value with
or , and save with .
Factory setting
The function is activated.
On/off band: 25 % Min. flow rate: 30 % of the nominal flow rate of one pump
9.7.24 Soft pressure build-up (4.3.3)
TM03 8957 4807 TM03 8970 4807
Fig. 65 Customised settings
Note
Rule of thumb: Speed reduction = 2 x delta pressure for gradient.
Example 1: Increasing the stop limit, Qmin (high flow limit) · Increase the delta pressure for gradient. · Reduce the delta time for gradient (pump stopped). · Reduce the delta time for gradient (pump running). · Increase the speed reduction.
Example of increased stop limit
Parameter
Delta pressure for gradient Delta time for gradient (pump stopped) Delta time for gradient (pump running) Speed reduction
Value
6 % 1.5 sec 2.0 sec 10 %
Example 2: Reducing the stop limit, Qmin (low flow limit) · Reduce the delta pressure for gradient. · Increase the delta time for gradient (pump stopped). · Increase the delta time for gradient (pump running). · Reduce the speed reduction.
Example of reduced flow limit
Parameter
Delta pressure for gradient Delta time for gradient (pump stopped) Delta time for gradient (pump running) Speed reduction
Value
3 % 15.0 sec 25.0 sec 6 %
Note The stop limit depends on the tank size.
System with flow switch
Make the following additional settings:
1. Mark Go to setting of digital input with or , and press . Now the display Digital inputs (4.3.7) appears.
2. Select the digital input where the flow switch is connected with or , and press .
3. Mark Flow switch with or , press
and return with
.
Note An open contact indicates low flow.
System with flowmeter Make the following additional settings:
Fig. 66 Soft pressure build-up
Description The function ensures a smooth start-up of systems with for instance empty pipes. Start-up takes place in two phases. See fig. 67. 1. Filling phase.
The pipework is slowly filled with water. When the pressure sensor of the system detects that the pipework has been filled, phase two begins. 2. Pressure build-up phase. The system pressure is increased until the setpoint is reached. The pressure build-up takes place over a ramp time. If the setpoint is not reached within a given time, a warning or an alarm can be given, and the pumps can be stopped at the same time.
H [psi]
1. Filling phase
2. Pressure build-up phase
Filling time
Time [sec] Ramp time
Fig. 67 Filling and pressure build-up phases
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Setting range · Activation of the function. · Setting of pump speed. · Setting of number of pumps. · Setting of filling pressure. · Setting of maximum filling time. · Setting of warning or alarm + stop. · Setting of ramp time for the pressure build-up phase.
Setting via control panel
1. Mark the Settings menu with
2. Mark Secondary functions with or , and press .
3. Mark Soft pressure build-up with .
or , and press
4. Mark Speed with or .
5. Set the value with
or , and save with .
6. Mark Number of pumps with or .
7. Set the value with
or , and save with .
8. Mark Filling pressure with or .
9. Set the value with
or , and save with .
10.Mark Max. time with or .
11.Set the value with
or , and save with .
12.Mark Warning or Alarm + stop with .
or , and press
13.Mark Ramp time with or .
14.Set the value with
or , and save with .
15.Mark Activated, and press .
Factory setting The function is deactivated.
9.7.25 Emergency run (4.3.5)
2. Mark Secondary functions with or , and press .
3. Mark Emergency run with or , and press .
4. Mark Go to setting of digital input with press .
or , and
5. Select a digital input with or , and press .
6. Mark Emergency run with or , and save with .
7. Return by pressing
twice.
8. Mark Go to setting of digital output with press .
or , and
9. Select a digital output with or , and press .
10.Mark Emergency run with or , and save with .
11.Return by pressing
twice.
12.Mark Setpoint, emergency run with or .
13.Set the value with
or , and save with .
Note
When this function has been set as described above, it can also be activated via the display System operating mode (2.1.1).
9.7.26 Digital inputs (4.3.7)
TM03 8971 4807 TM03 2359 4807
Fig. 68 Emergency run
Description When this function has been activated, the pumps will keep running regardless of warnings or alarms. The pumps will run according to a setpoint set specifically for this function.
In case of sensor fault, both main and standby Caution pumps will run at 100 % speed! Setting range · Setting of digital input (9.7.26 Digital inputs (4.3.7)). · Setting of digital output (9.7.31 Digital outputs (4.3.9)). · Setting of setpoint for emergency run. Setting via control panel 1. Mark the Settings menu with
Fig. 69 Digital inputs
Description In this menu, the digital inputs of the CU 351 can be set. Each input, except DI1, can be activated and related to a certain function. As standard, the Hydro MPC has three digital inputs. If the Hydro MPC incorporates an IO 351B module (option), the number of digital inputs is 12. In the display, all digital inputs are shown so that their physical position in the Hydro MPC can be identified.
Example DI1 (IO 351-41), [10]:
DI1: (IO 351-41): [10]:
Digital input No 1 IO 351, GENIbus number 41 Terminal No 10
For further information on the connection of various digital inputs, see the wiring diagram supplied with the control cabinet.
Setting range
The digital input to be set is selected in the display Digital inputs (4.3.7).
Note DI1 (CU 351) cannot be selected.
Setting via control panel 1. Mark the Settings menu with .
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2. Mark Secondary functions with or , and press . 3. Mark Digital inputs or , and press . 4. Select the digital input with or , and press .
9.7.27 Functions of digital inputs (4.3.7.1)
Fig. 70 Functions of digital inputs
Description In the displays 4.3.7.1, a function can be related to the digital inputs. Setting range It is possible to select one function in each display:
Function
Contact activated
Not used
Min. duty
= Operating mode Min.
Max. duty User-defined duty External fault
= Operating mode Max.
= Operating mode Userdefined
= External fault
Dry-running protection Flow switch Reset of alarm Emergency run Pilot pump fault
= Water shortage
= Flow rate > Set switch value
= Reset alarms = Operating mode
Emergency run
= Pilot pump fault
Alternative setpoint 2
= Setpoint 2 selected
Alternative setpoint 3
= Setpoint 3 selected
Alternative setpoint 4
= Setpoint 4 selected
Alternative setpoint 5
= Setpoint 5 selected
Alternative setpoint 6
= Setpoint 6 selected
Alternative setpoint 7
= Setpoint 7 selected
See the relevant sections for further information about the functions.
Generally, a closed contact activates the function selected.
TM03 8972 4807 TM03 2356 4807
Setting via control panel 1. Mark the Settings menu with . 2. Mark Secondary functions with or , and press . 3. Mark Digital inputs with or , and press . 4. Select the digital input with or , and press . 5. Select the desired function with or , and activate it
with . The activation is indicated by a check mark in the box.
Factory setting
Digital input
Function
DI1 (CU 351) [10] DI2 (CU 351) [12]
External start/stop. Open contact = stop. Note: Input No 1 cannot be changed.
Monitoring of water shortage (dry-running protection). Open contact = water shortage (if the Hydro MPC is supplied with this option).
Note
Monitoring of water shortage requires a pressure switch connected to the Hydro MPC.
9.7.28 Analog inputs (4.3.8)
Fig. 71 Analog inputs
Description
In this display, the analog inputs of the Hydro MPC can be set.
Each input can be activated and related to a certain function.
As standard, the Hydro MPC has three analog inputs. If the Hydro MPC incorporates an IO 351B module (option), the number of analog inputs is 5.
In the display, all analog inputs are shown so that their physical position in the Hydro MPC can be identified. A redundant primary sensor can be fitted as back-up for the primary sensor in order to increase reliability and prevent stop of operation.
Note
If two sensors are to be redundant, each must have a separate analog input.
Example AI1 (CU 351) [51]:
AI1: (CU 351): [51]:
Analog input No 1 CU 351 Terminal No 51
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Setting range In the display Analog inputs (4.3.8), the analog input to be set is selected.
Setting via control panel 1. Mark the Settings menu with . 2. Mark Secondary functions with or , and press . 3. Mark Analog inputs with or , and press . 4. Select the analog input with or , and press .
9.7.29 Analog inputs (4.3.8.1 to 4.3.8.7)
Factory setting
Analog input
Function
AI1 (CU 351) [51] AI2 (CU 351) [54] AI3 (CU 351) [57]
Discharge pressure
Tank precharge pressure (if Hydro MPC is supplied with measurement of tank precharge pressure)
Redundant primary sensor (if Hydro MPC is supplied with this option)
9.7.30 Analog inputs and measured value (4.3.8.1.1 to 4.3.8.7.1)
TM03 2357 4807 TM03 8973 4807
Fig. 72 Analog inputs
Description In the displays 4.3.8.1 to 4.3.8.7, analog inputs can be set. Each display is divided into three parts: · Setting of input signal, for instance 4-20 mA · Measured input value, for instance discharge pressure · Measuring range of the sensor/signal transmitter, for instance
0-16 bar.
Setting range It is possible to set the following parameters in each display: · Not used · Range of input signal, 0-20 mA, 4-20 mA, 0-10 V · Measured input value · Sensor range.
Setting via control panel 1. Mark the Settings menu with . 2. Mark Secondary functions with or , and press . 3. Mark Analog inputs with or , and press . 4. Select the analog input with or , and press . 5. Mark the setting of the analog input with or , and
activate it with . The activation is indicated by a check mark in the box.
Note
If an analog input is deactivated, the display will only show the top part, i.e. the setting of the analog input. If the input is activated, the middle part, "Measured input value", is shown. This makes it possible to relate a function to the analog input in another display. When the analog input has been related to a function, CU 351 will return to the display for setting of analog inputs.
Fig. 73 Analog inputs and measured value
Description In the display Analog inputs and measured value (4.3.8.1.1 to 4.3.8.7.1), a function can be related to the individual analog inputs.
Setting range It is possible to select one function per analog input. · Not used · 0-100 % signal · Inlet pressure · Discharge pressure · External pressure · Differential pressure, pump · Flow rate · Tank level, discharge side · Tank level, suction side · System pressure · Differential pressure, external · Tank precharge pressure · Differential pressure, inlet · Differential pressure, outlet · Return pipe temperature, external · Flow pipe temperature · Return pipe temperature · Differential temperature · Ambient temperature · Power, pump 1 to 6 · Power, VFD.
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Setting via control panel
1. Mark the Settings menu with .
2. Mark Secondary functions with or , and press .
3. Mark Analog inputs with or , and press .
4. Select the analog input with or , and press .
5. Set the range of the analog input with or .
The activation is indicated by a check mark.
, and press
6. Mark Measured input value with or , and press .
Now the display 4.3.8.1.1 appears.
7. Select the input with or , and press .
8. Press
to return to display 4.3.8.1.
9. Set the minimum sensor value with .
or , and save with
10.Set the maximum sensor value with .
or , and save with
9.7.31 Digital outputs (4.3.9)
Fig. 74 Digital outputs
Description In this display, the digital relay outputs of the Hydro MPC can be set. Each output can be activated and related to a certain function. As standard, the Hydro MPC has two digital outputs. If the Hydro MPC incorporates an IO 351B module (option), the number of digital outputs is 9. In the display, all digital outputs are shown so that their physical position in the Hydro MPC can be identified.
Example DO1 (IO 351-41) [71]:
DO1 (IO 351-41) [71]
Digital output No 1 IO 351B, GENIbus number 41 Terminal No 71
For further information on the connection of various digital outputs, see the wiring diagram supplied with the CU 351.
Setting range In the display Digital outputs (4.3.9), the digital output to be used is selected.
TM03 2333 4807 TM03 8974 4807
9.7.32 Functions of digital outputs (4.3.9.1 to 4.3.9.16)
Fig. 75 Functions of digital outputs
Description In the displays Functions of digital outputs (4.3.9.1 to 4.3.9.16), a function can be related to the individual outputs.
Setting range It is possible to select one function in each display: · No function · Operation, system · Alarm, system · Warning, system · Ready, system · Water shortage · Min. pressure · Max. pressure · Emergency run · Pilot pump control · Pressure relief valve · Operation, pump 1 to 6 · Alarm, pump 1 to 6 · Alarm, limit 1 exceeded · Warning, limit 1 exceeded · Alarm, limit 2 exceeded · Warning, limit 2 exceeded.
Setting via control panel 1. Mark the Settings menu with . 2. Mark Secondary functions with or , and press . 3. Mark Digital outputs with or , and press . 4. Select the digital output with or , and press . 5. Mark the desired function with or , and activate it with
. The activation is indicated by a check mark in the box.
Factory setting
Digital output DO1 (CU 351) [71] DO2 (CU 351) [74]
Function Alarm, system Operation, system
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9.7.33 Min., max. and user-defined duty (4.3.14)
TM03 2351 4807
Fig. 76 Min., max. and user-defined duty
Description Hydro MPC is usually controlled in a closed loop to maintain a discharge pressure. In certain periods, it may be necessary to let the booster system run in open loop at a set pump performance.
Setting range The CU 351 makes it possible to change between three operating modes: 1. Min. duty (4.3.14.1). 2. Max. duty (4.3.14.2). 3. User-defined duty (4.3.14.3).
Note
For each of these modes, the number of operating pumps and the pump performance (speed) can be set.
9.7.34 Min. duty (4.3.14.1)
TM03 2354 4807
Fig. 77 Min. duty
Description In all booster systems apart from Hydro MPC-S, minimum duty is only possible for variable-speed pumps. In Hydro MPC-S systems, only the number of pumps running at 100 % speed can be set.
Setting range · Number of pumps in operation. · Speed as percentage (25 to 100 %) for variable-speed pumps.
Setting via control panel
1. Mark the Settings menu with .
2. Mark Secondary functions with or , and press .
3. Mark Min., max. and user-defined duty with press .
or , and
4. Mark Min. duty with or , and press .
5. Mark Number of pumps in operation, min. duty with or .
6. Set the number with
or , and save with .
7. Mark Speed with or .
8. Set the value with
or , and save with .
Factory setting
Number of pumps in operation during min. duty:
1
Speed as percentage for variable-speed pumps:
70
9.7.35 Max. duty (4.3.14.2)
TM03 2353 4807
Fig. 78 Max. duty
Description
The function makes it possible for a set number of pumps to run at maximum performance when the function is activated.
Setting range
In this display, the number of pumps to run in the operating mode Max. can be set. All pumps run at 100 % speed.
Setting via control panel 1. Mark the Settings menu with .
2. Mark Secondary functions with or , and press .
3. Mark Min., max. and user-defined duty with press .
or , and
4. Mark Max. duty with or , and press .
5. Mark Number of pumps in operation at 100 % speed, max. duty with or .
6. Set the number with
or , and save with .
Factory setting
Number of pumps in operation during max. duty:
All pumps (except standby pumps)
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9.7.36 User-defined duty (4.3.14.3)
9.7.37 Pump curve data (4.3.19)
TM03 2352 4807 TM03 8975 4807
Fig. 79 User-defined duty
Description
In this display, it is possible to set a user-defined performance, typically a performance between min. and max. duty.
The function makes it possible to set a pump performance by selecting the number of pumps to run and the speed of variablespeed pumps.
This function primarily selects the variable-speed pumps. If the number of selected pumps exceeds the number of variable-speed pumps, mains-operated pumps are started too.
Setting range
· Number of pumps in operation.
· Speed as percentage for variable-speed pumps. Note: In Hydro MPC booster systems with only variable-speed pumps, the speed can be set between 25 and 100 %; in booster systems with both variable-speed pumps and mainsoperated pumps the speed can be set between 70 and 100 %.
Setting via control panel
1. Mark the Settings menu with .
2. Mark Secondary functions with or , and press .
3. Mark Min., max. and user-defined duty with press .
or , and
4. Mark User-defined duty with or , and press .
5. Mark Number of pumps in operation, user-defined duty with or .
6. Set the number with
or , and save with .
7. Mark Speed with or .
8. Set the value with
or , and save with .
Factory setting The function is not activated, as the following has been set:
Number of pumps in operation during user-defined duty: 0
Fig. 80 Pump curve data
Description
The CU 351 has a number of functions using these pump data: · Nominal flow rate, Qnom, in m3/h · Nominal head, Hnom, in metres · Max. head, Hmax, in metres · Max. flow rate, Qmax, in m3/h · Power, Q0, 100 % speed, in kW · Power, Q0, 50 % speed, in kW · Nominal power, Pnom, in kW.
Note
Grundfos can supply hydraulic data for CR, CRI, CRE and CRIE pumps where GSC files can be downloaded directly to the CU 351.
Note
The electrical data, "Power, Q0, 100 % speed" and "Power, Q0, 50 % speed" must be entered manually.
For Grundfos E-pumps, the data of input power (P1) must be entered.
The data are read by means of the pump performance curves which can be found in WebCAPS on Grundfos' homepage, www.grundfos.com. See examples in figs 81 to 84.
If WebCAPS is not accessible, try to bring a pump into the three duty points: Power, Q0, 100 % speed, Power, Q0, 50 % speed and Nominal power, Pnom. Read the power values in displays 1.3 to 1.8, depending on the pump. See section 9.4.8 Pump 1...6 (1.3 to 1.8).
Hmax Hnom
Nominal duty point
TM03 9993 4807
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Qnom
Qmax
Fig. 81 Reading of Qnom, Hnom, Hmax and Qmax (WebCAPS)
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Duty point, Q0, 100 % speed
Power, Q0, 100 % speed
Fig. 82 Reading of Power, Q0, 100 % speed (WebCAPS)
TM03 9994 4807
Note
Qnom and Hnom are the rated duty point of the pumps and usually the duty point with the
highest efficiency.
Setting via control panel
1. Mark the Settings menu with .
2. Mark Secondary functions with or , and press .
3. Mark Pump curve data with or , and press .
4. Mark Nominal flow rate Qnom with
or .
5. Set the value with
or , and save with .
6. Mark Nominal head Hnom with or .
7. Set the value with
or , and save with .
8. Mark Max. head Hmax with
or .
9. Set the value with
or , and save with .
10.Mark Max. flow rate Qmax with or .
11.Set the value with
or , and save with .
12.Mark Power, Q0, 100 % speed with or .
13.Set the value with
or , and save with .
14.Mark Power, Q0, 50 % speed with or .
15.Set the value with
or , and save with .
16.Mark Nominal power Pnom with or .
17.Set the value with
or , and save with .
9.7.38 Control source (4.3.20)
Duty point, Q0, 50 % speed
TM03 9995 4807
Power, Q0, 50 % speed
TM03 2342 4807
Fig. 83 Reading of Power, Q0, 50 % speed (WebCAPS)
Duty point, Nominal power, Pnom
Nominal power, Pnom
Fig. 84 Reading of Nominal power, Pnom (WebCAPS)
TM03 9996 4807
Fig. 85 Control source
Description
Hydro MPC can be remote-controlled via an external bus connection (option). See section 9.8.2 GENIbus. Control of the Hydro MPC can also take place via the bus connection. For further information, see section 9.8 Data communication.
In this display, the control source, CU 351 or the external bus connection, is selected.
Setting via control panel
1. Mark the Settings menu with .
2. Mark Secondary functions with or , and press .
3. Mark Control source with or , and press .
4. Select the desired control source with with .
or , and save
Factory setting The control source is CU 351.
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9.7.39 Fixed inlet pressure (4.3.22)
TM03 8975 4807
Fig. 86 Fixed inlet pressure
Description
If the Hydro MPC has a fixed inlet pressure, it can be entered in this display so that the CU 351 can optimise the performance and control of the booster system.
Setting range
A fixed inlet pressure can be set, and the function can be activated/deactivated.
Setting via control panel
1. Mark the Settings menu with .
2. Mark Secondary functions with or , and press .
3. Mark Fixed inlet pressure with or , and press .
4. Set the inlet pressure with
or , and save with .
5. Mark Activated with or , and press
. The
activation is indicated by a check mark in the box.
Factory setting The function is deactivated.
9.7.40 Flow estimation (4.3.23)
The loss is caused by non-return valves and pipe bends. To improve the flow estimation of the system, it is necessary to compensate for the difference between the measured and the actual differential pressure across the pump. This is done by entering the head loss in non-return valves and pipe bends at the rated flow rate of one pump.
Setting range · 2nd order QH polynomial · 5th order QH polynomial · Power polynomial, QP · Head loss.
Note
It is possible to select several curve types, as the CU 351 makes a priority based on the data available.
Setting via control panel 1. Mark the Settings menu with . 2. Mark Secondary functions with or , and press . 3. Mark Flow estimation with or , and press . 4. Select the curve type by marking one of the lines at the
selection box with or , and press .
Factory setting All polynomials are selected.
9.7.41 Monitoring functions (4.4)
TM03 8978 4807
Fig. 87 Flow estimation
Description As described in section 9.7.37 Pump curve data (4.3.19), the CU 351 can optimise operation according to performance curves and motor data. In this display, curve types are selected which the CU 351 will use for the optimisation if they are available. At large flow rates, there may be a considerable head loss between the pump discharge flange and the pressure sensor.
TM03 8977 4807
Fig. 88 Monitoring functions
Description Hydro MPC has a series of functions that constantly monitor the operation of the booster system. The primary purpose of the monitoring functions is to ensure that faults do not damage pumps or the system.
Setting range The following functions can be selected: · Dry-running protection (4.4.1) · Min. pressure (4.4.2) · Max. pressure (4.4.3) · External fault (4.4.4) · Limit 1 and 2 exceeded (4.4.5 and 4.4.6) · Pumps outside duty range (4.4.7) · Pressure relief (4.4.8).
Setting via control panel 1. Mark the Settings menu with . 2. Mark Monitoring functions with or , and press . 3. Select the function with or , and press .
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9.7.42 Dry-running protection (4.4.1)
9.7.43 Dry-running protection with pressure/level switch (4.4.1.1)
TM03 2320 4807 TM03 2329 4807
Fig. 89 Dry-running protection
Description
Dry-running protection is one of the most important monitoring functions, as bearings and shaft seal may be damaged if the pumps run dry. Grundfos thus always recommends dry-running protection in connection with Hydro MPC booster systems.
The function is based on monitoring of the inlet pressure or the level in a possible tank or pit on the suction side.
Level switches, pressure switches or analog sensors signalling water shortage at a set level can be used.
There are three different methods for detection of water shortage:
· Pressure switch on suction manifold or float switch/electrode relay in the supply tank. See section 9.7.43 Dry-running protection with pressure/level switch (4.4.1.1).
· Measurement of inlet pressure in the suction manifold by means of an analog pressure transmitter. See section 9.7.44 Dry-running protection with pressure transmitter (4.4.1.2).
· Measurement of level in the supply tank by means of an analog level transmitter. See section 9.7.45 Dry-running protection with level transmitter (4.4.1.3).
Setting via control panel
1. Mark the Settings menu with .
2. Mark Monitoring functions with or , and press .
3. Mark Dry-running protection with .
or , and press
4. Select the method with or , and press .
Fig. 90 Dry-running protection with pressure/level switch
Description
Dry-running protection can take place by means of a pressure switch on the suction manifold or a level switch in a tank on the suction side.
When the contact is open, the CU 351 will register water shortage after a time delay of approx. 5 sec. It is possible to set whether the indication is to be just a warning or an alarm stopping the pumps.
In the display, it is possible to set whether restart and reset of the alarm is to be automatic or manual.
Setting range · Selection of digital input for the function. · Reaction in case of water shortage: Warning or alarm + stop. · Restart: Manual or automatic.
Setting via control panel
1. Mark the Settings menu with .
2. Mark Monitoring functions with or , and press .
3. Mark Dry-running protection with .
or , and press
4. Mark Pressure/level switch with or , and press .
5. Mark Go to setting of digital input, and press . Now the
display Digital inputs (4.3.7) appears. Set the input to dryrunning protection. Return with .
6. Mark Warning or Alarm + stop with with .
or , and save
7. Mark Manual or Auto with or , and save with .
Factory setting
If the booster system is equipped with a pressure switch for dryrunning protection, it is set to alarm + stop in case of water shortage.
Restart: Manual.
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9.7.44 Dry-running protection with pressure transmitter (4.4.1.2)
9.7.45 Dry-running protection with level transmitter (4.4.1.3)
TM03 8979 4807 TM03 8980 4807
Fig. 91 Dry-running protection with pressure transmitter
Description
Dry-running protection can take place by means of a pressure transmitter measuring the inlet pressure.
It is possible to set two levels of inlet pressure: Warning and alarm + stop.
In the display, it is possible to set whether restart and reset of the alarm is to be automatic or manual.
Setting range · Selection of analog input for the function. · Activation of the function. · Inlet pressure level for warning. · Inlet pressure level for alarm + stop. · Restart: Manual or automatic.
Setting via control panel
1. Mark the Settings menu with .
2. Mark Monitoring functions with or , and press .
3. Mark Dry-running protection with .
or , and press
4. Mark Measurement, inlet pressure with press .
or , and
5. Mark Go to setting of analog input, and press . Now the display Analog inputs (4.3.8) appears. Set the input to Inlet pressure, and save with . Return with .
6. Mark Activated with or , and press .
7. Mark Warning with or . Set the level with and save with .
or ,
8. Mark Alarm + stop with
or . Set the level with
or
, and save with .
9. Mark Manual or Auto with or , and save with .
Note
If one of the levels is not required, the level value must be the minimum value of the inlet pressure transmitter. This deactivates the function.
Factory setting If the booster system is supplied with a pressure transmitter on the suction side, the transmitter has been set. The warning level is 0.5 bar and the alarm level 0.2 bar. The function is activated. Restart: Manual.
Fig. 92 Dry-running protection with level transmitter
Description Dry-running protection can take place by means of a level transmitter measuring the level in a tank on the suction side. It is possible to set two levels: Warning and alarm + stop. In the display, it is possible to set whether restart and reset of alarms is to be automatic or manual.
Setting range · Selection of analog input for the function. · Activation of the function. · Tank level for warning. · Tank level for alarm + stop. · Restart: Manual or automatic.
Setting via control panel
1. Mark the Settings menu with .
2. Mark Monitoring functions with or , and press .
3. Mark Dry-running protection with .
or , and press
4. Mark Measurement, tank level with .
or , and press
5. Mark Go to setting of analog input, and press . Now the display Analog inputs (4.3.8) appears. Set the input to Tank level, suction side. Return with .
6. Mark Activated with or , and press .
7. Mark Warning with or . Set the level with and save with .
or ,
8. Mark Alarm + stop with or . Set the level with or , and save with .
9. Mark Manual or Auto with or , and save with .
Factory setting The function is deactivated.
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9.7.46 Min. pressure (4.4.2)
Factory setting The function is deactivated. 9.7.47 Max. pressure (4.4.3)
TM03 8981 4807 TM03 8982 4807
Fig. 93 Min. pressure
Description
The discharge pressure can be monitored so that the CU 351 can react if the pressure becomes lower than a set minimum level for an adjustable time.
The minimum pressure can be monitored if a fault indication is required in situations where the discharge pressure becomes lower than the set minimum pressure.
It is possible to set whether the indication is to be just a warning or an alarm stopping the pumps. This may be desirable if Hydro MPC is used for an irrigation system where a very low discharge pressure may be due to pipe fracture and thus an extraordinarily high consumption and a very low counterpressure. In such situations, it is desirable that the booster system stops and indicates alarm. This situation will require a manual reset of alarms.
It is possible to set a start-up delay ensuring that the Hydro MPC can build up pressure before the function is activated. It is also possible to set a time delay, i.e. for how long time the discharge pressure may be lower than the set minimum pressure before the alarm is activated.
Setting range · Activation of the function. · Minimum pressure level within the range of the primary
sensor. · Activation of stop when the pressure falls below the minimum
pressure. · Time delay at start-up. · Time delay during operation.
Setting via control panel
1. Mark the Settings menu with .
2. Mark Monitoring functions with or , and press .
3. Mark Min. pressure with or , and press .
4. Mark Activated with or deactivate the function.
, and press
to activate/
5. Mark Min. pressure with or or , and save with .
. Set the pressure with
6. Mark Stop at min. pressure with or to activate/deactivate the function.
, and press
7. Mark Time delay of function at start-up with
the time with
or , and save with .
or . Set
8. Mark Time delay of function during operation with or
. Set the time with
or , and save with .
Fig. 94 Max. pressure
Description
The discharge pressure can be monitored so that the CU 351 can react if the pressure becomes higher than a set maximum level.
In certain installations, a too high discharge pressure may cause damage. It may therefore be necessary to stop all pumps for a short period if the pressure is too high.
It is possible to set whether the Hydro MPC is to restart automatically after the pressure has dropped below the maximum level, or if the system must be reset manually. Restart will be delayed by an adjustable time. See section 9.7.12 Min. time between start/stop (4.2.1).
Setting range · Activation of the function. · Maximum pressure level within the range of the primary
sensor. · Manual or automatic restart after fault.
Setting via control panel
1. Mark the Settings menu with .
2. Mark Monitoring functions with or , and press .
3. Mark Max. pressure with or , and press .
4. Mark Activated with or deactivate the function.
, and press
to activate/
5. Mark Max. pressure with or or , and save with .
. Set the pressure with
6. Mark Manual or Auto with or . Activate the function with .
Factory setting The function is deactivated.
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9.7.48 External fault (4.4.4)
9.7.49 Limit 1 and 2 exceeded (4.4.5 and 4.4.6)
TM03 2313 4807 TM03 8983 4807
Fig. 95 External fault
Description
The function is used when the CU 351 is to be able to receive a fault signal from an external contact. In case of external fault, the CU 351 indicates warning or alarm. In case of alarm, the booster system changes to another manual operating mode, for instance Stop.
Setting range · Selection of digital input for the function. · Setting of time delay from closing of the contact until the
CU 351 reacts. · Reaction in case of external fault: Warning or alarm and
change of operating mode. · Restart after alarm: Manual or automatic.
Setting via control panel
1. Mark the Settings menu with .
2. Mark Monitoring functions with or , and press .
3. Mark External fault with or , and press .
4. Mark Go to setting of digital input with or , and press . Now the display Digital inputs (4.3.7) appears. Set the input to External fault. Return with .
5. Mark Time delay, fault indication with or
time with
or , and save with .
. Set the
6. Mark Warning with or if only a warning is required in case of external fault. Activate the function with .
7. Select operating mode with or if the booster system is to give alarm and change operating mode in case of external fault. Activate the function with .
8. Mark Manual or Auto with with .
or . Activate the function
Factory setting The function is deactivated. If the function is activated, the following values have been set from factory: · Time delay: 5 seconds. · Operating mode in case of alarm: Stop. · Restart: Manual.
Fig. 96 Limit 1 exceeded
Description With this function, the CU 351 can monitor set limits of analog values. It will react if the values exceed the limits. Each limit can be set as a maximum or minimum value. For each of the monitored values, a warning limit and an alarm limit must be defined. The function makes it possible to monitor two different locations in a pump system at the same time. For instance the pressure at a consumer and the pump discharge pressure. This ensures that the discharge pressure does not reach a critical value. If the value exceeds the warning limit, a warning is given. If the value exceeds the alarm limit, the pumps are stopped. A delay can be set between the detection of an exceeded limit and the activation of a warning or an alarm. A delay can also be set for resetting a warning or an alarm. A warning can be reset automatically or manually. It is possible to set whether the system is to restart automatically after an alarm, or if the alarm must be reset manually. Restart can be delayed by an adjustable time. It is also possible to set a startup delay ensuring that the system reaches a steady state before the function becomes active.
Setting range · Activation of an analog input for the function. · Selection of the measured value to be monitored. · Setting of limit type (min./max.). · Setting of warning limit. · Setting of alarm limit.
Setting via control panel
Note
Analog inputs must be correctly set before the function is activated. See section 9.7.28 Analog inputs (4.3.8).
1. Mark the Settings menu with
2. Mark Monitoring functions with or , and press
3. Mark Limit 1 exceeded or Limit 2 exceeded with and press .
or ,
4. Mark Go to setting of analog input with press .
or , and
5. Select the analog input with or , and press .
6. Mark the setting of the analog input with or , and activate it with . The activation is indicated by a check mark in the box.
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7. Mark Measured value with or the display 4.3.8.1.1 appears.
, and press
. Now
8. Select the input with or , and press .
9. Press
to return to display 4.3.8.1.
10.Set the minimum sensor value with .
or , and save with
11.Set the maximum sensor value with .
or , and save with
12.Return by pressing
twice.
13.Mark Measured value to be monitored with or ., and press . Select the input with or , and press .
14.Return with .
15.Mark Min. limit or Max. limit with .
or ., and press
16.Mark Set delays with or , and press
17.Mark Time delay of function at start-up with
the time with
or , and save with .
or . Set
18.Mark Time delay of function during operation with or
. Set the time with
or , and save with .
19.Mark Time delay of function at reset with or
the time with
or , and save with .
. Set
20.Return with .
21.Mark Set warning limit with or , and press .
22.Mark Activated with or , and press .
23.Mark Warning limit with or or , and save with .
. Set the value with
24.Mark Manual or Auto with with .
or . Activate the function
25.Return with .
26.Mark Set alarm limit with or , and press .
27.Mark Activated with or , and press .
28.Mark Alarm limit with
or . Set the value with
or
, and save with .
29.Mark Manual or Auto with with .
or . Activate the function
30.Return with .
31.Mark Activated with the function.
or , and press
to activate
Factory setting The function is deactivated.
9.7.50 Pumps outside duty range (4.4.7)
Description
The function gives a warning if the duty point of the pumps moves outside the defined range. For instance, if the inlet pressure becomes lower than a minimum permissible value, thus causing a risk of cavitation for some pump types.
The warning is given with a set time delay. It is possible to set whether the warning is to be reset automatically or manually when the duty point comes within the defined duty range. It is also possible to set a relay output to be activated when the warning is given, and to be deactivated when the warning is reset.
This function requires that the discharge pressure and the inlet pressure (either measured or configured) or the differential pressure of the pumps is monitored, and that CU 351 contains valid pump data from either a GSC file or from manual input. See section 9.7.37 Pump curve data (4.3.19).
Setting range · Activation of the function. · Setting of manual or automatic reset. · Setting of warning delay.
Setting via control panel
1. Mark the Settings menu with
2. Mark Monitoring functions with or , and press .
3. Mark Pumps outside duty range with .
or , and press
4. Mark Manual or Auto with function with .
or , and activate the
5. Mark Warning delay with or . Set the time with or , and save with .
6. Mark Activated with the function.
or , and press
to activate
Factory setting The function is deactivated.
9.7.51 Pressure relief (4.4.8)
TM03 8984 4807 TM03 8986 4807
Fig. 98 Pressure relief
Fig. 97 Pumps outside duty range
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Description
The purpose of the function is to reduce the pressure in the pipework by opening a solenoid valve if it exceeds a set limit. If the pressure is not reduced within a given time, the solenoid valve will be closed, and a warning can be given.
P [psi]
1: Solenoid valve opens. 2: Solenoid valve closes. 3: Solenoid valve opens. 4: Warning is activated. 5: Solenoid valve closes, and warning is reset.
1
23
45
Valve opening pressure
Band
Valve opening pressure minus band
Fig. 99 Pressure relief
Warning Time [sec] delay
Setting range · Setting of digital output. · Setting of pressure to be monitored. · Setting of valve opening pressure. · Setting of band for valve opening pressure. · Setting of warning or alarm. · Activation of the function.
Setting via control panel
1. Mark the Settings menu with
2. Mark Monitoring functions with or , and press .
3. Mark Pressure relief with or , and press .
4. Mark Go to setting of digital output with press .
or , and
5. Select a digital output with or , and press .
6. Mark Pressure relief with or , and save with .
7. Return by pressing
twice.
8. Mark Pressure to be monitored with .
or , and press
9. Mark Discharge pressure, System pressure or External pressure with or , and save with .
10.Return with .
11.Mark Valve opening pressure with or . Set the
pressure with
or , and save with .
12.Mark Band, valve opening pressure with or
pressure with
or , and save with .
. Set the
13.Mark Warning, Deactivated or Activated with and press .
or ,
14.Mark Delay with
or . Set the time with
or ,
and save with . (Only to be set if warning has been
activated.)
15.Mark Activated with function.
or , and press
activate the
Factory setting The function is deactivated.
TM03 9206 3607 TM03 2295 4807
9.7.52 Functions, CU 351 (4.5)
Fig. 100 Functions, CU 351
Description
In this submenu, it is possible to make the basic settings of the CU 351.
CU 351 comes with most of these settings, or they are made at start-up and normally not to be changed.
The service language, English, can be activated for service purposes. If no buttons are touched for 15 minutes, the display will return to the language selected at start-up or to the language set in section 9.7.53 Display language (4.5.1).
Note
If the service language is selected, the symbol will be shown to the right of the top line of all displays.
Setting range · Activation of service language, British English. · Re-activation of start-up wizard.
(After start-up, the wizard is inactive.) · Selection of display language. · Selection of display units. · Setting date and time. · Selection of password for the menus Operation and Settings. · Setting of Ethernet communication. · Setting of GENIbus number. · Reading of software status.
9.7.53 Display language (4.5.1)
TM03 8987 4807
Fig. 101 Display language
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Description Here the language for the CU 351 display is selected.
Setting range · British English · German · Danish · Spanish · Finnish · French · Greek · Italian · Dutch · Polish · Portuguese · Russian · Swedish · Chinese · Korean · Japanese · Czech · Turkish.
Setting via control panel 1. Mark the Settings menu with . 2. Mark Functions, CU 351 with or , and press . 3. Mark Display language with or , and press . 4. Select language with or , and save with .
Factory setting The display language is English. It can be changed at start-up.
9.7.54 Display units (4.5.2)
Setting range
Parameter
Basic setting
Possible units
SI
US
Pressure
Differential pressure Head Level Flow rate Volume
Specific energy
Temperature Differential temperature Power Energy
bar
psi
kPa, MPa, mbar, bar, m, psi
m
psi
kPa, MPa, mbar, bar, m, psi
m
ft m, cm, ft, in
m
ft m, cm, ft, in
m3/h
gpm
m3/s, m3/h, l/s, gpm, yd3/s, yd3/min, yd3/h
m3
gal l, m3, gal, yd3
kWh/m3, Wh/gal, kWh/m3 Wh/gal Wh/kgal, BTU/gal,
HPh/gal
°C
°F K, °C, °F
K
KK
kW
HP W, kW, MW, HP
kWh
kWh
kWh, MWh, BTU, HPh
Note
If units are changed from SI to US or vice versa, all individually set parameters will be changed to the basic setting in question.
Setting via control panel 1. Mark the Settings menu with . 2. Mark Functions, CU 351 with or , and press . 3. Mark Units with or , and press . 4. Select the unit with or , and save with .
A check mark shows that the unit has been selected. 5. Select the measuring parameter with or , and press
to open the display for the measuring parameter. See the example.
TM03 8988 4807 TM03 2310 4807
Fig. 102 Display units
Description In this display, it is possible to select units for the various parameters. As basic setting, it is possible to select between SI and US units. It is also possible to select other units for the individual parameters.
Fig. 103 Example of selection of display units
6. Select the unit with or , and save with . A check mark shows that the unit has been selected.
Factory setting CU 351 has been set to US units from factory.
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9.7.55 Date and time (4.5.3)
9.7.56 Passwords (4.5.4)
TM03 8989 4807 TM03 2899 4807
Fig. 104 Date and time
Description In this display, date and time are set as well as how they are to be shown in the display. The clock has a built-in rechargeable voltage supply which can supply the clock for up to 20 days if the voltage supply to the Hydro MPC is interrupted. If the clock is without voltage for more than 20 days, it must be set again.
Setting range The date can be set as day, month and year. The time can be set as a 24-hour clock showing hours and minutes. There are three formats.
Examples of format
2005-09-27 13:49 27-09-2005 13:49 9/27/2005 1:49pm
It is also possible to select if Sunday or Monday is to be the first day of week.
Setting via control panel
1. Mark the Settings menu with .
2. Mark Functions, CU 351 with or , and press .
3. Mark Date and time with or , and press .
4. Mark Day, Month and Year with or , and set the date with or . Save with .
5. Mark Hours and Minutes with or with or . Save with .
, and set the time
6. Select the format with or , and save with .
7. Mark First day of week, Sunday or Monday with or ,
and save with
Factory setting Local time.
Note
If the booster has been without voltage for more than 20 days since it left the factory, the clock may have returned to the original setting: 01-012005 0:00.
Date and time may have been changed during the setting of Hydro MPC.
There is no automatic changeover to/from daylight-saving time.
Fig. 105 Passwords
Description
In this display it is possible to limit the access to the Operation and Settings menus by means of a password. If the access is limited, it is not possible to view or set any parameters in the menus.
The password must consist of four digits and may be used for both menus.
Note
If you have forgotten the password(s), contact Grundfos.
Setting via control panel 1. Mark the Settings menu with . 2. Mark Functions, CU 351 with or , and press . 3. Mark Password with or , and press . 4. Mark the password to be activated, and press . 5. Mark Enter password, and press .
Now the first digit of the password is flashing. 6. Select the digit with or , and save with .
Now the second digit of the password is flashing. 7. Repeat points 4 to 6 if it is necessary to activate the other
password.
Factory setting
Both passwords are deactivated. If a password is activated, the factory setting will be "6814".
9.7.57 Ethernet (4.5.5)
Fig. 106 Ethernet
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TM03 2298 4807
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Description The CU 351 is equipped with an Ethernet connection for communication with a computer, either directly or via Internet. For further information, see section 9.8.1 Ethernet.
9.7.58 GENIbus number (4.5.6)
9.7.59 Software status (4.5.9)
TM03 2297 4807 TM03 2296 4807
Fig. 107 GENIbus number
Description
CU 351 can communicate with external units via an RS-485 interface (option). For further information, see fig. 109 and section 9.8.2 GENIbus.
Communication is carried out according to the Grundfos bus protocol, GENIbus, and enables connection to a building management system or another external control system.
Operating parameters, such as setpoint and operating mode, can be set via the bus signal. Furthermore, status about important parameters, such as current value and input power, and fault indications can be read from the CU 351.
Contact Grundfos for further information.
Setting range The number can be set between 1 and 64.
Setting via control panel 1. Mark the Settings menu with 2. Mark Functions, CU 351 with 3. Mark GENIbus number with 4. Select the number with or
. or , and press .
or , and press . , and save with .
Factory setting No number is set ("").
Fig. 108 Software status
Description This display shows the status of the software installed in the CU 351. Furthermore, the version code and the product numbers of configuration files (GSC) read into the unit are shown. As it is a status display, no settings can be made.
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9.8 Data communication
CU 351 is equipped with a hardware enabling communication with external units, such as a computer, via an external GENIbus or Ethernet connection.
Third-party gateway
Grundfos G100 gateway
Intranet
External GENIbus connection
External GENIbus module (factory option)
Ethernet connection
Internet
TM03 2044 3505
Fig. 109 Data communication via external GENIbus and Ethernet connection
9.8.1 Ethernet
Ethernet is the most widely used standard for local networks (LAN). The standardisation of this technology has created some of the easiest and cheapest ways of creating communication between electrical units, for instance between computers or between computers and control units.
The web server of the CU 351 makes it possible to connect a computer to the CU 351 via an Ethernet connection. The user interface can thus be exported from the CU 351 to a computer so that the CU 351 and consequently the Hydro MPC booster system can be monitored and controlled externally.
Note
Grundfos recommends that you protect the connection to the CU 351 according to your safety requirements in consultation with the system administrator.
In order to use the web server, you must know the IP address of the CU 351. All network units must have a unique IP address in order to communicate with each other. The IP address of the CU 351 from factory is 192.168.0.102.
Alternatively to the factory-set IP address, it is possible to use a dynamic assignment of IP address. This is possible by activating a DHCP (Dynamic Host Configuration Protocol) either directly in the CU 351 or via the web server. See the example in fig. 110.
Fig. 110 Example of setting of Ethernet
Dynamic assignment of an IP address for the CU 351 requires a DHCP server in the network. The DHCP server assigns a number of IP addresses to the electrical units and makes sure that two units do not receive the same IP address. A traditional Internet browser is used for connection to the web server of the CU 351. If you want to use the factory-set IP address, no changes are required in the display. Open the Internet browser and enter the IP address of the CU 351.
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TM03 2047 3505
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In order to use dynamic assignment, the function must be
activated. Click
Use DHCP in the menu line. A check mark
next to the menu line shows that activation has been made.
After activation in the display, open the Internet and enter the
host name of the CU 351 instead of the IP address. The Internet
browser will now try to connect to the CU 351. The host name can
be read in the display, but can only be changed by either a GSC-
file (configuration file) or via a web server. See Change of
network setting on page 63.
Note To use DHCP, a host name is required. This is the first display shown when connecting to the CU 351.
Fig. 113 Network setting
Change of network setting When connection to the web server of the CU 351 has been established, it is possible to change the network setting.
TM03 2048 3505
Fig. 111 Connection to CU 351
Factory setting User name: admin Password: admin When user name and password have been entered, a Java Runtime Environment application starts up in the CU 351, provided that it has been installed on the computer in question. If this is not the case, but the computer is connected to Internet, then use the link on the screen to download and install the Java Runtime Environment application.
Fig. 114 Change of network setting
1. Press the icon >Network admin. 2. Enter the changes. 3. Press Submit to activate the changes.
TM03 2050 3505
TM03 2049 3505
Fig. 112 Display with link to the JavaScript® program
The Java Runtime Environment application will then export the CU 351 user interface (including display and operating panel) to the computer screen. It is now possible to monitor and control the CU 351 from the computer.
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Change of password
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TM03 2051 3505
Fig. 115 Change of password
1. Press the icon >Change password. 2. Enter the new password. 3. Press Submit to activate the new password.
9.8.2 GENIbus
By installing a GENIbus module it is possible to connect a CU 351 to an external network. The connection can take place via a GENIbus-based network or a network based on another protocol via a gateway. See fig. 109. For further information, contact Grundfos. The gateway may be a Grundfos G100 gateway or a third party gateway. For further information on the G100 gateway, see the G100 data booklet (publication number V7139522).
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10. External variable frequency drive
External variable frequency drives used in Hydro MPC booster system variants -F, -EF and -EDF come with the manufacturer's factory settings. See tables below.
At start-up, the factory settings must be changed to the Grundfos settings in the tables below.
In order not to affect the functions of the CU 351 at optimum operation, only the parameters shown should be adjusted. Other parameters should be as set from factory.
10.1 VLT 2800
Press [QUICK MENU] + [+] to access all parameters.
Parameter Function
Factory setting
Value or number in the display of VLT
2
Local/remote operation
3
Local reference
101 Torque characteristics
102 Motor power
103 Motor voltage
104 Motor frequency
105 Motor current
106 Rated motor speed
107 Automatic motor adaptation
128 Thermal motor protection
204 Minimum reference
205 Maximum reference
206 Ramp type
207 Ramp up time
208 Ramp down time
214 Reference function
215 Preset reference
302 Digital input
304 Digital input
305 Digital input6
323 Relay output
406 Automatic restart time
411 Switching frequency
* Thermistor function used for thermal protection of LC filter.
** For information about languages available, see relevant documentation.
*** Use data from the Hydro MPC booster set.
Factory setting of VLT 2800 To recall the factory settings of all parameters, follow one of the procedures below: 1. Set the parameter 620 to (3). 2. Disconnect the power supply. 3. Re-connect the power supply. 4. All parameters are now factory-set except from the fault log. or 1. Disconnect the power supply. 2. Press and hold [QUICK MENU] + [+] + [CHANGE DATA] and
re-connect the power supply. All parameters are now factory-set, including the fault log.
Grundfos setting
Function
Value or number in the display of VLT
Local/remote operation
0
Local reference
Default
Torque characteristics
2
Motor power
Motor nameplate in kW
Motor voltage
Motor nameplate
Motor frequency
Motor nameplate, Hz
Motor current
Motor nameplate, SFA
Rated motor speed
Motor nameplate RPM
Automatic motor adaptation 2
Thermal motor protection 4
Minimum reference
20 Hz
Maximum reference
60 Hz
Ramp type
2
Ramp up time
1.5 sec
Ramp down time
3 sec
Reference function
2
Preset reference
100
Digital input
7
Digital input
0
Digital input6
24
Relay output
1
Automatic restart time Switching frequency
10 sec 4500
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10.2 Danfoss VLT 8000 factory settings
Press [EXTEND MENU] to access all parameters.
Parameter
001 002 003 004 005 006 201 202 207 208 323 326
Function
Language Motor power Motor voltage Motor frequency Motor current Motor speed Minimum frequency Maximum frequency Ramp up time Ramp down time Relay 1 function Relay 2 function
Grundfos setting
Value
English
0
Motor nameplate
Motor nameplate
Motor nameplate
Motor nameplate (SFA)
Motor nameplate (RPM)
20 Hz
60 Hz
1.5 sec
3 sec
Ready signal
1
Running
3
10.3 Danfoss VLT 8000 extended menu programming
Parameter Function
Grundfos setting Value
007
Large readout
Frequency [Hz]
3
008
Small display readout
Motor voltage [V]
16
009
Small display readout
Motor current
5
010
Small display readout
Power [Hp]
6
101
Torque characteristics
VT low
2
113
Motor Preheater DC Current
0%
117
Motor Thermal Protection
ETR Trip 1
4
208
Automatic ramp-down
Disable
0
210
Reference type
External/preset
2
302
Pin 18
Start
1
303
Pin 19
Reverse and start
2
304
Pin 27
Safety interlock
3
308
Pin 53
Reference
1
309
Term. 53, min. scaling
0.0 V
310
Term. 53, max. scaling
10 V
325
Relay 01, off delay
1 sec.
400
Reset function
Automatic reset x 10
6
401
Automatic restart time
5 sec.
407
Switching frequency
4500
408
Interference reduction method
Fixed switching freq.
0
016
Lock for data change
Locked
1
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10.4 Danfoss VLT 8000 factory settings
Press [EXTEND MENU] to access all parameters.
Parameter
001 002 003 004 005 006 201 202 207 208 323 326
Function
Language Motor power Motor voltage Motor frequency Motor current Motor speed Minimum frequency Maximum frequency Ramp up time Ramp down time Relay 1 function Relay 2 function
Grundfos setting
Value
English
0
Motor nameplate
Motor nameplate
Motor nameplate
Motor nameplate (SFA)
Motor nameplate (RPM)
20 Hz
60 Hz
1.5 sec
3 sec
Ready signal
1
Running
3
10.5 Danfoss VLT 8000 extended menu programming
Parameter Function
Grundfos setting Value
007
Large readout
Frequency [Hz]
3
008
Small display readout
Motor voltage [V]
16
009
Small display readout
Motor current
5
010
Small display readout
Power [Hp]
6
101
Torque characteristics
VT low
2
113
Motor Preheater DC Current
0%
117
Motor Thermal Protection
ETR Trip 1
4
208
Automatic ramp-down
Disable
0
210
Reference type
External/preset
2
302
Pin 18
Start
1
303
Pin 19
Reverse and start
2
304
Pin 27
Safety interlock
3
308
Pin 53
Reference
1
309
Term. 53, min. scaling
0.0 V
310
Term. 53, max. scaling
10 V
325
Relay 01, off delay
1 sec.
400
Reset function
Automatic reset x 10
6
401
Automatic restart time
5 sec.
407
Switching frequency
4500
408
Interference reduction method
Fixed switching freq.
0
016
Lock for data change
Locked
1
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual 10.6 Baldor Smart motor settings
Section
Parameter
Level 2 blocks Output limts Output limts Output limts Output limts
Miscellaneous Motor data Motor data
Level 1 blocks Preset speed
Accel
Min. output frequency Max. output PK current limit PWM frequency Restart aut/man Motor voltage Motor rated amps
Preset speed #1 Accel #1
Decel rate
Decel #1
Output Input Input V/Hz and Boost
Opto output #1 Operating mode ANA CMD select V/Hz profile
Grundfos setting Value
12 Hz 60 Hz Max. of drive 6 kHz Auto 230 V SFA on nameplate
60 Hz CR 3 - CR 10 CR 15 - CR 90 CR 3 - CR 10 CR 15 - CR 90 Ready #1 2 wire / 7 spd Pot. / 0-10 V 67% sqr. law
1.5 sec. 2.0 sec. 3.0 sec. 4.0 sec.
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10.7 VLT FC 202
Press [EXTEND MENU] to access all parameters.
Parameter Function
Grundfos setting Value
001 002 003 020 021 022 023 024 100 103 121 122 123 124 125 190 302 303 304 310 313 341 342 412 414 419 511 513 540.0 542.0 610 611 614 615 1400 1401
Language Motor Speed Unit Regional Settings Display Line 1.1 Display Line 1.2 Display Line 1.3 Display Line 2 Large Display Line 3 Large Configuration Mode Torque Characteristics Motor Power [HP] Motor Voltage Motor Frequency Motor Current Motor Nominal Speed Motor Thermal Protection Minimum Reference Maximum Reference Reference Function Preset Reference Reference Site Ramp 1 Ramp up Time Ramp 1 Ramp down Time Motor Speed Low Limit [Hz] Motor Speed High Limit [Hz] Max Output Frequency Terminal 19 Digital Input Terminal 29 Digital Input Function Relay Off Delay, Relay Terminal 53 Low Voltage Terminal 53 High Voltage Terminal 53 Low Ref. / Feedb. Terminal 53 High Ref. / Feedb. Switching Pattern Switching Frequency
English Hz North America Small Power [hp] Small Motor Voltage Small Motor Current Frequency Speed [RMP] Open Loop Variable Torque Nameplate Nameplate Nameplate Nameplate Nameplate ETR trip 1 0.000 Hz 60.000 Hz Sum 100.00% Remote 1.50 s 3.00 s 0.0 Hz 60.0 Hz 65.0 Hz Start reversing Preset reference on Drive ready 2.00 s 0.00 V 10.00 V 20.000 Hz 60.000 Hz 60 AVM 5.0 kHz
0 1 1 1611 1612 1614 1615 1617 0 1
4
0 1
11 15 2
0 7
Factory setting of VLT FC 100 To recall the factory settings of all parameters, follow one of the procedures below: 1. Select parameter 14-22. 2. Press [OK]. 3. Select "Initialisation" (for NLCP select "2"). 4. Press [OK]. 5. Disconnect the power supply. 6. Reconnect the power supply. 7. All parameters are now factory-set, except RFI 1, protocol,
address, baud rate, minimum response delay, maximum response delay, maximum inter-char delay, operating data, historic log and fault log.
or 1. Disconnect the power supply. 2. Press and hold [STATUS] + [MAIN MENU] + [OK] and
reconnect the power supply. 3. All parameters are now factory-set, except operating hours,
the number of power-ups and overtemp's and overvolt's.
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11. Fault finding chart
Warning
Before making any connections in pumps, terminal boxes or breaker cabinet, make sure that the electricity supply has been switched off for at least 5 minutes and that it cannot be accidentally switched on.
Fault
Possible cause
Remedy
Current pressure is higher than or equal to the setpoint.
Wait until the pressure has dropped, or lower the pressure on the discharge side of the Hydro MPC, and check that the pumps start.
Electricity supply disconnected.
Connect the electricity supply.
Main switch cut out.
Cut in the main switch.
Pumps do not run when started.
Main switch is defective. Motor protection is activated.
Replace the main switch. Contact Grundfos.
Motor is defective.
Repair or replace the motor.
Pressure transmitter fault - Pressure transmitter is defective.
Replace the pressure transmitter. Transmitters with 0-20 mA or 4-20 mA output signals are monitored by the Hydro MPC.
- Cable is broken or short-circuited.
Repair or replace the cable.
The pumps start, but stop immediately. The operating pressure Dry running or no inlet pressure. is not reached.
Re-establish the supply of water to the Hydro MPC. When the inlet pressure has been re-established, the pumps will restart after 15 seconds.
The Hydro MPC is stopped and cannot restart.
Pressure transmitter fault - Pressure transmitter is defective.
- Cable is broken or short-circuited. CU 351 fault - Electricity supply disconnected.
Replace the pressure transmitter. Transmitters with 0-20 mA or 4-20 mA output signals are monitored by the Hydro MPC. Repair or replace the cable.
Connect the electricity supply.
- CU 351 defective.
Contact Grundfos.
Inlet pressure is too low.
Unstable water delivery from
Suction pipe or pumps partly blocked by
Hydro MPC (applies to unstable water impurities.
supply).
Pumps suck air.
Check the suction pipe and possible suction strainer.
Clean the suction pipes, strainer or pumps.
Check the suction pipe for leakages.
Pressure transmitter defective.
Replace the transmitter.
The valves are closed.
Open the valves.
Suction pipe or pumps blocked by impurities.
Clean the suction pipe or pumps.
Pumps are running, but deliver no water.
Non-return valve blocked in closed position.
Clean the non-return valve. The non-return valve must move freely.
Suction pipe leaky.
Check the suction pipe for leakages.
Air in suction pipe or pumps.
Vent and prime the pumps. Check the suction pipe for leakages.
The Hydro MPC is unable to reach the setpoint.
Too high consumption. Too many standby pumps selected. Pipe fracture or leakage in the system.
- Reduce consumption (if possible). - Install a bigger Hydro MPC booster system.
Reduce the number of standby pumps.
Check the system, and repair damages, if necessary.
Leakage from the shaft seal.
Shaft seal is defective.
Replace the shaft seal.
Height adjustment of pump shaft inaccurate. Readjust the shaft height.
The pumps are cavitating.
Clean the suction pipe/pumps and possibly the suction strainer.
Noise.
The pumps do not rotate freely (friction resistance) due to inaccurate height adjustment of the pump shaft.
Readjust the shaft height.
Very frequent starts and stops.
Wrong diaphragm tank precharge pressure. Set correct precharge pressure.
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12. Maintenance
Warning Before starting work on the pumps, make sure that the electricity supply has been switched off. Lock the main switch with a padlock to ensure that it cannot be accidentally switched on.
12.1 Pumps
Pump bearings and shaft seal are maintenance-free.
12.2 Motor bearings
Motors without grease nipples are maintenance-free. Motors with grease nipples should be lubricated with a hightemperature lithium-based grease. See the instructions on the fan cover of Grundfos motors. In the case of seasonal operation (motor is idle for more than 6 months of the year), it is recommended to grease the motor when the pump is taken out of operation.
12.3 CU 351
The CU 351 is maintenance-free. It must be kept clean and dry. Protect it against direct sunlight. Furthermore, the CU 351 must not be outside the ambient temperature range. See section 15. Technical data.
13. Frost protection
Pumps which are not being used during periods of frost should be drained to avoid damage. Drain the pump by loosening the vent screw in the pump head and by removing the drain plug from the base.
Warning Care must be taken to ensure that the escaping water does not cause injury to persons or damage to the motor or other components. In hot water installations, special attention should be paid to the risk of injury caused by scalding hot water. Do not tighten the vent screw and replace the drain plug until the pump is to be used again.
14. Taking out of operation
Switch off the main switch to take the booster system out of operation.
Warning The conductors in front of the main switch are still energised. Lock the main switch with a padlock to ensure that it cannot be accidentally switched on. Individual pumps are taken out of operation by switching off the corresponding motor-protective circuit breaker, automatic circuit breaker or fuse.
15. Technical data
15.1 Pressure
Inlet pressure Hydro MPC booster sets can operate with a positive inlet pressure (precharged pressure system) or with a negative inlet pressure (i.e vacuum at the inlet manifold). Calculation of the inlet pressure is recommended when · water is drawn through long pipes, · water is drawn from depths, · inlet conditions are poor.
Note
In this installation and operating instruction the term `inlet pressure' is defined as the pressure/ vacuum which can be measured immediately before the booster set.
To avoid cavitation, make sure that there is a minimum inlet pressure on the suction side of the booster set. The minimum inlet pressure in bar can be calculated as follows:
H = Pb NPSH Hf Hv Hs
Pb = Barometric pressure in feet (33.9 feet at sea level). In closed systems, Pb indicates system pressure in feet.
Hf = Friction loss in suction piping in feet. (At the highest flow the pump will be delivering).
Hv = Vapor pressure in feet. NPSH = Net Positive Suction Head in feet.
NPSH can be read from the NPSH curve at the maximum capacity at which the pump will run. (See installation and operating instructions for CR, CRI, CRN).
HS = Safety margin = minimum 2 feet. If "H" is calculated as positive, the pump can operate at a suction
of maximum "H" feet. If "H" is calculated as negative, an inlet pressure (psia) of minimum "H" feet is required.
Maximum inlet pressure
Pump
60 Hz CR(E) 5-7 CR(E) 10-3 CR(E) 15-3 CR(E) 20-3 CR(E) 32-2 CR(E) 45-2-1 CR(E) 64-2-1 CR 90-2-1
Maximum inlet pressure [psi]
145 116 145 145 58 145 145 218
Note
The maximum inlet pressure is determined by the construction of the pump, such as bearing pressure. For information about other CR pump sizes, see WebCAPS on www.grundfos.com.
Operating pressure As standard the maximum operating pressure is 230 psi [16 bar]. On request, Grundfos offers Hydro MPC booster systems with a maximum operating pressure higher than 230 psi [16 bar].
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15.2 Temperature
Liquid temperature: Ambient temperature:
32 °F to +158 °F 32 °F to +104 °F
15.3 Relative humidity
Max. relative humidity: 95 %
15.4 Sound pressure
For sound pressure level, see the installation and operating instructions for the CR pumps.
The sound pressure level for a number of pumps can be calculated as follows:
Lmax = Lmax = Lpump = n=
Lpump + (n 1) x 3 Maximum sound pressure level. Sound pressure level for one pump. Number of pumps.
16. Electrical data
Supply voltage See nameplate of the Hydro MPC. Backup fuse See the wiring diagram supplied with the Hydro MPC. Digital inputs
Open circuit voltage: Closed circuit current: Frequency range:
24 VDC 5 mA, DC 0-4 Hz
Note
All digital inputs are supplied with PELV voltage (Protective Extra-Low Voltage).
Analog inputs
Input current and voltage:
Tolerance: Repetitive accuracy: Input resistance, current: Input resistance, voltage, CU 351: Input resistance, voltage, IO 351:
Supply to sensor:
0-20 mA 4-20 mA 0-10 V ±3.3 % of full scale ±1% of full scale < 250 10 k ±10 % > 50 k ± 10 % 24 V, maximum 50 mA, short-circuit protected
Note
All analog inputs are supplied with PELV voltage (Protective Extra-Low Voltage).
Digital outputs (relay outputs)
Maximum contact load: Minimum contact load:
240 VAC, 2 A 5 VDC, 10 mA
All digital outputs are potential-free relay contacts.
Note
Some outputs have a common C terminal. For further information, see the wiring diagram supplied with the Hydro MPC.
Inputs for PTC sensor/thermal switch
For PTC sensors to DIN 44082. Thermal switches can also be connected.
Open circuit voltage: Closed circuit current:
12 VDC ±15 % 2.6 mA, DC
Note
Inputs for PTC sensors are electrically separated from the other inputs and outputs of the Hydro MPC.
17. Related documents
Further product information about Hydro MPC booster systems can be found in the following documents. All documents are available in WebCAPS on Grundfos' homepage, www.grundfos.com.
Title
Frequency
Publication number
Product Guide
Grundfos Hydro MPC Grundfos CR,CRI,CRN
60 Hz 60 Hz
Installation and operating instructions
CR, CRI, CRN
CRE, CRIE, CRNE, CRKE, SPKE, MTRE, CHIE *
60 Hz 60 Hz
Service documentation
Service instructions Service kit catalog
50/60 Hz 50/60 Hz
Other documentation
Wiring diagram**
-
L-BPQ-PG-01 L-CR-PG-001
L-CP-TL-003 L-MLE-TL-02
96646712 96488862
-
* Only relevant for Hydro MPC-E, -ED and -ES booster systems. ** A wiring diagram is supplied with the booster system.
18. Disposal
This product or parts of it must be disposed of in an environmentally sound way: 1. Use the public or private waste collection service. 2. If this is not possible, contact the nearest Grundfos company
or service workshop.
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3 Valves
SUPPLIER: MODEL:
Tyco Northgate 88 Frederick Street Northgate Qld 4013
Ph: (07) 3266 2255 Fax: (07) 3260 5221
150 Dia DF R.S Sluice Valve ACC
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4 Flowmeter
SUPPLIER:
Endress & Hauser Australia 2/35 Miles Platting Rd. Eight Mile Plains Qld 4113 Ph: (07) 3457 0200 Fax: (07) 3457 0299
MODEL:
DN150 PROMAG 50W1F
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Operating Instructions
Proline Promag 50
Electromagnetic Flow Measuring System
6
BA046D/06/en/03.05 50097090 Valid as of version: V 2.00.XX (Device software)
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Brief operating instructions
Proline Promag 50
Brief operating instructions
!
These brief operating instructions show you how to configure the measuring device quickly and easily:
Safety instructions
Installation
Wiring
Display and operating elements
Commissioning with "QUICK SETUP"
You can commission the measuring device quickly and easily, using the special "Quick Setup" menu. It enables to configure important basic functions using the local display, for example display language, measured variables, units engineering, type of signal, etc. The following adjustments can be made separately as necessary: Empty-pipe/full-pipe adjustment for empty pipe detection (EPD) Configuration of current output (active/passive)
Customer-specific cofiguration
Complex measuring operations necessitate additional functions that you can configure as necessary with the aid of the function matrix, and customize to suit the process parameters. All functions are described in detail, as is the function matrix itself, in the "Description of Device Functions" manual, which is a separate part of this Operating Instruction.
Page 7 Page 13 Page 47 Page 61 Page 80 ff.
Page 62
Note! Always start trouble-shooting with the checklist on Page 89, if faults occur after commissioning or during operation. The routine takes you directly to the cause of the problem and the appropriate remedial measures.
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"QUICK SETUP" commissioning
"QUICK SETUP" commissioning
ENDRESS+HAUSER
-+E ESC
E
++
HOME-POSITION
Quick Setup E+
QS Commission
Language
Defaults
Unit Volume flow Measuring
Mode
Current Output
Freq.-/ Pulse Output
Quit
Operation Mode
Assign Current
Current Span
Value 20 mA
Time Constant
Failsafe Mode
Frequency
Assign Frequency
End Value Freq.
Value f max Output Signal
Time Constant
Failsafe Mode
Pulse
Assign Pulse
Pulse Value
Pulse Width Output Signal
Failsafe Mode
Automatic parameterization of the display
Quit Quick Setup
F06-50xxxxxx-19-xx-xx-en-000
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"QUICK SETUP" commissioning
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Contents
Contents
1 Safety instructions . . . . . . . . . . . . . . . . . . . 7
1.1 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1.2 Installation, commissioning and operation . . . . . . . . 7 1.3 Operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1.4 Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1.5 Notes on safety conventions and icons . . . . . . . . . . . 8
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Device designation . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.1.1 Nameplate of the transmitter . . . . . . . . . . . 9 2.1.2 Nameplate of the sensor . . . . . . . . . . . . . 10 2.1.3 Nameplate, connections . . . . . . . . . . . . . 11
2.2 CE mark, declaration of conformity . . . . . . . . . . . . 11 2.3 Registered trademarks . . . . . . . . . . . . . . . . . . . . . . 12
3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1 Incoming acceptance, transport and storage . . . . . . 13 3.1.1 Incoming acceptance . . . . . . . . . . . . . . . . 13 3.1.2 Transport . . . . . . . . . . . . . . . . . . . . . . . . 13 3.1.3 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2 Installation conditions . . . . . . . . . . . . . . . . . . . . . . 15 3.2.1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . 15 3.2.2 Mounting location . . . . . . . . . . . . . . . . . . 15 3.2.3 Orientation . . . . . . . . . . . . . . . . . . . . . . . 17 3.2.4 Vibrations . . . . . . . . . . . . . . . . . . . . . . . . 18 3.2.5 Foundations, supports . . . . . . . . . . . . . . . 19 3.2.6 Adapters . . . . . . . . . . . . . . . . . . . . . . . . . 20 3.2.7 Nominal diameter and flow rate . . . . . . . 20 3.2.8 Length of connecting cable . . . . . . . . . . . 25
3.3 Installation instructions . . . . . . . . . . . . . . . . . . . . . 26 3.3.1 Installing the Promag W sensor . . . . . . . . 26 3.3.2 Installing the Promag P sensor . . . . . . . . . 33 3.3.3 Installing the Promag H sensor . . . . . . . . 39 3.3.4 Turning the transmitter housing . . . . . . . 42 3.3.5 Turning the local display . . . . . . . . . . . . . 43 3.3.6 Installing the wall-mount transmitter housing . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.4 Installation check . . . . . . . . . . . . . . . . . . . . . . . . . 46
4 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.1 Connecting the remote version . . . . . . . . . . . . . . . 47 4.1.1 Connecting Promag W / P / H . . . . . . . . 47 4.1.2 Cable specifications . . . . . . . . . . . . . . . . . 51
4.2 Connecting the measuring unit . . . . . . . . . . . . . . . 52 4.2.1 Transmitter . . . . . . . . . . . . . . . . . . . . . . . 52 4.2.2 Terminal assignment . . . . . . . . . . . . . . . . 54 4.2.3 HART connection . . . . . . . . . . . . . . . . . . 55
4.3 Potential equalisation . . . . . . . . . . . . . . . . . . . . . . . 56 4.3.1 Standard case . . . . . . . . . . . . . . . . . . . . . 56 4.3.2 Special cases . . . . . . . . . . . . . . . . . . . . . . 57
4.4 Degree of protection . . . . . . . . . . . . . . . . . . . . . . . 59 4.5 Electical connection check . . . . . . . . . . . . . . . . . . . 60
5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.1 Display and operating elements . . . . . . . . . . . . . . . 61 5.2 Brief operating instruction to the function matrix . . 62
5.2.1 General notes . . . . . . . . . . . . . . . . . . . . . 63 5.2.2 Enabling the programming mode . . . . . . . 63 5.2.3 Disabling the programming mode . . . . . . 63 5.3 Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 5.4 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 5.4.1 Operating options . . . . . . . . . . . . . . . . . . 66 5.4.2 Current device description files . . . . . . . . 67 5.4.3 Device and process variables . . . . . . . . . . 68 5.4.4 Universal / Common practice HART
commands . . . . . . . . . . . . . . . . . . . . . . . . 69 5.4.5 Device status / Error messages . . . . . . . . 74
6 Commissioning . . . . . . . . . . . . . . . . . . . . . 79
6.1 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 6.1.1 Switching on the measuring device . . . . . 79
6.2 Application-specific commissioning . . . . . . . . . . . . 80 6.2.1 "Commissioning" Quick Setup menu . . . . 80 6.2.2 Empty-pipe/full-pipe adjustment . . . . . . . 81 6.2.3 Current output: active/passive . . . . . . . . . 82
6.3 Data storage device (HistoROM) . . . . . . . . . . . . . . 82 6.3.1 HistoROM/S-DAT (sensor-DAT) . . . . . . . 82
7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . 83
7.1 Exterior cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 83 7.2 Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
8 Accessories . . . . . . . . . . . . . . . . . . . . . . . . 85
8.1 Device-specific accessories . . . . . . . . . . . . . . . . . . . 85 8.2 Measuring principle-specific accessories . . . . . . . . . 86 8.3 Communication-specific accessories . . . . . . . . . . . . 87 8.4 Communication-specific accessories . . . . . . . . . . . . 87
9 Trouble-shooting . . . . . . . . . . . . . . . . . . . 89
9.1 Trouble-shooting instructions . . . . . . . . . . . . . . . . . 89 9.2 System error messages . . . . . . . . . . . . . . . . . . . . . . 90 9.3 Process error messages . . . . . . . . . . . . . . . . . . . . . . 93 9.4 Process errors without messages . . . . . . . . . . . . . . 94 9.5 Response of outputs to errors . . . . . . . . . . . . . . . . . 95 9.6 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 9.7 Removing and installing printed circuit boards . . . . 98 9.8 Replacing the device fuse . . . . . . . . . . . . . . . . . . . 102 9.9 Replacing exchangeable measuring electrodes . . . 103 9.10 Software history . . . . . . . . . . . . . . . . . . . . . . . . . . 105
10 Technical data . . . . . . . . . . . . . . . . . . . . . 107
10.1 Technical data at a glance . . . . . . . . . . . . . . . . . . 107 10.1.1 Application . . . . . . . . . . . . . . . . . . . . . . 107 10.1.2 Function and system design . . . . . . . . . . 107
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10.1.3 Input . . . . . . . . . . . . . . . . . . . . . . . . . . 107 10.1.4 Output . . . . . . . . . . . . . . . . . . . . . . . . . 108 10.1.5 Power supply . . . . . . . . . . . . . . . . . . . . 108 10.1.6 Performance characteristics . . . . . . . . . 109 10.1.7 Operating conditions . . . . . . . . . . . . . . 110 10.1.8 Mechanical construction . . . . . . . . . . . 114 10.1.9 Human interface . . . . . . . . . . . . . . . . . 118 10.1.10 Certificates and approvals . . . . . . . . . . . 118 10.1.11 Ordering information . . . . . . . . . . . . . . 119 10.1.12 Accessories . . . . . . . . . . . . . . . . . . . . . . 119 10.1.13 Supplementary documentation . . . . . . . 119
11 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
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1 Safety instructions
1 Safety instructions
1.1 Designated use
The measuring device described in this Operating Manual is to be used only for measuring the flow rate of conductive fluids in closed pipes. A minimum conductivity of 20 µS/cm is required for measuring demineralized water. Most fluids can be metered, provided they have a minimum conductivity of 5 µS/cm, for example: · acids, alkalis, · drinking water, wastewater, sewage sludge, · milk, beer, wine, mineral water, etc.
Resulting from incorrect use or from use other than that designated the operational safety of the measuring devices can be suspended. The manufacturer accepts no liability for damages being produced from this.
1.2 Installation, commissioning and operation
Note the following points: · Installation, connection to the electricity supply, commissioning and maintenance of the device
must be carried out by trained, qualified specialists authorized to perform such work by the facility's owner-operator. The specialist must have read and understood this Operating Manual and must follow the instructions it contains. · The device must be operated by persons authorized and trained by the facility's owner-operator. Strict compliance with the instructions in the Operating Manual is mandatory. · Endress+Hauser will be happy to assist in clarifying the chemical resistance properties of parts wetted by special fluids, including fluids used for cleaning. · If welding work is performed on the piping system, do not ground the welding appliance through the Promag flowmeter. · The installer must ensure that the measuring system is correctly wired in accordance with the wiring diagrams. The transmitter must be grounded, unless the power supply is galvanically insulated. · Invariably, local regulations governing the opening and repair of electrical devices apply.
1.3 Operational safety
Note the following points: · Measuring systems for use in hazardous environments are accompanied by separate Ex documen-
tation, which is an integral part of this Operating Manual. Strict compliance with the installation instructions and ratings as stated in this supplementary documentation is mandatory. The symbol on the front of this supplementary Ex documentation indicates the approval and the certification body ( 0 Europe, 2 USA, 1 Canada). · The measuring device complies with the general safety requirements in accordance with EN 61010, the EMC requirements of EN 61326/A1, and NAMUR recommendation NE 21. · Depending on the application, the seals of the process connections of the Promag H sensor require periodic replacement. · The manufacturer reserves the right to modify technical data without prior notice. Your Endress+Hauser distributor will supply you with current information and updates to this Operating Manual.
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Proline Promag 50
!
#
1.4 Return
The following procedures must be carried out before a flowmeter requiring repair or calibration, for example, is returned to Endress+Hauser:
· Always enclose a duly completed "Declaration of contamination" form. Only then can Endress+Hauser transport, examine and repair a returned device.
· Enclose special handling instructions if necessary, for example a safety data sheet as per EN 91/155/EEC.
· Remove all residues. Pay special attention to the grooves for seals and crevices which could contain residues. This is particularly important if the substance is hazardous to health, e.g. flammable, toxic, caustic, carcinogenic, etc.
Note! You will find a preprinted "Declaration of contamination" form at the back of this manual.
Warning! · Do not return a measuring device if you are not absolutely certain that all traces of hazardous
substances have been removed, e.g. substances which have penetrated crevices or diffused through plastic. · Costs incurred for waste disposal and injury (burns, etc.) due to inadequate cleaning will be charged to the owner-operator.
#
"
!
1.5 Notes on safety conventions and icons
The devices are designed to meet state-of-the-art safety requirements, have been tested, and left the factory in a condition in which they are safe to operate. The devices comply with the applicable standards and regulations in accordance with EN 61010 "Protection Measures for Electrical Equipment for Measurement, Control, Regulation and Laboratory Procedures". They can, however, be a source of danger if used incorrectly or for other than the designated use. Consequently, always pay particular attention to the safety instructions indicated in this Operating Manual by the following icons:
Warning! "Warning" indicates an action or procedure which, if not performed correctly, can result in injury or a safety hazard. Comply strictly with the instructions and proceed with care.
Caution! "Caution" indicates an action or procedure which, if not performed correctly, can result in incorrect operation or destruction of the device. Comply strictly with the instructions.
Note! "Note" indicates an action or procedure which, if not performed correctly, can have an indirect effect on operation or trigger an unexpected response on the part of the device.
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2 Identification
2 Identification
2.1 Device designation
The "Promag 50" flow measuring system consists of the following components: · Promag 50 transmitter · Promag W, Promag P or Promag H sensor
In the compact version, transmitter and sensor form a single mechanical unit; in the remote version they are installed separately.
2.1.1 Nameplate of the transmitter
67
PROMAG 50
1
Order Code: 50P1H-XXXXXXXXXXXX Ser.No.: 12345678901
TAG No.: ABCDEFGHJKLMNPQRST
2
16-62VDC/20-55VAC 50-60Hz
15VA/W
3
EPD/MSU
4
I-OUT (HART), f-OUT
STATUS-OUT, STATUS-IN
5
IP67 / NEMA/Type 4X
i
-20°C (-4°F) <Tamb<+60°C (+140°F)
Pat. UK EP 541 878 EP 618 680 Pat. UK 2 084 740 EP 219 725 EP 521 169 Pat. US 5,323,156 5,479,007 Pat. US 4,382,387 4,704,908 5,351,554
Fig. 1: Nameplate specifications for the "Promag 50" transmitter (example)
F06-50xxxxxx-18-06-xx-xx-000
1 Ordering code/serial number: See the specifications on the order confirmation for the meanings of the individual letters and digits.
2 Power supply / frequency: 16...62 V DC / 20...55 V AC / 50...60 Hz Power consumption: 15 VA / W
3 Additional functions and software: EPD/MSU: with Empty Pipe Detection ECC: with Electrode Cleaning Circuitry
4 Outputs / inputs: I-OUT (HART): with current output (HART) f-OUT: with pulse/frequency output STATUS-IN: with status input (auxiliary input) STATUS-OUT: with status output (switch output)
5 Reserved for information on special products 6 Ambient temperature range 7 Degree of protection
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2.1.2 Nameplate of the sensor
PROMAG P
1
Order Code: XXP1H-XXXXXXXXXXXX
Ser.No.: 12345678901
2
TAG No.: ABCDEFGHJKLMNPQRST
3
K-factor: 0.5328/-5 DN100 DIN/EN PN16
4
Materials: PFA / 1.4435
5
TMmax.: 150°C/300°F EPD/MSÜ, R/B
6
7
8
-20°C (-4°F)<Tamb<+60°C (+140°F)
NEMA/Type4X
9
Pat. US 4,382,387 4,704,908 5,540,103
10
11
Fig. 2: Nameplate specifications for the "Promag" sensor (example)
F06-xxxxxxxx-18-05-xx-xx-000
1 Ordering code/serial number: See the specifications on the order confirmation for the meanings of the individual letters and digits.
2 Calibration factor: 0.5328; zero point: -5
3 Nominal diameter: DN 100 Pressure rating: EN (DIN) PN 16 bar
4 TMmax +150 °C (max. fluid temperature) 5 Materials:
Lining: PFA Measuring electrodes: stainless steel 1.4435 6 Additional information (examples): EPD/MSU: with Empty Pipe Detection electrode R/B: with reference electrode 7 Reserved for information on special products 8 Ambient temperature range 9 Degree of protection 10 Reserved for additional information on device version (approvals, certificates) 11 Flow direction
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2.1.3 Nameplate, connections
2 Identification
See operating manual Betriebsanleitung beachten Observer manuel d'instruction
A: active P: passive NO: normally open contact NC: normally closed contact
1
Ser.No.: 12345678912
12
Supply /
4
Versorgung /
Tension d'alimentation
L1/L+ N/LPE
I-OUT (HART)
Active: 0/4...20mA, RL max. = 700 Ohm Passive: 4...20mA, max. 30VDC, Ri < 150 Ohm (HART: RL.min. = 250 OHM)
f-OUT
fmax = 1kHz Passive: 30VDC, 250mA
A P
5
Passive: 30VDC, 250mA
STATUS-OUT
X
3...30VDC, Ri = 5kOhm
STATUS-IN
X
ex-works Version info
Update 1
Update 2
6
Device SW: XX.XX.XX
7
Communication: XXXXXXXXXX
8
Revision: XX.XX.XX
9
Date: DD.MMM.YYYY
319475-00XX
10
Fig. 3: Nameplate specifications for Proline transmitter (example)
1 Serial number 2 Possible configuration of current output 3 Possible configuration of relay contacts 4 Terminal assignment, cable for power supply: 85...260 V AC, 20...55 V AC, 16...62 V DC
Terminal No. 1: L1 for AC, L+ for DC Terminal No. 2: N for AC, L- for DC 5 Signals present at inputs and outputs, possible configuration and terminal assignment (20...27), see also "Electrical values of inputs/outputs" 6 Version of device software currently installed 7 Installed communication type, e.g.: HART, PROFIBUS PA, etc. 8 Information on current communication software (Device Revision and Device Description), e.g.: Dev. 01 / DD 01 for HART 9 Date of installation 10 Current updates to data specified in points 6 to 9
20(+) / 21(-) 22(+) / 23(-) 24(+) / 25(-) 26(+) / 27(-)
2 3
A0000963
2.2 CE mark, declaration of conformity
The devices are designed to meet state-of-the-art safety requirements in accordance with sound engineering practice. They have been tested and left the factory in a condition in which they are safe to operate. The devices comply with the applicable standards and regulations in accordance with EN 61010 "Protection Measures for Electrical Equipment for Measurement, Control, Regulation and Laboratory Procedures" and with the EMC reqiurements of EN 61326/A1. The measuring system described in this Operating Manual is therefore in conformity with the statutory requirements of the EC Directives. Endress+Hauser confirms successful testing of the device by affixing to it the CE mark.
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2.3 Registered trademarks
KALREZ ®, VITON ® are registered trademarks of E.I. Du Pont de Nemours & Co., Wilmington, USA TRI-CLAMP ® is a registered trademark of Ladish & Co., Inc., Kenosha, USA HART ® is a registered trademark of HART Communication Foundation, Austin, USA HistoROMTM, S-DAT®, ToF Tool - Fieldtool® Package, Fieldcheck®, Applicator® are registered trademarks of Endress+Hauser Flowtec AG, Reinach, CH
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3 Installation
3 Installation
3.1 Incoming acceptance, transport and storage
3.1.1 Incoming acceptance
· Check the packaging and the contents for damage. · Check the shipment, make sure nothing is missing and that the scope of supply matches your
order.
"
#
3.1.2 Transport
The following instructions apply to unpacking and to transporting the device to its final location: · Transport the devices in the containers in which they are delivered. · Do not remove the protective plates or caps on the process connections until the device is ready
to install. This is particularly important in the case of sensors with PTFE linings.
Special notes on flanged devices
Caution! · The wooden covers mounted on the flanges before the device leaves the factory protect the linings
on the flanges during storage and transportation. Do not remove these covers until immediately before the device is installed in the pipe. · Do not lift flanged devices by the transmitter housing, or the connection housing in the case of the remote version.
Transporting flanged devices (DN 300): Use webbing slings slung round the two process connections (Fig. 4). Do not use chains, as they could damage the housing.
Warning! Risk of injury if the measuring device slips. The center of gravity of the assembled measuring device might be higher than the points around which the slings are slung. At all times, therefore, make sure that the device does not unexpectedly turn around its axis or slip.
Fig. 4: Transporting transmitters with DN 300
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Transporting flanged devices (DN 350): Use only the metal eyes on the flanges for transporting the device, lifting it and positioning the sensor in the piping.
"
Caution! Do not attempt to lift the sensor with the tines of a fork-lift truck beneath the metal casing. This
would buckle the casing and damage the internal magnetic coils.
Fig. 5: Transporting sensors with DN 350
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3.1.3 Storage
Note the following points: · Pack the measuring device in such a way as to protect it reliably against impact for storage
(and transportation). The original packaging provides optimum protection. · The storage temperature corresponds to the operating temperature range of the measuring
transmitter and the appropriate measuring sensors. · The measuring device must be protected against direct sunlight during storage in order to avoid
unacceptably high surface temperatures. · Choose a storage location where moisture does not collect in the measuring device. This will help
prevent fungus and bacteria infestation which can damage the liner. · Do not remove the protective plates or caps on the process connections until you are ready to
install the device. This is particularly important in the case of sensors with PTFE linings.
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3.2 Installation conditions
3.2.1 Dimensions
All the dimensions and lengths of the sensor and transmitter are provided in the separate documentation "Technical Information".
3.2.2 Mounting location
Correct measuring is possible only if the pipe is full. Avoid the following locations: · Highest point of a pipeline. Risk of air accumulating · Directly upstream a free pipe outlet in a vertical pipeline.
Fig. 6: Location
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Installation of pumps Do not install the sensor on the intake side of a pump. This precaution is to avoid low pressure and the consequent risk of damage to the lining of the measuring tube. Information on the lining's resistance to partial vacuum can be found on Page 113.
It might be necessary to install pulse dampers in systems incorporating reciprocating, diaphragm or peristaltic pumps. Information on the measuring system's resistance to vibration and shock can be found on Page 110.
Fig. 7: Installation of pumps
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Partially filled pipes Partially filled pipes with gradients necessitate a drain-type configuration. The Empty Pipe Detection function (see Page 81) offers additional protection by detecting empty or partially filled pipes.
"
Caution! Risk of solids accumulating. Do not install the sensor at the lowest point in the drain.
It is advisable to install a cleaning valve.
Fig. 8: Installation in partially filled pipe
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Down pipes Install a siphon or a vent valve downstream of the sensor in down pipes longer than 5 meters. This precaution is to avoid low pressure and the consequent risk of damage to the lining of the measuring tube. These measures also prevent the system losing prime, which could cause air inclusions. Information on the lining's resistance to partial vacuum can be found on Page 113.
Fig. 9: Measures for installation in a down pipe (a = vent valve; b = siphon)
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3.2.3 Orientation
An optimum orientation position helps avoid gas and air accumulations and deposits in the measuring tube. Promag, nevertheless, supplies a range of functions and accessories for correct measuring of problematic fluids: · Electrode Cleaning Circuit (ECC) for applications with accretive fluids, e.g. electrically conduc-
tive deposits "Description of Device Functions" manual. · Empty Pipe Detection (EPD) ensures the detection of partially filled measuring tubes, e.g. in the
case of degassing fluids or varying process pressure (see Page 81) · Exchangeable Measuring Electrodes for abrasive fluids (see Page 103)
Vertical orientation This is the ideal orientation for self-emptying piping systems and for use in conjunction with Empty Pipe Detection.
Fig. 10: Vertical orientation
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Horizontal orientation The measuring electrode plane should be horizontal. This prevents brief insulation of the two electrodes by entrained air bubbles.
"
Caution! Empty Pipe Detection functions correctly only when the measuring device is installed horizontally
and the transmitter housing is facing upward (Fig. 11). Otherwise there is no guarantee that Empty
Pipe Detection will respond if the measuring tube is only partially filled or empty.
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Fig. 11: Horizontal orientation
1 EPD electrode for the detection of empty pipes (not with Promag H, DN 2...4) 2 Measurement electrodes for the signal acquisition 3 Reference electrode for the potential equalisation (not with Promag H)
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Inlet and outlet runs If possible, install the sensor well clear of fittings such as valves, T-pieces, elbows, etc. Compliance with the following requirements for the inlet and outlet runs is necessary in order to ensure measuring accuracy. · Inlet run 5 x DN · Outlet run 2 x DN
Fig. 12: Inlet and outlet runs
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3.2.4 Vibrations
Secure the piping and the sensor if vibration is severe.
"
Caution! It is advisable to install sensor and transmitter separately if vibration is excessively severe. Informa-
tion on resistance to vibration and shock can be found on Page 110.
> 10 m
Fig. 13: Measures to prevent vibration of the measuring device
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3.2.5 Foundations, supports
If the nominal diameter is DN 350, mount the transmitter on a foundation of adequate load-bearing strength.
"
Caution! Risk of damage. Do not support the weight of the sensor on the metal casing:
the casing would buckle and damage the internal magnetic coils.
Fig. 14: Correct support for large nominal diameters (DN 350)
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!
3.2.6 Adapters
Suitable adapters to DIN EN 545 (double-flange reducers) can be used to install the sensor in largerdiameter pipes. The resultant increase in the rate of flow improves measuring accuracy with very slow-moving fluids.
The nomogram shown here can be used to calculate the pressure loss caused by cross-section reduction:
Note! The nomogram applies to fluids of viscosity similar to water.
1. Calculate the ratio of the diameters d/D. 2. From the nomogram read off the pressure loss as a function of flow velocity
(downstream from the reduction) and the d/D ratio.
max. 8°
dD
[mbar] 100
10
1
8 m/s 7 m/s 6 m/s 5 m/s 4 m/s 3 m/s 2 m/s
1 m/s
0.5 0.6 0.7 0.8 0.9 d / D
!
Fig. 15: Pressure loss due to adapters
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3.2.7 Nominal diameter and flow rate
The diameter of the pipe and the flow rate determine the nominal diameter of the sensor. The optimum velocity of flow is 2...3 m/s. The velocity of flow (v), moreover, has to be matched to the physical properties of the fluid: · v < 2 m/s: for abrasive fluids such as potter's clay, lime milk, ore slurry, etc. · v > 2 m/s: for fluids producing build-up such as wastewater sludge, etc.
Note! Flow velocity can be increased, if necessary, by reducing the nominal diameter of the sensor (see Chap. 3.2.6).
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Promag W
Flow rate characteristic values Promag W (SI units)
Nominal diameter
[mm] 25 32 40 50 65 80 100 125 150 200 250 300 350 400 450 500 600 700 800 900 1000 - 1200 1400 - 1600 - 1800 - 2000
[inch] 1"
1 1/4" 1 1/2"
2" 2 1/2"
3" 4" 5" 6" 8" 10" 12" 14" 16" 18" 20" 24" 28" 30" 32" 36" 40" 42" 48" 54" 60" 66" 72" 78"
Recommended flow rate
min./max. full scale value (v ~ 0.3 or 10 m/s) 9...300 dm3/min 15...500 dm3/min 25...700 dm3/min 35...1100 dm3/min 60...2000 dm3/min 90...3000 dm3/min 145...4700 dm3/min 220...7500 dm3/min 20...600 m3/h 35...1100 m3/h 55...1700 m3/h 80...2400 m3/h 110...3300 m3/h 140...4200 m3/h 180...5400 m3/h 220...6600 m3/h 310...9600 m3/h
420...13500 m3/h 480...15000 m3/h 550...18000 m3/h 690...22500 m3/h 850...28000 m3/h 950...30000 m3/h 1250...40000 m3/h 1550...50000 m3/h 1700...55000 m3/h 1950...60000 m3/h 2200...70000 m3/h 2500...80000 m3/h 2800...90000 m3/h 3300...100000 m3/h 3400...110000 m3/h
Factory setting
Full scale value (v ~ 2.5 m/s)
75 dm3/min 125 dm3/min 200 dm3/min 300 dm3/min 500 dm3/min 750 dm3/min 1200 dm3/min 1850 dm3/min 150 m3/h 300 m3/h 500 m3/h 750 m3/h 1000 m3/h 1200 m3/h 1500 m3/h 2000 m3/h 2500 m3/h 3500 m3/h 4000 m3/h 4500 m3/h 6000 m3/h 7000 m3/h 8000 m3/h 10000 m3/h 13000 m3/h 14000 m3/h 16000 m3/h 18000 m3/h 20500 m3/h 23000 m3/h 28500 m3/h 28500 m3/h
Pulse value (~ 2 pulse/s)
0.50 dm3 1.00 dm3 1.50 dm3 2.50 dm3 5.00 dm3 5.00 dm3 10.00 dm3 15.00 dm3 0.025 m3 0.05 m3 0.05 m3 0.10 m3 0.10 m3 0.15 m3 0.25 m3 0.25 m3 0.30 m3 0.50 m3 0.50 m3 0.75 m3 0.75 m3 1.00 m3 1.00 m3 1.50 m3 1.50 m3 2.00 m3 2.00 m3 2.50 m3 2.50 m3 3.00 m3 3.50 m3 3.50 m3
Low flow cutoff (v ~ 0.04 m/s)
1 dm3/min 2 dm3/min 3 dm3/min 5 dm3/min 8 dm3/min 12 dm3/min 20 dm3/min 30 dm3/min 2.5 m3/h 5.0 m3/h 7.5 m3/h 10 m3/h 15 m3/h 20 m3/h 25 m3/h 30 m3/h 40 m3/h 50 m3/h 60 m3/h 75 m3/h 100 m3/h 125 m3/h 125 m3/h 150 m3/h 200 m3/h 225 m3/h 250 m3/h 300 m3/h 325 m3/h 350 m3/h 450 m3/h 450 m3/h
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Flow rate characteristic values Promag W (US units)
Nominal diameter
[inch] 1"
1 1/4" 1 1/2"
2" 2 1/2"
3" 4" 5" 6" 8" 10" 12" 14" 16" 18" 20" 24" 28" 30" 32" 36" 40" 42" 48" 54" 60" 66" 72" 78"
[mm] 25 32 40 50 65 80 100 125 150 200 250 300 350 400 450 500 600 700 800 900 1000 - 1200 1400 - 1600 - 1800 - 2000
Recommended flow rate
min./max. full scale value (v ~ 0.3 or 10 m/s) 2.5...80 gal/min 4...130 gal/min 7...190 gal/min 10...300 gal/min 16...500 gal/min 24...800 gal/min 40...1250 gal/min 60...1950 gal/min 90...2650 gal/min 155...4850 gal/min 250...7500 gal/min 350...10600 gal/min 500...15000 gal/min 600...19000 gal/min 800...24000 gal/min
1000...30000 gal/min 1400...44000 gal/min 1900...60000 gal/min 2150...67000 gal/min 2450...80000 gal/min 3100...100000 gal/min 3800...125000 gal/min 4200...135000 gal/min 5500...175000 gal/min
9...300 Mgal/d 10...340 Mgal/d 12...380 Mgal/d 13...450 Mgal/d 14...500 Mgal/d 16...570 Mgal/d 18...650 Mgal/d 20...700 Mgal/d
Factory setting
Full scale value (v ~ 2.5 m/s)
18 gal/min 30 gal/min 50 gal/min 75 gal/min 130 gal/min 200 gal/min 300 gal/min 450 gal/min 600 gal/min 1200 gal/min 1500 gal/min 2400 gal/min 3600 gal/min 4800 gal/min 6000 gal/min 7500 gal/min 10500 gal/min 13500 gal/min 16500 gal/min 19500 gal/min 24000 gal/min 30000 gal/min 33000 gal/min 42000 gal/min 75 Mgal/d 85 Mgal/d 95 Mgal/d 110 Mgal/d 120 Mgal/d 140 Mgal/d 175 Mgal/d 175 Mgal/d
Pulse value (~ 2 pulse/s)
0.20 gal 0.20 gal 0.50 gal 0.50 gal
1 gal 2 gal 2 gal 5 gal 5 gal 10 gal 15 gal 25 gal 30 gal 50 gal 50 gal 75 gal 100 gal 125 gal 150 gal 200 gal 225 gal 250 gal 250 gal 400 gal 0.0005 Mgal 0.0005 Mgal 0.0005 Mgal 0.0008 Mgal 0.0008 Mgal 0.0008 Mgal 0.001 Mgal 0.001 Mgal
Low flow cutoff (v ~ 0.04 m/s) 0.25 gal/min 0.50 gal/min 0.75 gal/min 1.25 gal/min 2.0 gal/min 2.5 gal/min 4.0 gal/min 7.0 gal/min 12 gal/min 15 gal/min 30 gal/min 45 gal/min 60 gal/min 60 gal/min 90 gal/min 120 gal/min 180 gal/min 210 gal/min 270 gal/min 300 gal/min 360 gal/min 480 gal/min 600 gal/min 600 gal/min 1.3 Mgal/d 1.3 Mgal/d 1.3 Mgal/d 1.7 Mgal/d 2.2 Mgal/d 2.6 Mgal/d 3.0 Mgal/d 3.0 Mgal/d
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Promag P
Flow rate characteristic values Promag P (SI units)
Nominal diameter
[mm] 15 25 32 40 50 65 80 100 125 150 200 250 300 350 400 450 500 600
[inch] 1/2"
1" 1 1/4" 1 1/2"
2" 2 1/2"
3" 4" 5" 6" 8" 10" 12" 14" 16" 18" 20" 24"
Recommended flow rate
min./max. full scale value (v ~ 0.3 or 10 m/s) 4...100 dm3/min 9...300 dm3/min 15...500 dm3/min 25...700 dm3/min 35...1100 dm3/min 60...2000 dm3/min 90...3000 dm3/min
145...4700 dm3/min 220...7500 dm3/min
20...600 m3/h 35...1100 m3/h 55...1700 m3/h 80...2400 m3/h 110...3300 m3/h 140...4200 m3/h 180...5400 m3/h 220...6600 m3/h 310...9600 m3/h
Factory setting
Full scale value (v ~ 2.5 m/s)
25 dm3/min 75 dm3/min 125 dm3/min 200 dm3/min 300 dm3/min 500 dm3/min 750 dm3/min 1200 dm3/min 1850 dm3/min 150 m3/h 300 m3/h 500 m3/h 750 m3/h 1000 m3/h 1200 m3/h 1500 m3/h 2000 m3/h 2500 m3/h
Pulse value (~ 2 pulse/s)
0.20 dm3 0.50 dm3 1.00 dm3 1.50 dm3 2.50 dm3 5.00 dm3 5.00 dm3 10.00 dm3 15.00 dm3 0.025 m3 0.05 m3 0.05 m3 0.10 m3 0.10 m3 0.15 m3 0.25 m3 0.25 m3 0.30 m3
Low flow cutoff (v ~ 0.04 m/s) 0.5 dm3/min
1 dm3/min 2 dm3/min 3 dm3/min 5 dm3/min 8 dm3/min 12 dm3/min 20 dm3/min 30 dm3/min 2.5 m3/h 5.0 m3/h 7.5 m3/h 10 m3/h 15 m3/h 20 m3/h 25 m3/h 30 m3/h 40 m3/h
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Flow rate characteristic values Promag P (US units)
Nominal diameter
[inch] 1/2"
1" 1 1/4" 1 1/2"
2" 2 1/2"
3" 4" 5" 6" 8" 10" 12" 14" 16" 18" 20" 24"
[mm] 15 25 32 40 50 65 80 100 125 150 200 250 300 350 400 450 500 600
Recommended flow rate
min./max. full scale value (v ~ 0.3 or ~ 10 m/s) 1.0...27 gal/min 2.5...80 gal/min 4...130 gal/min 7...190 gal/min 10...300 gal/min 16...500 gal/min 24...800 gal/min 40...1250 gal/min 60...1950 gal/min 90...2650 gal/min 155...4850 gal/min 250...7500 gal/min 350...10600 gal/min 500...15000 gal/min 600...19000 gal/min 800...24000 gal/min
1000...30000 gal/min 1400...44000 gal/min
Factory setting
Full scale value (v ~ 2.5 m/s)
6 gal/min 18 gal/min 30 gal/min 50 gal/min 75 gal/min 130 gal/min 200 gal/min 300 gal/min 450 gal/min 600 gal/min 1200 gal/min 1500 gal/min 2400 gal/min 3600 gal/min 4800 gal/min 6000 gal/min 7500 gal/min 10500 gal/min
Pulse value (~ 2 pulse/s)
0.05 gal 0.20 gal 0.20 gal 0.50 gal 0.50 gal
1 gal 2 gal 2 gal 5 gal 5 gal 10 gal 15 gal 25 gal 30 gal 50 gal 50 gal 75 gal 100 gal
Low flow cutoff (v ~ 0.04 m/s) 0.10 gal/min 0.25 gal/min 0.50 gal/min 0.75 gal/min 1.25 gal/min 2.0 gal/min 2.5 gal/min 4.0 gal/min 7.0 gal/min 12 gal/min 15 gal/min 30 gal/min 45 gal/min 60 gal/min 60 gal/min 90 gal/min 120 gal/min 180 gal/min
Promag H
Flow rate characteristic values Promag H (SI units)
Nominal diameter
[mm] 2 4 8 15 25 40 50 65 80
100
inch] 1/12" 5/32" 5/16" 1/2"
1" 1 1/2"
2" 2 1/2"
3" 4"
Recommended flow rate
min./max. full scale value (v ~ 0.3 or 10 m/s) 0.06...1.8 dm3/min 0.25...7 dm3/min 1...30 dm3/min 4...100 dm3/min 9...300 dm3/min 25...700 dm3/min 35...1100 dm3/min 60...2000 dm3/min 90...3000 dm3/min
145...4700 dm3/min
Full scale value (v ~ 2.5 m/s) 0.5 dm3/min
2 dm3/min 8 dm3/min 25 dm3/min 75 dm3/min 200 dm3/min 300 dm3/min 500 dm3/min 750 dm3/min 1200 dm3/min
Factory settings
Pulse value (~ 2 pulse/s) 0.005 dm3 0.025 dm3
0.10 dm3 0.20 dm3 0.50 dm3 1.50 dm3 2.50 dm3 5.00 dm3 5.00 dm3 10.00 dm3
Low flow cutoff (v ~ 0.04 m/s) 0.01 dm3/min 0.05 dm3/min 0.1 dm3/min 0.5 dm3/min
1 dm3/min 3 dm3/min 5 dm3/min 8 dm3/min 12 dm3/min 20 dm3/min
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Flow rate characteristic values Promag H (US units)
Nominal diameter
[inch] 1/12" 5/32" 5/16" 1/2"
1" 1 1/2"
2" 2 1/2"
3" 4"
[mm] 2 4 8 15 22 40 50 65 80
100
Recommended flow rate
min./max. full scale value (v ~ 0.3 or 10 m/s) 0.015...0.5 gal/min 0.07...2 gal/min 0.25...8 gal/min 1.0...27 gal/min 2.5...65 gal/min 7...190 gal/min 10...300 gal/min 16...500 gal/min 24...800 gal/min 40...1250 gal/min
Factory settings
Full scale value (v ~ 2.5 m/s) 0.1 gal/min 0.5 gal/min
2 gal/min 6 gal/min 18 gal/min 50 gal/min 75 gal/min 130 gal/min 200 gal/min 300 gal/min
Pulse value (~ 2 Pulse/s) 0.001 gal 0.005 gal
0.02 gal 0.05 gal 0.20 gal 0.50 gal 0.50 gal
1 gal 2 gal 2 gal
Low flow cutoff (v ~ 0.04 m/s) 0.002 gal/min 0.008 gal/min 0.025 gal/min 0.10 gal/min 0.25 gal/min 0.75 gal/min 1.25 gal/min
2.0 gal/min 2.5 gal/min 4.0 gal/min
3.2.8 Length of connecting cable
In order to ensure measuring accuracy, comply with the following instructions when installing the remote version: · Secure the cable run or route the cable in a conduit. Movement of the cable can falsify the measu-
ring signal, particularly if the fluid conductivity is low. · Route the cable well clear of electrical machines and switching elements. · Ensure potential equalisation between sensor and transmitter, if necessary. · The permissible cable length Lmax depends on the fluid conductivity (Fig. 16).
A minimum conductivity of 20 µS/cm is required for measuring demineralized water.
[µS/cm] 200
L max
100
5 10
Fig. 16: Permissible cable length for the remote version Gray shaded area = permissible range Lmax = length of connecting cable in [m] Fluid conductivity in [µS/cm]
100 L max
[m] 200
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3.3 Installation instructions
!
3.3.1 Installing the Promag W sensor
Note! Bolts, nuts, seals, etc. are not included in the scope of supply and must be supplied by the customer.
The sensor is designed for installation between the two piping flanges: · Observe in any case the necessary screw tightening torques on Page 28 ff. · The mounting of additional ground disks is described on Page 27.
Fig. 17: Installing the Promag W sensor
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Seals Comply with the following instructions when installing seals: · Hard rubber lining additional seals are always necessary. · Polyurethane lining additional seals are recommended. · For DIN flanges, use only seals according to DIN EN 1514-1. · Make sure that the seals do not protrude into the piping cross-section.
"
Caution! Risk of short circuit. Do not use electrically conductive sealing compound such as graphite. An
electrically conductive layer could form on the inside of the measuring tube and short-circuit the
measuring signal.
Ground cable (DN 25...2000) If necessary, the special ground cable for potential equalisation can be ordered as an accessory (see Page 85). Detailled assembly instructions Page 57 ff.
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Assembly with ground disks (DN 25...300) Depending on the application, e.g. with lined or ungrounded pipes (see Page 56 ff.), it may be necessary to mount ground disks between the sensor and the pipe flange for potential equalisation. Ground disks can be ordered separately as an accessory from Endress+Hauser (see Page 85).
"
Caution! · In this case, when using ground disks (including seals) the total fitting length increases!
All the dimensions are provided in the separate documentation "Technical Information"
· Hard rubber lining install additional seals between the sensor and ground disk and between
the ground disk and pipe flange.
· Polyurethane lining only install additional seals between the ground disk and pipe flange.
1. Place the ground disk and additional seal(s) between the instrument and the pipe flange (Fig. 18).
2. Insert the bolts through the flange holes. Tighten the nuts so that they are still loose. 3. Now rotate the ground disk as shown in Fig. 18 until the handle strikes the bolts. This will
center the ground disk automatically. 4. Now tighten the bolts to the required torque (see Page 28 ff.) 5. Connect the ground disk to ground Page 58.
Fig. 18: Assembly with ground disks (Promag W, DN 25...300)
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Screw tightening torques (Promag W) Note the following points: · The tightening torques listed below are for lubricated threads only. · Always tighten threaded fasteners uniformly and in diagonally opposite sequence. · Overtightening the fasteners will deform the sealing faces or damage the seals. · The tightening torques listed below apply only to pipes not subjected to tensile stress.
Promag W Nominal diameter
[mm] 25 32 40 50 65 * 65 80 80 100 100 125 125 150 150 200 200 200 250 250 250 300 300 300 350 350 350 400 400 400 450 450 450 500 500 500
EN (DIN) Pressure rating
[bar] PN 40 PN 40 PN 40 PN 40 PN 16 PN 40 PN 16 PN 40 PN 16 PN 40 PN 16 PN 40 PN 16 PN 40 PN 10 PN 16 PN 25 PN 10 PN 16 PN 25 PN 10 PN 16 PN 25 PN 10 PN 16 PN 25 PN 10 PN 16 PN 25 PN 10 PN 16 PN 25 PN 10 PN 16 PN 25
Threaded fasteners
4 x M 12 4 x M 16 4 x M 16 4 x M 16 8 x M 16 8 x M 16 8 x M 16 8 x M 16 8 x M 16 8 x M 20 8 x M 16 8 x M 24 8 x M 20 8 x M 24 8 x M 20 12 x M 20 12 x M 24 12 x M 20 12 x M 24 12 x M 27 12 x M 20 12 x M 24 16 x M 27 16 x M 20 16 x M 24 16 x M 30 16 x M 24 16 x M 27 16 x M 33 20 x M 24 20 x M 27 20 x M 33 20 x M 24 20 x M 30 20 x M 33
Max. tightening torque [Nm]
Hard rubber - - - - 32 32 40 40 43 59 56 83 74
104 106 70 104 82 98 150 94 134 153 112 152 227 151 193 289 153 198 256 155 275 317
Polyurethane 15 24 31 40 27 27 34 34 36 50 48 71 63 88 91 61 92 71 85 134 81 118 138 118 165 252 167 215 326 133 196 253 171 300 360
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Proline Promag 50
3 Installation
Promag W Nominal diameter
EN (DIN) Pressure rating
Threaded fasteners
[mm]
[bar]
600
PN 10
20 x M 27
600 *
PN 16
20 x M 33
600
PN 25
20 x M 36
700
PN 10
24 x M 27
700
PN 16
24 x M 33
700
PN 25
24 x M 39
800
PN 10
24 x M 30
800
PN 16
24 x M 36
800
PN 25
24 x M 45
900
PN 10
28 x M 30
900
PN 16
28 x M 36
900
PN 25
28 x M 45
1000
PN 10
28 x M 33
1000
PN 16
28 x M 39
1000
PN 25
28 x M 52
1200
PN 6
32 x M 30
1200
PN 10
32 x M 36
1200
PN 16
32 x M 45
1400
PN 6
36 x M 33
1400
PN 10
36 x M 39
1400
PN 16
36 x M 45
1600
PN 6
40 x M 33
1600
PN 10
40 x M 45
1600
PN 16
40 x M 52
1800
PN 6
44 x M 36
1800
PN 10
44 x M 45
1800
PN 16
44 x M 52
2000
PN 6
48 x M 39
2000
PN 10
48 x M 45
2000
PN 16
48 x M 56
* Designed acc. to EN 1092-1 (not to DIN 2501)
Max. tightening torque [Nm]
Hard rubber 206 415 431 246 278 449 331 369 664 316 353 690 402 502 970 319 564 701 430 654 729 440 946 1007 547 961 1108 629 1047 1324
Polyurethane 219 443 516 246 318 507 316 385 721 307 398 716 405 518 971 299 568 753 398 618 762 417 893 1100 521 895 1003 605 1092 1261
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Proline Promag 50
Promag W Nominal diameter
[mm]
[inch]
700
28"
750
30"
800
32"
900
36"
1000
40"
1050
42"
1200
48"
1350
54"
1500
60"
1650
66"
1800
72"
2000
78"
AWWA Pressure rating
Class D Class D Class D Class D Class D Class D Class D Class D Class D Class D Class D Class D
Threaded fasteners
28 x 1 1/4" 28 x 1 1/4 28 x 1 1/2" 32 x 1 1/2" 36 x 1 1/2" 36 x 1 1/2" 44 x 1 1/2" 44 x 1 3/4" 52 x 1 3/4" 52 x 1 3/4" 60 x 1 3/4"
64 x 2"
Max. tightening torque [Nm]
Hard rubber 247 287 394 419 420 528 552 730 758 946 975 853
Polyurethane 292 302 422 430 477 518 531 633 832 955 1087 786
Promag W Nominal diameter
[mm]
[inch]
25
1"
25
1"
40
1 1/2"
40
1 1/2"
50
2"
50
2"
80
3"
80
3"
100
4"
100
4"
150
6"
150
6"
200
8"
250
10"
300
12"
350
14"
400
16"
450
18"
500
20"
600
24"
ANSI Pressure rating
[lbs] Class 150 Class 300 Class 150 Class 300 Class 150 Class 300 Class 150 Class 300 Class 150 Class 300 Class 150 Class 300 Class 150 Class 150 Class 150 Class 150 Class 150 Class 150 Class 150 Class 150
Threaded fasteners
4 x 1/2" 4 x 5/8" 4 x 1/2" 4 x 3/4" 4 x 5/8" 8 x 5/8" 4 x 5/8" 8 x 3/4" 8 x 5/8" 8 x 3/4" 8 x 3/4" 12 x 3/4" 8 x 3/4" 12 x 7/8" 12 x 7/8" 12 x 1" 16 x 1" 16 x 1 1/8" 20 x 1 1/8" 20 x 1 1/4"
Max. tightening torque [Nm]
Hard rubber - - - - - - 60 38 42 58 79 70
107 101 133 135 128 204 183 268
Polyurethane 7 8 10 15 22 11 43 26 31 40 59 51 80 75
103 158 150 234 217 307
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Proline Promag 50
3 Installation
Promag W Nominal diameter
[mm] 25 25 32 32 40 40 50 50 65 65 80 80 100 100 125 125 150 150 200 200 250 250 300 300
JIS Pressure rating
Threaded fasteners
10K
4 x M 16
20K
4 x M 16
10K
4 x M 16
20K
4 x M 16
10K
4 x M 16
20K
4 x M 16
10K
4 x M 16
20K
8 x M 16
10K
4 x M 16
20K
8 x M 16
10K
8 x M 16
20K
8 x M 20
10K
8 x M 16
20K
8 x M 20
10K
8 x M 20
20K
8 x M 22
10K
8 x M 20
20K
12 x M 22
10K
12 x M 20
20K
12 x M 22
10K
12 x M 22
20K
12 x M 24
10K
16 x M 22
20K
16 x M 24
Max. tightening torque [Nm]
Hard rubber - - - - - - - - 55 28 29 42 35 56 60 91 75 81 61 91
100 159 74 138
Polyurethane 19 19 22 22 24 24 33 17 45 23 23 35 29 48 51 79 63 72 52 80 87 144 63 124
Promag W Nominal diameter
[mm] 80 100 150 200 250 300 350 400 500 600
AS 2129 Pressure rating
Table E Table E Table E Table E Table E Table E Table E Table E Table E Table E
Threaded fasteners
4 x M 16 8 x M 16 8 x M 20 8 x M 20 12 x M 20 12 x M 24 12 x M 24 12 x M 24 16 x M 24 16 x M 30
Max. tightening torque [Nm]
Hard rubber 49 38 64 96 98 123 203 226 271 439
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Proline Promag 50
Promag W Nominal diameter
AS 4087 Pressure rating
Threaded fasteners
[mm]
80
Cl.14
4 x M 16
100 *
Cl.14
8 x M 16
150
Cl.14
8 x M 20
200
Cl.14
8 x M 20
250
Cl.14
8 x M 20
300
Cl.14
12 x M 24
350
Cl.14
12 x M 24
400
Cl.14
12 x M 24
500
Cl.14
16 x M 24
600
Cl.14
16 x M 30
* Designed acc. to EN 2129 (not to DIN 4087)
Max. tightening torque [Nm]
Hard rubber 49 38 52 77 147 103 203 226 271 393
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Proline Promag 50
3 Installation
"
!
3.3.2 Installing the Promag P sensor
Caution! · The protective covers mounted on the two sensor flanges guard the PTFE lining, which is turned
over the flanges. Consequently, do not remove these covers until immediately before the sensor is installed in the pipe. · The covers must remain in place while the device is in storage. · Make sure that the lining is not damaged or removed from the flanges.
Note! Bolts, nuts, seals, etc. are not included in the scope of supply and must be supplied by the customer.
The sensor is designed for installation between the two piping flanges. · Observe in any case the necessary screw tightening torques on Page 36 ff. · The mounting of additional ground disks is described on Seite 34.
Fig. 19: Installing the Promag P sensor
F-5xFxxxxx-17-05-xx-xx-000
Seals Comply with the following instructions when installing seals: · Measuring tube linings with PFA or PTFE No seals are required. · In case you use seals with DIN flanges, use only seals according to DIN EN 1514-1. · Make sure that the seals do not protrude into the piping cross-section.
"
Caution! Risk of short circuit. Do not use electrically conductive sealing compound such as graphite. An
electrically conductive layer could form on the inside of the measuring tube and short-circuit the
measuring signal.
Ground cable (DN 15...600) If necessary, a special ground cable for potential equalisation can be ordered as an accessory (see Page 85). Detailled assembly instructions Page 57 ff.
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Proline Promag 50
Assembly with ground disks (DN 15...300) Depending on the application, e.g. with lined or ungrounded pipes (see Page 56 ff.), it may be necessary to mount ground disks between the sensor and the pipe flange for the potential equalisation. Ground disks can be ordered separately as an accessory from Endress+Hauser (see Page 85).
"
Caution! · In this case, when using ground disks (including seals) the total fitting length increases!
All the dimensions are provided in the separate documentation "Technical Information".
· PTFE and PFA lining only install additional seals between the ground disk and pipe flange.
1. Place the ground disk and the additional seal between the instrument and the pipe flange (Fig. 20).
2. Insert the bolts through the flange holes. Tighten the nuts so that they are still loose. 3. Now rotate the ground disk as shown in Fig. 20 until the handle strikes the bolts. This will
center the ground disk automatically. 4. Now tighten the bolts to the required torque (see Page 36 ff.) 5. Connect the ground disk to ground Page 58.
Fig. 20: Assembly with ground disks (Promag P, DN 15...300)
F06-5xFxxxxx-17-05-xx-xx-001
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Proline Promag 50
3 Installation
!
"
Installing the high-temperature version (with PFA lining) The high-temperature version has a housing support for the thermal separation of sensor and transmitter. The high-temperature version is always used for applications in which high ambient temperatures are encountered in conjunction with high fluid temperatures. The high-temperature version is obligatory if the fluid temperature exceeds +150 °C.
Note! You will find information on permissible temperature ranges on Page 111
Insulation Pipes generally have to be insulated if they carry very hot fluids, in order to avoid energy losses and to prevent accidental contact with pipes at temperatures that could cause injury. Guidelines regulating the insulation of pipes have to be taken into account.
Caution! Risk of measuring electronics overheating. The housing support dissipates heat and its entire surface area must remain uncovered. Make sure that the sensor insulation does not extend past the top of the two sensor shells (Fig. 21).
Fig. 21: Promag P (high-temperature version): Insulating the pipe
F06-5xPxxxxx-17-05-00-xx-000
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Proline Promag 50
Tightening torques for threaded fasteners (Promag P) Note the following points: · The tightening torques listed below are for lubricated threads only. · Always tighten threaded fasteners uniformly and in diagonally opposite sequence. · Overtightening the fasteners will deform the sealing faces or damage the seals. · The tightening torques listed below apply only to pipes not subjected to tensile stress.
Promag P Nominal diameter
[mm] 15 25 32 40 50 65 * 65 80 80 100 100 125 125 150 150 200 200 200 250 250 250 300 300 300 350 350 350 400 400 400 450 450 450 500 500
EN (DIN) Pressure rating
[bar] PN 40 PN 40 PN 40 PN 40 PN 40 PN 16 PN 40 PN 16 PN 40 PN 16 PN 40 PN 16 PN 40 PN 16 PN 40 PN 10 PN 16 PN 25 PN 10 PN 16 PN 25 PN 10 PN 16 PN 25 PN 10 PN 16 PN 25 PN 10 PN 16 PN 25 PN 10 PN 16 PN 25 PN 10 PN 16
Threaded fasteners
4 x M 12 4 x M 12 4 x M 16 4 x M 16 4 x M 16 8 x M 16 8 x M 16 8 x M 16 8 x M 16 8 x M 16 8 x M 20 8 x M 16 8 x M 24 8 x M 20 8 x M 24 8 x M 20 12 x M 20 12 x M 24 12 x M 20 12 x M 24 12 x M 27 12 x M 20 12 x M 24 16 x M 27 16 x M 20 16 x M 24 16 x M 30 16 x M 24 16 x M 27 16 x M 33 20 x M 24 20 x M 27 20 x M 33 20 x M 24 20 x M 30
Max. tightening torque [Nm]
PTFE
PFA
11
-
26
20
41
35
52
47
65
59
43
40
43
40
53
48
53
48
57
51
78
70
75
67
111
99
99
85
136
120
141
101
94
67
138
105
110
-
131
-
200
-
125
-
179
-
204
-
188
-
254
-
380
-
260
-
330
-
488
-
235
-
300
-
385
-
265
-
448
-
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Proline Promag 50
3 Installation
Promag P Nominal diameter
EN (DIN) Pressure rating
Threaded fasteners
[mm]
[bar]
500
PN 25
20 x M 33
600
PN 10
20 x M 27
600 *
PN 16
20 x M 33
600
PN 25
20 x M 36
* Designed acc. to EN 1092-1 (not to DIN 2501)
Max. tightening torque [Nm]
PTFE
PFA
533
-
345
-
658
-
731
-
Promag P Nominal diameter
[mm]
[inch]
15
1/2"
15
1/2"
25
1"
25
1"
40
1 1/2"
40
1 1/2"
50
2"
50
2"
80
3"
80
3"
100
4"
100
4"
150
6"
150
6"
200
8"
250
10"
300
12"
350
14"
400
16"
450
18"
500
20"
600
24"
ANSI Pressure rating
[lbs] Class 150 Class 300 Class 150 Class 300 Class 150 Class 300 Class 150 Class 300 Class 150 Class 300 Class 150 Class 300 Class 150 Class 300 Class 150 Class 150 Class 150 Class 150 Class 150 Class 150 Class 150 Class 150
Threaded fasteners
4 x 1/2" 4 x 1/2" 4 x 1/2" 4 x 5/8" 4 x 1/2" 4 x 3/4" 4 x 5/8" 8 x 5/8" 4 x 5/8" 8 x 3/4" 8 x 5/8" 8 x 3/4" 8 x 3/4" 12 x 3/4" 8 x 3/4" 12 x 7/8" 12 x 7/8" 12 x 1" 16 x 1" 16 x 1 1/8" 20 x 1 1/8" 20 x 1 1/4"
Max. tightening torque [Nm]
PTFE
PFA
6
-
6
-
11
10
14
12
24
21
34
31
47
44
23
22
79
67
47
42
56
50
67
59
106
86
73
67
143
109
135
-
178
-
260
-
246
-
371
-
341
-
477
-
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Proline Promag 50
Promag P Nominal diameter
[mm] 15 15 25 25 32 32 40 40 50 50 65 65 80 80 100 100 125 125 150 150 200 200 250 250 300 300
JIS Pressure rating
Threaded fasteners
10K
4 x M 12
20K
4 x M 12
10K
4 x M 16
20K
4 x M 16
10K
4 x M 16
20K
4 x M 16
10K
4 x M 16
20K
4 x M 16
10K
4 x M 16
20K
8 x M 16
10K
4 x M 16
20K
8 x M 16
10K
8 x M 16
20K
8 x M 20
10K
8 x M 16
20K
8 x M 20
10K
8 x M 20
20K
8 x M 22
10K
8 x M 20
20K
12 x M 22
10K
12 x M 20
20K
12 x M 22
10K
12 x M 22
20K
12 x M 24
10K
16 x M 22
20K
16 x M 24
Max. tightening torque [Nm]
PTFE
PFA
16
-
16
-
32
-
32
-
38
-
38
-
41
-
41
-
54
-
27
-
74
-
37
-
38
-
57
-
47
-
75
-
80
-
121
-
99
-
108
-
82
-
121
-
133
-
212
-
99
-
183
-
Promag P Nominal diameter
[mm] 25 50
AS 2129 Pressure rating
Threaded fasteners
Table E Table E
4 x M 12 4 x M 16
Max. tightening torque [Nm]
PTFE 21 42
Promag P Nominal diameter
[mm]
50
AS 4087 Pressure rating
Threaded fasteners
Cl.14
4 x M 16
Max. tightening torque [Nm]
PTFE 42
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Proline Promag 50
3 Installation
3.3.3 Installing the Promag H sensor
The Promag H is supplied to order, with or without pre-installed process connections. Pre-installed process connections are secured to the sensor with hex-head threaded fasteners.
"
Caution! · The sensor might require support or additional attachments, depending on the application and the
length of the piping run. When plastic process connections are used, the sensor must be addition-
ally supported mechanically. A wall-mounting kit can be ordered separately from Endress+Hauser
as an accessory (see Page 85).
DN 2...25 A
DN 40...100 C
B
Fig. 22: Promag H process connections (DN 2...25, DN 40...100)
F06-xxHxxxxx-17-05-xx-xx-000
A: DN 2...25 / process connections with O-rings: Welding flanges (DIN EN ISO 1127, ODT / SMS), flange (EN (DIN), ANSI, JIS), flange PVDF (EN (DIN), ANSI, JIS), external and internal pipe threads, hose connection, PVC adhesive fitting
B: DN 2...25 / process connections with aseptic gasket seals: Weld nipples (DIN 11850, ODT / SMS), Clamp (ISO 2852, DIN 32676, L14 AM7), coupling (DIN 11851, DIN 11864-1, SMS 1145), flange DIN 11864-2
C: DN 40...100 / process connections with aseptic gasket seals: Weld nipples (DIN 11850, ODT / SMS), Clamp (ISO 2852, DIN 32676), L14 AM7), coupling (DIN 11851, DIN 11864-1, ISO 2853, SMS 1145), flange DIN 11864-2
Seals When installing the process connections, make sure that the seals are clean and correctly centered.
"
Caution! · With metallic process connections, you must fully tighten the screws. The process connection
forms a metallic connection with the sensor, which ensures a defined compression of the seal.
· With plastic process connections, note the max. torques for lubricated threads (7 Nm).
With plastic flanges, always use seals between connection and counter flange.
· The seals must be replaced periodically, depending on the application, particularly in the case of
gasket seals (aseptic version)! The period between changes depends on the frequency of cleaning
cycles, the cleaning temperature and the fluid temperature.
Replacement seals can be ordered as accessories Page 85.
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Proline Promag 50
Usage and assembly of ground rings (DN 2...25) In case the process connections are made of plastic (e.g. flanges or adhesive fittings), the potential between the sensor and the fluid must be equalised using additional ground rings. If the ground rings are not installed this can affect the accuracy of the measurements or cause the destruction of the sensor through the electrochemical erosion of the electrodes.
"
Caution! · Depending on the option ordered, plastic disks may be installed at the process connections instead
of ground rings. These plastic disks serve only as spacers and have no potential equalization func-
tion. In addition, they provide a sealing function at the interface between the sensor and process
connection. For this reason, with process connections without ground rings, these plastic
disks/seals must not be removed, or must always be installed.
· Ground rings can be ordered separately from Endress+Hauser as accessories (see Page 85).
When placing the order, make certain that the ground ring is compatible with the material used
for the electrodes. Otherwise, there is a risk that the electrodes may be destroyed by electroche-
mical corrosion! Information about the materials can be found on Page 117.
· Ground rings, including the seals, are mounted within the process connections. Therefore, the
fitting length is not affected.
1. Loosen the four hexagonal headed bolts (1) and remove the process connection from the sensor (5).
2. Remove the plastic disk (3), including the two O-ring seals (2, 4). 3. Place one seal (2) in the groove of the process connection. 4. Place the metal ground ring (3) on the process connection. 5. Now place the second seal (4) in the groove of the ground ring. 6. Finally, mount the process connection on the sensor again. With plastic process connections,
note the max. torques for lubricated threads (7 Nm).
1
2
3
2
4
Fig. 23: Installing ground rings with a Promag H (DN 2...25)
1 = Hexagonal headed bolts (process connection) 2 = O-ring seals 3 = Ground ring or plastic disk (placeholder) 4 = Sensor Promag H
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Proline Promag 50
3 Installation
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!
Welding the sensor into the piping (weld nipples)
Caution! Risk of destroying the measuring electronics. Make sure that the welding machine is not grounded via the sensor or the transmitter.
1. Tack-weld the Promag H sensor into the pipe. A suitable welding jig can be ordered separately from Endress+Hauser as an accessory (see Page 85).
2. Remove the threaded fasteners from the process-connection flange. Remove the sensor complete with seal from the pipe.
3. Weld the process connection to the pipe. 4. Reinstall the sensor in the pipe. Make sure that everything is clean and that the seal is correctly
seated.
Note! · If thin-walled foodstuffs pipes are not welded correctly, the heat could damage the installed seal.
It is therefore advisable to remove the sensor and the seal prior to welding. · The pipe has to be spread approximately 8 mm to permit disassembly.
Cleaning with pigs If pigs are used for cleaning, it is essential to take the inside diameters of measuring tube and process connection into account. All the dimensions and lengths of the sensor and transmitter are provided in the separate documentation "Technical Information".
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#
3.3.4 Turning the transmitter housing
Turning the aluminum field housing
Warning! The turning mechanism in devices with EEx d/de or FM/CSA Cl. I Div. 1 classification is not the same as that described here. The procedure for turning these housings is described in the Ex-specific documentation.
1. Loosen the two securing screws. 2. Turn the bayonet catch as far as it will go. 3. Carefully lift the transmitter housing as far as it will go. 4. Turn the transmitter housing to the desired position (max. 2 x 90° in either direction). 5. Lower the housing into position and re-engage the bayonet catch. 6. Retighten the two securing screws.
2
4
5
1
3
6
Fig. 24: Turning the transmitter housing (aluminum field housing)
F06-xxxxxxxx-17-06-xx-xx-000
Turning the stainless-steel field housing
1. Loosen the two securing screws. 2. Carefully lift the transmitter housing as far as it will go. 3. Turn the transmitter housing to the desired position (max. 2 x 90° in either direction). 4. Lower the housing into position. 5. Retighten the two securing screws.
3
4
1
2
5
Fig. 25: Turning the transmitter housing (stainless-steel field housing)
F06-xxxxxxxx-17-06-xx-xx-001
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Proline Promag 50
3 Installation
3.3.5 Turning the local display
1. Remove the cover of the electronics compartment. 2. Press the side latches on the display module and remove it from the electronics compartment
cover plate. 3. Rotate the display to the desired position (max. 4 x 45° in each direction), and place it back
into the electronics compartment cover plate. 4. Screw the cover of the electronics compartment firmly onto the transmitter housing.
Fig. 26: Turning the local display (field housing)
F06-xxxxxxxx-07-xx-06-xx-000
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3.3.6 Installing the wall-mount transmitter housing
There are various ways of installing the wall-mount transmitter housing: · Mounted directly on the wall · Installation in control panel (with separate mounting kit, accessories Page 85) · Pipe mounting (with separate mounting kit, accessories Page 85)
"
Caution! · Make sure that ambient temperature does not exceed the permissible range
(20...+60 °C), (optional -40...+60 °C). Install the device at a shady location.
Avoid direct sunlight.
· Always install the wall-mount housing in such a way that the cable entries are pointing down.
Direct wall mounting
1. Drill the holes as illustrated in Fig. 27. 2. Remove the cover of the connection compartment (a). 3. Push the two securing screws (b) through the appropriate bores (c) in the housing.
Securing screws (M6): max. Ø 6.5 mm Screw head: max. Ø 10.5 mm 4. Secure the transmitter housing to the wall as indicated. 5. Screw the cover of the connection compartment (a) firmly onto the housing.
b 35
90
c
a 192
Fig. 27: Mounted directly on the wall
81.5
c
A0001130
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3 Installation
Panel installation
1. Prepare the opening in the panel (Fig. 28). 2. Slide the housing into the opening in the panel from the front. 3. Screw the fasteners onto the wall-mount housing. 4. Place the threaded rods in the fasteners and screw them down until the housing is seated
tightly against the panel. Afterwards, tighten the locking nuts. Additional support is not necessary.
210 +00.5.5
+0.5
245 0.5
~110
Fig. 28: Panel Installation (wall-mount housing)
A0001131
Pipe mounting The assembly should be performed by following the instructions in Fig. 29.
"
Caution! If the device is mounted to a warm pipe, make certain that the housing temperature does not exceed
+60 °C, which is the maximum permissible temperature.
Ø 20...70
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Fig. 29: Pipe mounting (wall-mount housing) Active: 18/04/2016
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A0001132
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3.4 Installation check
Perform the following checks after installing the measuring device in the pipe:
Device condition and specifications
Notes
Is the device damaged (visual inspection)?
-
Does the device correspond to specifications at the measuring point, including see Page 107 ff. process temperature and pressure, ambient temperature, minimum fluid conductivity, measuring range, etc.?
Installation
Notes
Does the arrow on the sensor nameplate match the direction of flow through the - pipe?
Is the plane of the measuring-electrode axis correct?
Horizontal
Is the position of the Empty Pipe Detection (EPD) electrode correct?
see Page 17
Were all threaded fasteners tightened to the specified torques when the sensor was installed?
Were the correct seals installed (type, material, installation)?
see Chap. 3.3
Promag W Page 26 Promag P Page 33 Promag H Page 39
Are the measuring-point number and labeling correct (visual inspection)?
-
Process environment / process conditions Are the inlet and outlet runs to respected?
Notes
Inlet run 5 x DN Outlet run 2 x DN
Is the measuring device protected against moisture and direct sunlight?
-
Is the sensor adequately protected against vibration (attachment, support)?
Acceleration up to 2 g by analogy with IEC 600 68-2-6 (see Page 110)
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4 Wiring
#
4 Wiring
Warning! · When connecting Ex-certified devices, see the notes and diagrams in the Ex-specific supplement
to this Operating Manual. Please do not hesitate to contact your Endress+Hauser representative if you have any questions. · If you use remote versions, connect each sensor only to the transmitter having the same serial number. Measuring errors can occur if the devices are not connected in this way.
4.1 Connecting the remote version
#
4.1.1 Connecting Promag W / P / H
Warning! · Risk of electric shock. Switch off the power supply before opening the device. Do not install or
wire the device while it is connected to the power supply. Failure to comply with this precaution can result in irreparable damage to the electronics. · Risk of electric shock. Connect the protective conductor to the ground terminal on the housing before the power supply is applied.
Procedure (Fig. 30, Fig. 31):
1. Transmitter: Loosen the screws and remove cover (a) from the connection compartment.
2. Sensor: Remove cover (b) from the connection housing. 3. Feed signal cable (c) and coil cable (d) through the appropriate cable entries.
" Caution!
Make sure the connecting cables are secured (see Page 25). Risk of damaging the coil driver. Always switch off the power supply before
connecting or disconnecting the coil cable.
4. Preterminate signal cable and coil current cable: Promag W, P Refer to the information on Page 49 Promag H Refer to the information on Page 50
5. Establish the connections between sensor and transmitter in accordance with the wiring diagram: Fig. 30, Fig. 31 wiring diagram inside the cover
" Caution!
Insulate the shields of cables that are not connected to eliminate the risk of short-circuits with neighboring cable shields inside the sensor connection housing.
6. Transmitter: Secure cover (a) on the connection compartment. 7. Sensor: Secure cover (b) on the connection housing.
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2 1 2 1
wht brn
a c
b
Electrode circuit Meas.signal Pipe EPD S1 E1 E2 S2 GND E S 6 5 7 8 4 37 36
Coil circuit 42 41
yel
grn
brn
d
n.c.
n.c.
n.c.
5 7 4 37
E1 E2 GND E
42 41
Fig. 30: Connecting the remote version of Promag W/P
F06-5xFxxxxx-04-xx-xx-en-000
a = cover of the connection compartment, b = cover of the sensor connection housing, c = signal cable, d = coil current cable, n.c. = not connected, insulated cable shields
a
c b
Electrode circuit Meas. signal Pipe EPD S1 E1 E2 S2 GND E S 6 5 7 8 4 37 36
Coil circuit 42 41
yel
grn
wht
d
n.c.
n.c.
n.c.
5 7 4 37
E1 E2 GND E
42 41
DN 40...100
DN 2...25
Fig. 31: Connecting the remote version of Promag H
F06-5xHxxxxx-04-xx-xx-de-000
a = cover of the connection compartment, b = cover of the sensor connection housing, c = signal cable, d = coil current cable, n.c. = not connected, insulated cable shields
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4 Wiring
Cable termination for the remote version Promag W / Promag P
Terminate the signal and coil current cables as shown in the figure below (Detail A). Fit the fine-wire cores with cable end sleeves (Detail B).
" Caution!!
When fitting the connectors, pay attention to the following points:
· Signal cable Make sure that the cable end sleeves do not touch the wire shield on the sensor side.
Minimum distance = 1 mm (exception "GND" = green cable).
· Coil current cable Insulate one core of the three-core wire at the level of the core reinforcement; you only require two cores for the connection.
TRANSMITTER
Signal cable
Coil current cable
17 8
100* 80
50
90* 70
50 10
8
A
m
m
n m
n
m
GND
n
B n
Signal cable
A0002643
SENSOR
m m m
Coil current cable
20*
170*
80
50
17
8
20*
160*
70
50
10 8
A
B
A0002644
A
m
GND
B
n ³1 n
n m
= Red cable sleeves 1.0 mm = White cable sleeves 0.5 mm * = Stripping for armoured cables only
A0002646
A m m m
B
A0002645
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Cable termination for the remote version Promag H
Terminate the signal and coil current cables as shown in the figure below (Detail A). Fit the fine-wire cores with cable end sleeves (Detail B).
" Caution!!
When fitting the connectors, pay attention to the following points:
· Signal cable Make sure that the cable end sleeves do not touch the wire shield on the sensor side.
Minimum distance = 1 mm (exception "GND" = green cable).
· Coil current cable Insulate one core of the three-core wire at the level of the core reinforcement; you only require two cores for the connection.
· On the sensor side, reverse both cable shields approx. 15 mm over the outer jacket. The strain relief ensures an electrical connection with the connection housing.
TRANSMITTER
Signal cable
Coil current cable
17 8
80 50
70 50 10
8
m m n m
n m n
GND
n
A
B
A0002686
SENSOR
Signal cable
m m m
Coil current cable
B
A0002684
A
80
15
17
8
70
15
40
8
A
³1
n
n
GND
n
B
m
= Red cable sleeves 1.0 mm = White cable sleeves 0.5 mm
A
m m B
A0002647
A0002648
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4.1.2 Cable specifications
Coil cable: · 2 x 0.75 mm2 PVC cable with common, braided copper shield (Ø approx. 7 mm) · Conductor resistance: 37 /km · Capacitance: core/core, shield grounded: 120 pF/m · Permanent operating temperature: 20...+80 ° · Cable cross-section: max. 2.5 mm2
Signal cable: · 3 x 0.38 mm2 PVC cable with common, braided copper shield (Ø approx. 7 mm) and individually
shielded cores · With Empty Pipe Detection (EPD): 4 x 0.38 mm2 PVC cable with common, braided copper shield
(Ø approx. 7 mm) and individually shielded cores · Conductor resistance: 50 /km · Capacitance: core/shield: 420 pF/m · Permanent operating temperature: 20...+80 °C · Cable cross-section: max. 2.5 mm2
1 2 3 4 5 6 7
a
b
F06-5xWxxxxx-04-11-08-xx-003
Fig. 32: Cable cross-section (a = Signal cable, b = Coil current cable) 1 = Core, 2 = Core insulation, 3 = Core shield, 4 = Core jacket, 5 = Core reinforcement, 6 = Cable shield, 7 = Outer jacket
As an option, Endress+Hauser can also deliver reinforced connecting cables with an additional, reinforcing metal braid. We recommend such cables for the following cases: · Directly buried cable · Cables endangered by rodents · Device operation which should comply with the IP 68 standard of protection
Operation in zones of severe electrical interference: The measuring device complies with the general safety requirements in accordance with EN 61010, the EMC requirements of EN 61326/A1, and NAMUR recommendation NE 21.
"
Caution! Grounding is by means of the ground terminals provided for the purpose inside the connection
housing. Keep the stripped and twisted lengths of cable shield to the terminals as short as possible.
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4.2 Connecting the measuring unit
#
4.2.1 Transmitter
Warning! · Risk of electric shock. Switch off the power supply before opening the device.
Do not install or wire the device while it is connected to the power supply. Failure to comply with this precaution can result in irreparable damage to the electronics. · Risk of electric shock. Connect the protective conductor to the ground terminal on the housing before the power supply is applied (not necessary if the power supply is galvanically isolated). · Compare the specifications on the nameplate with the local voltage supply and frequency. The national regulations governing the installation of electrical equipment also apply.
1. Remove the cover of the connection compartment (f) from the transmitter housing. 2. Feed the power supply cable (a) and signal cables (b) through the appropriate cable entries. 3. Connect the cables in accordance with the wiring diagram:
Wiring diagram (aluminium housing) Fig. 33 Wiring diagram (stainless steel housing) Fig. 34 Wiring diagram (wall-mount housing) Fig. 35 Terminal assignment Page 54
4. Screw the cover of the connection compartment (f) firmly onto the transmitter housing.
f
27
+ 26
b
e
25 + 24
b
23
d
+ 22
21 + 20
a
N (L-) 2
c
g
L1 (L+) 1
a
F06-xxxxxxxx-04-06-xx-xx-005
Fig. 33: Connecting the transmitter (aluminium field housing). Cable cross-section: max. 2.5 mm2
a Cable for power supply: 85...260 V AC, 20...55 V AC, 16...62 V DC Terminal No. 1: L1 for AC, L+ for DC
Terminal No. 2: N for AC, L- for DC b Signal cable: Terminals Nos. 2027 Page 54
c Ground terminal for protective conductor d Ground terminal for signal cable shield e Service adapter for connecting service interface FXA 193 (Fieldcheck, ToF Tool - Fieldtool Package) f Cover of the connection compartment g Securing clamp
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27
+ 26
b
e
25 + 24
b
23
d
+ 22
21
a
+ 20
N (L-) 2
c
f
L1 (L+) 1
a
F06-xxxxxxxx-04-06-xx-xx-006
Fig. 34: Connecting the transmitter (stainless-steel field housing). Cable cross-section: max. 2.5 mm2
a Cable for power supply: 85...260 V AC, 20...55 V AC, 16...62 V DC Terminal No. 1: L1 for AC, L+ for DC
Terminal No. 2: N for AC, L- for DC b Signal cable: Terminals Nos. 2027 Page 54
c Ground terminal for protective conductor d Ground terminal for signal cable shield e Service adapter for connecting service interface FXA 193 (Fieldcheck, ToF Tool - Fieldtool Package) f Cover of the connection compartment
N (L-) L1 (L+)
+ + + +
e
12
20 2122 2324 25 26 27
ab
f
a
c
b
d
Fig. 35: Connecting the transmitter (wall-mount housing). Cable cross-section: max. 2.5 mm2
a Cable for power supply: 85...260 V AC, 20...55 V AC, 16...62 V DC Terminal No. 1: L1 for AC, L+ for DC
Terminal No. 2: N for AC, L- for DC b Signal cable: Terminals Nos. 2027 Page 54
c Ground terminal for protective conductor d Ground terminal for signal cable shield e Service adapter for connecting service interface FXA 193 (Fieldcheck, ToF Tool - Fieldtool Package) f Cover of the connection compartment
A0001135
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4.2.2 Terminal assignment
Order variant
20 (+) / 21 ()
50***-***********W
-
Terminal No. (inputs / outputs)
22 (+) / 23 ()
24 (+) / 25 ()
-
-
50***-***********A
-
-
Frequency output
50***-***********D
Status input
Status output
Frequency output
50***-***********S
-
-
Frequency output Ex i
50***-***********T
-
-
Frequency output Ex i
Status input (auxiliary input)
galvanically isolated, 3...30 V DC, Ri = 5 k
Status output Open collector, max. 30 V DC / 250 mA, galvanically isolated, freely configurable
Frequency output (passive)
Open collector, galvanically isolated, full scale frequency 2...1000 Hz (fmax = 1.25 kHz) 30 V DC, 250 mA
Current output (active/passive)
galvanically isolated, active: 0/4...20 mA, RL < 700 (HART: RL 250 ) passive: 4...20 mA, supply voltage Vs: 18...30 V DC, Ri 150
Ground connection, power supply Page 52 ff.
26 (+) / 27 ()
Current output HART
Current output HART
Current output HART
Current output Ex i active, HART
Current output Ex i passive, HART
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4 Wiring
!
4.2.3 HART connection
Users have the following connection options at their disposal: · Direct connection to transmitter by means of terminals 26(+) / 27() · Connection by means of the 4...20 mA circuit
Note! · The measuring loop's minimum load must be at least 250 . · After commissioning, make the following settings:
CURRENT SPAN function "420 mA HART" or "420 mA (25 mA) HART" · See also the documentation issued by the HART Communication Foundation, and in particular
HCF LIT 20: "HART, a technical summary".
Connection of the HART handheld communicator
³ 250 W
4
3
-27 +26
2
1
Page Up
Bksp
Delete
Page On
# % &
1
Copy
G H I
4
P Q R S
7
A B C
2
Paste
J K L
5
Insert
T UV
8
D E F
3
Hot Key
M N O
6
+ Hot Key
W XY Z
9
, ( )`
_ < >
+ * /
.0-
375 FIELD COMMUNICATOR
F06-xxxxxxxx-04-xx-xx-xx-007
Fig. 36: Electrical connection of the HART handheld communicator: 1 = HART communicator, 2 = power supply, 3 = shield, 4 = other evaluation devices or PLC with passive input
Connection of a PC with an operating software In order to connect a PC with an operating software (e.g. "ToF Tool - Fieldtool Package"), a HART modem (e.g. "Commubox FXA 191") is needed.
³ 250 W
4 1
3
RS 232
5
-27 +26
2
F06-xxxxxxxx-04-xx-xx-xx-008
Fig. 37: Electrical connection of a PC with an operating software: 1 = PC with an operating software, 2 = power supply, 3 = shield, 4 = other evaluation devices or PLC with passive input, 5 = HART modem, e.g. Commubox FXA 191
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4.3 Potential equalisation
!
4.3.1 Standard case
Perfect measurement is only ensured when the medium and the sensor have the same electrical potential. Most Promag sensors have a standard installed reference electrode which guarantees the required connection. This usually means that additional potential matching measures are unnecessary.
Promag W: Reference electrode is standard
Promag P: · Reference electrode is standard for electrode materials 1.4435, Alloy C-22 and tantalum. · Reference electrode is optional for electrode material Pt/Rh.
Promag H: · No reference electrode. The metallic process connection provides a permanent electrical
connection to the fluid. · If the process connections are made of a synthetic material, ground rings have to be used to ensure
that potential is equalised (see Page 40). Ground rings can be ordered with the main product structure or as accessories Page 85.
Note! For installation in metal pipes, it is advisable to connect the ground terminal of the transmitter housing to the piping. Also, observe company-internal grounding guidelines.
Fig. 38: Potential equalisation by means of the transmitter's ground terminal
F06-5xxxxxxx-04-xx-xx-xx-002
"
Caution! For sensors without reference electrodes or without metal process terminals, carry out potential
equalisation as per the instructions for special cases described below. These special measures are
particularly important when standard grounding practice cannot be ensured or extremely strong
matching currents are expected.
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"
!
4.3.2 Special cases
Metal, ungrounded piping In order to prevent outside influences on measurement, it is advisable to use ground cables to connect each sensor flange to its corresponding pipe flange and ground the flanges. Connect the transmitter or sensor connection housing, as applicable, to ground potential by means of the ground terminal provided for the purpose (Fig. 39).
Caution! Also, observe company-internal grounding guidelines.
Note! The ground cable for flange-to-flange connections can be ordered separately as an accessory from Endress+Hauser Page 85. · DN 300: The ground cable is in direct connection with the conductive flange coating and is
secured by the flange screws. · DN 350: The ground cable connects directly to the metal transport bracket.
6 mm² Cu
DN 300
DN 350
F06-5xxxxxxx-04-xx-xx-xx-003
Fig. 39: Potential equalisation with equalising currents in metallic, non-grounded piping systems
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Plastic pipes and isolating lined pipes Normally, potential is matched using the reference electrodes in the measuring tube. However, in exceptional cases it is possible that, due to the grounding plan of a system, large matching currents flow over the reference electrodes. This can lead to destruction of the sensor, e.g. through electrochemical decomposition of the electrodes. In such cases, e.g. for fibre-glass or PVC piping, it is recommended that you use additional ground disks for potential matching (Fig. 40).
Mounting of ground disks Page 27, 34
"
Caution! · Risk of damage by electrochemical corrosion. Note the electrochemical insulation rating,
if the ground disks and measuring electrodes are made of different materials.
· Also, observe company-internal grounding guidelines.
Fig. 40: Potential equalisation/ground disks with plastic pipes or lined pipes
F06-5xxxxxxx-04-xx-xx-xx-004
Lined pipes (cathodic protection) In such cases, install the measuring instrument without potential in the piping: · When installing the measuring device, make sure that there is an electrical connection between
the two piping runs (copper wire, 6 mm2). · Make sure that the installation materials do not establish a conductive connection to the measu-
ring device and that the installation materials withstand the tightening torques applied when the threaded fasteners are tightened. · Also comply with the regulations applicable to potential-free installation.
Fig. 41: Potential equalisation and cathode protection 1 = isolating transformer power supply, 2 = electrically insulated
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4 Wiring
4.4 Degree of protection
The devices fulfill all the requirements for IP 67. Compliance with the following points is mandatory following installation in the field or servicing, in order to ensure that IP 67 protection is maintained:
· The housing seals must be clean and undamaged when inserted into their grooves. The seals must be dried, cleaned or replaced if necessary.
· All threaded fasteners and screw covers must be firmly tightened. · The cables used for connection must be of the specified outside diameter (see Page 108). · Firmly tighten the cable entries (Fig. 42). · The cables must loop down before they enter the cable entries ("water trap", Fig. 42).
This arrangement prevents moisture penetrating the entry. Always install the measuring device in such a way that the cable entries do not point up. · Remove all unused cable entries and insert plugs instead. · Do not remove the grommet from the cable entry.
"
!
Fig. 42: Installation instructions, cable entries
F06-xxxxxxxx-04-xx-xx-xx-005
Caution! Do not loosen the threaded fasteners of the Promag sensor housing, as otherwise the degree of protection guaranteed by Endress+Hauser no longer applies.
Note! The Promag W and Promag P sensors can be supplied with IP 68 rating (permanent immersion in water to a depth of 3 meters). In this case the transmitter must be installed remote from the sensor.
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4.5 Electical connection check
Perform the following checks after completing electrical installation of the measuring device:
Device condition and specifications
Notes
Are cables or the device damaged (visual inspection)?
-
Electrical connection
Notes
Does the supply voltage match the specifications on the nameplate?
85...260 V AC (45...65 Hz) 20...55 V AC (45...65 Hz) 16...62 V DC
Do the cables comply with the specifications?
see Page 51, 108
Do the cables have adequate strain relief?
-
Cables correctly segregated by type?
-
Without loops and crossovers?
Are the power-supply and signal cables correctly connected?
See the wiring diagram inside the cover of the terminal compartment
Are all screw terminals firmly tightened?
-
Have the measures for grounding/potential equalisation been correctly implemen- see Page 56 ff. ted?
Are all cable entries installed, firmly tightened and correctly sealed? Cables looped see Page 59 as "water traps"?
Are all housing covers installed and firmly tightened?
-
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5 Operation
5 Operation
5.1 Display and operating elements
The local display enables you to read all important parameters directly at the measuring point and configure the device.
The display area consists of two lines; this is where measured values are displayed, and/or status variables (direction of flow, partially filled pipe, bar graph, etc.). You can change the assignment of display lines to variables at will in order to customize the display to suit your needs and preferences ( see the "Description of Device Functions" manual).
+48.25 xx/yy
1
+3702.6 x
Esc
-+E
2
3
Fig. 43: Display and operating elements
A0001141
Liquid-crystal display (1) The backlit, two-line liquid-crystal display shows measured values, dialog texts, error messages and information messages. The display as it appears when normal measuring is in progress is known as the HOME position (operating mode).
Upper display line: Shows primary measured values, e.g. volume flow in [ml/min] or in [%]. Lower display line: Shows supplementary measured variables and status variables, e.g. totalizer reading in [m3], bar graph, measuring point designation
Push buttons (2) Enter numerical values, select parameters Select different function groups within the function matrix
Press the +/- keys simultaneously to trigger the following functions:
Exit the function matrix step by step HOME position Press and hold down +/- keys for longer than 3 seconds Return directly to HOME position
Cancel data entry
Enter push button (3)
HOME position Entry into the function matrix
Save the numerical values you input or settings you change
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!
5.2 Brief operating instruction to the function matrix
Note! · See the general notes on Page 63. · Function descriptions see the "Description of Device Functions" manual
1. HOME position F Enter the function matrix 2. Select a function group (e.g. CURRENT OUTPUT 1) 3. Select a function (e.g. TIME CONSTANT)
Change parameter / enter numerical values: O S select or enter enable code, parameters, numerical values F save your entries
4. Exit the function matrix: Press and hold down Esc key (X) for longer than 3 seconds HOME position Repeatedly press Esc key (X) return step by step to HOME position
Esc
-+ E
mE
p
Esc
+
Esc
+
>3s
o
E
Esc
+
E
E
E
E
n
+
E E E E
Fig. 44: Selecting functions and configuring parameters (function matrix)
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5 Operation
!
"
"
5.2.1 General notes
The Quick Setup menu (see Page 80) is adequate for commissioning in most instances. Complex measuring operations on the other hand necessitate additional functions that you can configure as necessary and customize to suit your process parameters. The function matrix, therefore, comprises a multiplicity of additional functions which, for the sake of clarity, are arranged in a number of function groups.
Comply with the following instructions when configuring functions: · You select functions as described on Page 62. · You can switch off certain functions (OFF). If you do so, related functions in other
function groups will no longer be displayed. · Certain functions prompt you to confirm your data entries. Press OS to select "SURE [ YES ]" and
press F again to confirm. This saves your setting or starts a function, as applicable. · Return to the HOME position is automatic if no key is pressed for 5 minutes.
Note! · The transmitter continues to measure while data entry is in progress, i.e. the current measured
values are output via the signal outputs in the normal way. · If the power supply fails, all preset and parameterized values remain safely stored in the EEPROM.
Caution! All functions are described in detail, including the function matrix itself, in the "Description of Device Functions" manual, which is a separate part of this Operating Instruction.
5.2.2 Enabling the programming mode
The function matrix can be disabled. Disabling the function matrix rules out the possibility of inadvertent changes to device functions, numerical values or factory settings. A numerical code (factory setting = 50) has to be entered before settings can be changed. If you use a code number of your choice, you exclude the possibility of unauthorized persons accessing data ( see the "Description of Device Functions" manual).
Comply with the following instructions when entering codes: · If programming is disabled and the OS key is pressed in any function, a prompt for the code
automatically appears on the display. · If "0" is entered as the customer's code, programming is always enabled. · The Endress+Hauser service organisation can be of assistance if you mislay your personal code.
Caution! Changing certain parameters such as all sensor characteristics, for example, influences numerous functions of the entire measuring system, particularly measuring accuracy. There is no need to change these parameters under normal circumstances and consequently, they are protected by a special code known only to the Endress+Hauser service organization. Please contact Endress+Hauser if you have any questions.
5.2.3 Disabling the programming mode
Programming is disabled if you do not press a key within 60 seconds following automatic return to the HOME position. You can also disable programming in the "ACCESS CODE" function by entering any number (other than the customer's code).
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5.3 Error messages
Type of error Errors which occur during commissioning or measuring operation are displayed immediately. If two or more system or process errors occur, the error with the highest priority is the one shown on the display.
The measuring system distinguishes between two types of error: · System errors: This group comprises all device errors, e.g. communication errors, hardware faults,
etc. see Page 90 · Process errors: This group comprises all application errors, e.g. empty pipe, etc. see Page 93
1 P XXXXXXXXXX #000 00:00:05
!
2
4
5
3
Fig. 45: Error messages on the display (example)
1 Error type: P = process error, S = system error
2 Error message type: $ = fault message; ! = notice message
3 Error designation: e.g. EMPTY PIPE = measuring tube is only partly filled or completely empty 4 Error number: e.g. #401 5 Duration of most recent error occurrence in hours / minutes / seconds
A0000991
Error message types Users have the option of weighting certain errors differently, in other words having them classed as "Fault messages" or "Notice messages". You can define messages in this way with the aid of the function matrix see the "Description of Device Functions" manual. Serious system errors, e.g. module defects, are always identified and classed as "fault messages" by the measuring device.
Notice message (!) · Displayed as Exclamation mark (!), error type (S: system error, P: process error). · The error in question has no effect on the outputs of the measuring device.
Fault message ( $) · Displayed as Lightning flash ( $), error type (S: system error, P: process error). · The error in question has a direct effect on the outputs.
The response of the outputs (failsafe mode) can be defined by means of functions in the function matrix (see Page 95).
Note! For security reasons, error messages should be output via the status output.
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5.4 Communication
In addition to local operation, the measuring device can be configured and measured values can be obtained by means of the HART protocol. Digital communication takes place using the 420 mA current output HART (see Page 55).
The HART protocol allows the transfer of measuring and device data between the HART master and the field devices for configuration and diagnostics purposes. The HART master, e.g. a handheld terminal or PC-based operating programs (such as ToF Tool - Fieldtool Package), require device description (DD) files which are used to access all the information in a HART device. Information is exclusively transferred using so-called "commands". There are three different command groups:
Universal commands: All HART device support and use universal commands. The following functionalities are linked to them: · Identify HART devices · Reading digital measured values (volume flow, totalizer, etc.)
Common practice commands: Common practice commands offer functions which are supported and can be executed by most but not all field devices.
Device-specific commands: These commands allow access to device-specific functions which are not HART standard. Such commands access individual field device information, amongst other things, such as empty/full pipe calibration values, low flow cutoff settings, etc.
Note! Promag 50 has access to all three command classes. On Page 69, you will find a list with all the supported "Universal Commands" and "Common Practice Commands".
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5.4.1 Operating options
For the complete operation of the measuring device, including device-specific commands, there are DD files available to the user to provide the following operating aids and programs:
Note! The HART protocol requires the "4...20 mA HART" setting (individual options see device function) in the CURRENT SPAN function (current output 1).
HART handheld terminal DXR 375 Selecting device functions with a HART Communicator is a process involving a number of menu levels and a special HART function matrix. The HART manual in the carrying case of the HART Communicator contains more detailed information on the device.
Operating program "ToF Tool - Fieldtool Package" Modular software package consisting of the service program "ToF Tool" for configuration and diagnosis of ToF level measuring devices (time-of-flight measurement) and evolution of pressure measuring instruments as well as the "Fieldtool" service program for the configuration and diagnosis of Proline flow measuring devices. The Proline flow measuring devices are accessed via a service interface or via the service interface FXA 193 or the HART protocol.
Contents of the "ToF Tool - Fieldtool Package": · Commissioning, maintenance analysis · Configuring flowmeters · Service functions · Visualisation of process data · Trouble-shooting · Controlling the "Fieldcheck" tester/simulator
Fieldcare FieldCare is Endress+Hauser's FDT-based plant Asset Management Tool and allows the configuration and diagnosis of intelligent field devices. By using status information, you also have a simple but effective tool for monitoring devices. The Proline flow measuring devices are accessed via a service interface or via the service interface FXA 193.
Operating program "SIMATIC PDM" (Siemens) SIMATIC PDM is a standardised, manufacturer-independent tool for the operation, configuration, maintenance and diagnosis of intelligent field devices.
Operating program "AMS" (Emerson Process Management) AMS (Asset Management Solutions): program for operating and configuring devices
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5.4.2 Current device description files
The following table illustrates the suitable device description file for the operating tool in question and then indicates where these can be obtained.
HART protocol:
Valid for software: Device data HART Manufacturer ID: Device ID: HART version data: Software release: Operating program: Handheld terminal DXR 375 ToF Tool - Fieldtool Package
Fieldcare / DTM
AMS
SIMATIC PDM
2.00.XX
Function "Device software"
11hex (ENDRESS+HAUSER) 41hex
Device Revison 6/ DD Revision 1
Function "Manufacturer ID" Function "Device ID"
03.2005
Sources for obtaining device descriptions:
· Use update function of handheld terminal
· www.tof-fieldtool.endress.com ( Download Software Device driver) · CD-ROM (Endress+Hauser order number 50097200)
· www.endress.com ( Download Software Device driver) · CD-ROM (Endress+Hauser order number 50097200)
· www.endress.com ( Download Software Device driver) · CD-ROM (Endress+Hauser order number 50097200)
· www.endress.com ( Download Software Device driver) · CD-ROM (Endress+Hauser order number 50097200)
Operation via the service protocol
Valid for device software:
2.00.XX
Function "Device software"
Software release:
03.2005
Operating program:
Sources for obtaining device descriptions:
ToF Tool - Fieldtool Package
· www.tof-fieldtool.endress.com ( Download Software Device driver) · CD-ROM (Endress+Hauser order number 50097200)
Tester/simulator: Fieldcheck
Sources for obtaining device descriptions: · Update by means of ToF Tool - Fieldtool Package via Fieldflash module
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5.4.3 Device and process variables
Device variables: The following device variables are available using the HART protocol:
Code (decimal) 0 1
250 251
Device variable OFF (not assigned) Volume flow Totalizer 1 Totalizer 2
Process variables: At the factory, the process variables are assigned to the following device variables:
· Primary process variable (PV) Volume flow · Second process variable (SV) Totalizer 1 · Third process variable (TV) not assigned · Fourth process variable (FV) not assigned
Note! You can set or change the assignment of device variables to process variables using Command 51 (see Page 73).
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5.4.4 Universal / Common practice HART commands
The following table contains all the universal and common practice commands supported by Promag 50.
Command No. HART command / Access type
Universal Commands
0
Read unique device identifier
Access type = read
Command data (numeric data in decimal form)
none
1
Read primary process variable
none
Access type = read
2
Read the primary process variable none
as current in mA and percentage
of the set measuring range
Access type = read
Response data (numeric data in decimal form)
Device identification delivers information on the device and the manufacturer. It cannot be changed.
The response consists of a 12 byte device ID: Byte 0: fixed value 254 Byte 1: Manufacturer ID, 17 = E+H Byte 2: Device type ID, 65 = Promag 50 Byte 3: Number of preambles Byte 4: Universal commands rev. no. Byte 5: Device-specific commands rev. no. Byte 6: Software revision Byte 7: Hardware revision Byte 8: Additional device information Bytes 9-11: Device identification
Byte 0: HART unit code of the primary process variable
Bytes 1-4: Primary process variable
Factory setting: Primary process variable = Volume flow
! Note!
· You can set the assignment of device variables to process variables using Command 51.
· Manufacturer-specific units are represented using the HART unit code "240".
Bytes 0-3: actual current of the primary process variable in mA
Bytes 4-7: Percentage of the set measuring range
Factory setting: Primary process variable = Volume flow
! Note!
You can set the assignment of device variables to process variables using Command 51.
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Command No. HART command / Access type
Command data (numeric data in decimal form)
3
Read the primary process variable none
as current in mA and four
(preset using Command 51)
dynamic process variables
Access type = read
Response data (numeric data in decimal form)
24 bytes are sent as a response: Bytes 0-3: primary process variable current in mA Byte 4: HART unit code of the primary process
variable Bytes 5-8: Primary process variable Byte 9: HART unit code of the second process
variable Bytes 10-13: Second process variable Byte 14: HART unit code of the third process
variable Bytes 15-18: Third process variable Byte 19: HART unit code of the fourth process
variable Bytes 20-23: Fourth process variable
6
Set HART shortform address
Byte 0: desired address (0...15)
Factory setting: · Primary process variable = Volume flow · Second process variable = Totalizer 1 · Third process variable = not assigned · Fourth process variable = not assigned
! Note!
· You can set the assignment of device variables to process variables using Command 51.
· Manufacturer-specific units are represented using the HART unit code "240".
Byte 0: active address
Access type = write
Factory setting: 0
! Note!
With an address >0 (multidrop mode), the current
output of the primary process variable is set to 4 mA.
11 Read unique device identification Bytes 0-5: TAG using the TAG (measuring point designation)
Access type = read
Device identification delivers information on the device and the manufacturer. It cannot be changed. The response consists of a 12 byte device ID if the given TAG agrees with the one saved in the device:
Byte 0: fixed value 254 Byte 1: Manufacturer ID, 17 = E+H Byte 2: Device type ID, 65 = Promag 50 Byte 3: Number of preambles Byte 4: Universal commands rev. no. Byte 5: Device-specific commands rev. no. Byte 6: Software revision Byte 7: Hardware revision Byte 8: Additional device information Bytes 9-11: Device identification
12 Read user message
none
Bytes 0-24: User message
Access type = read
! Note!
You can write the user message using Command 17.
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Command No. HART command / Access type
13 Read TAG, descriptor and date
Access type = read
Command data (numeric data in decimal form)
none
14 Read sensor information on
none
primary process variable
15 Read output information of pri- none mary process variable
Access type = read
Response data (numeric data in decimal form)
Bytes 0-5: TAG Bytes 6-17: descriptor Bytes 18-20: Date
! Note!
You can write the TAG, descriptor and date using Command 18.
Bytes 0-2: Sensor serial number Byte 3: HART unit code of sensor limits and
measuring range of the primary process variable Bytes 4-7: Upper sensor limit Bytes 8-11: Lower sensor limit Bytes 12-15: Minimum span
! Note!
· The data relate to the primary process variable (= volume flow).
· Manufacturer-specific units are represented using the HART unit code "240".
Byte 0: Alarm selection ID Byte 1: Transfer function ID Byte 2: HART unit code for the set measuring range
of the primary process variable Bytes 3-6: upper range, value for 20 mA Bytes 7-10: lower range, value for 4 mA Bytes 11-14: Damping constant in [s] Byte 15: Write protection ID Byte 16: OEM dealer ID, 17 = E+H
16 Read the device production num- none ber
Factory setting: Primary process variable = Volume flow
! Note!
· You can set the assignment of device variables to process variables using Command 51.
· Manufacturer-specific units are represented using the HART unit code "240".
Bytes 0-2: Production number
Access type = read
17 Write user message Access = write
You can save any 32-character long text in the device under this parameter:
Bytes 0-23: Desired user message
Displays the current user message in the device: Bytes 0-23: Current user message in the device
18 Write TAG, descriptor and date With this parameter, you can store an 8 character TAG, a 16 character descriptor and a date:
Access = write Bytes 0-5: TAG Bytes 6-17: descriptor Bytes 18-20: Date
Displays the current information in the device:
Bytes 0-5: TAG Bytes 6-17: descriptor Bytes 18-20: Date
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Command No. HART command / Access type
Command data (numeric data in decimal form)
Response data (numeric data in decimal form)
Common Practice Commands
34 Write damping value for primary Bytes 0-3: Damping value of the primary process vari- Displays the current damping value in the device:
process variable
able in seconds
Bytes 0-3: Damping value in seconds
Access = write
Factory setting:
Primary process variable = Volume flow
35 Write measuring range of primary Write the desired measuring range:
The currently set measuring range is displayed as a
process variable
Byte 0: HART unit code of the primary process
response:
variable
Access = write
Bytes 1-4: upper range, value for 20 mA
Byte 0: HART unit code for the set measuring range
Bytes 5-8: lower range, value for 4 mA
of the primary process variable
Bytes 1-4: upper range, value for 20 mA
Factory setting:
Bytes 5-8: lower range, value for 4 mA
Primary process variable = Volume flow
! Note!
! Note!
Manufacturer-specific units are represented using the
· You can set the assignment of device variables to HART unit code "240".
process variables using Command 51.
· If the HART unit code is not the correct one for the
process variable, the device will continue with the
last valid unit.
38 Device status reset (Configura- none
none
tion changed)
Access = write 40 Simulate output current of
primary process variable
Access = write
Simulation of the desired output current of the primary process variable. An entry value of 0 exits the simulation mode:
Bytes 0-3: Output current in mA
The momentary output current of the primary process variable is displayed as a response:
Bytes 0-3: Output current in mA
42 Perform master reset
Factory setting: Primary process variable = Volume flow
! Note!
You can set the assignment of device variables to
process variables using Command 51.
none
none
Access = write
44 Write unit of primary process vari- Set unit of primary process variable. Only unit which The current unit code of the primary process variable is
able
are suitable for the process variable are transferred to displayed as a response:
the device:
Access = write
Byte 0: HART unit code
Byte 0: HART unit code
Factory setting: Primary process variable = Volume flow
! Note!
Manufacturer-specific units are represented using the
HART unit code "240".
! Note!
· If the written HART unit code is not the correct one for the process variable, the device will continue with the last valid unit.
· If you change the unit of the primary process variable, this has no impact on the system units.
48 Read additional device status
none
Access = read
The device status is displayed in extended form as the response:
Coding: see table on Page 74
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Command No. HART command / Access type
50 Read assignment of the device variables to the four process variables
Command data (numeric data in decimal form)
none
Access = read
Response data (numeric data in decimal form)
Display of the current variable assignment of the process variables:
Byte 0: Device variable code to the primary process variable
Byte 1: Device variable code to the second process variable
Byte 2: Device variable code to the third process variable
Byte 3: Device variable code to the fourth process variable
Factory setting: · Primary process variable: Code 1 for volume flow · Second process variable: Code 250 for totalizer 1 · Third process variable: Code 0 for OFF (not assig-
ned) · Fourth process variable: Code 0 for OFF (not assig-
ned)
! Note!
You can set or change the assignment of device
variables to process variables using Command 51.
51 Write assignments of the device Setting of the device variables to the four process
The variable assignment of the process variables is
variables to the four process
variables:
displayed as a response:
variables
Byte 0: Device variable code to the primary process Byte 0: Device variable code to the primary process
Access = write
variable
variable
Byte 1: Device variable code to the second process Byte 1: Device variable code to the second process
variable
variable
Byte 2: Device variable code to the third process Byte 2: Device variable code to the third process
variable
variable
Byte 3: Device variable code to the fourth process Byte 3: Device variable code to the fourth process
variable
variable
Code of the supported device variables: See data on Page 68
Factory setting: · Primary process variable = Volume flow · Second process variable = Totalizer 1 · Third process variable = OFF (not assigned) · Fourth process variable = OFF (not assigned)
53 Write device variable unit Access = write
This command set the unit of the given device variables. Only those units which suit the device variable are transferred:
Byte 0: Device variable code Byte 1: HART unit code
Code of the supported device variables: See data on Page 68
! Note!
· If the written unit is not the correct one for the device variable, the device will continue with the last valid unit.
· If you change the unit of the device variable, this has no impact on the system units.
The current unit of the device variables is displayed in the device as a response:
Byte 0: Device variable code Byte 1: HART unit code
! Note!
Manufacturer-specific units are represented using the HART unit code "240".
59
Write number of preambles in
This parameter sets the number of preambles which As a response, the current number of the preambles is
response message
are inserted in the response messages:
displayed in the response message:
Access = write
Byte 0: Number of preambles (2...20)
Byte 0: Number of preambles
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5.4.5 Device status / Error messages
You can read the extended device status, in this case, current error messages, via Command "48". The command delivers information which are partly coded in bits (see table below).
Note! You can find a detailed explanation of the device status and error messages and their elimination on Page 90 ff.
Byte Bit 0-0 0-1 0-2 0-3 0-4 0-5 0-6 0-7 1-0 1-1 1-2 1-3 1-4 1-5 1-6 1-7 2-0 2-1 2-2 2-3 2-4 2-5 2-6 2-7 3-0 3-1 3-2 3-3 3-4 3-5 3-6 3-7 4-0 4-1 4-2 4-3 4-4
Error No. 001 011 012 not assigned not assigned not assigned not assigned not assigned not assigned 031 032 not assigned not assigned 051 not assigned not assigned not assigned not assigned not assigned not assigned not assigned not assigned not assigned not assigned not assigned not assigned not assigned 111 121 not assigned not assigned not assigned not assigned not assigned not assigned 251 261
Short error description ( Page 90 ff. ) Serious device error Measuring amplifier has faulty EEPROM Error when accessing data of the measuring amplifier EEPROM S-DAT: defective or missing S-DAT: Error accessing saved values I/O board and the amplifier board are not compatible. Totalizer checksum error I/O board and the amplifier board are not compatible. Internal communication fault on the amplifier board. No data reception between amplifier and I/O board
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Byte Bit 4-5 4-6 4-7 5-0 5-1 5-2 5-3 5-4 5-5 5-6 5-7 6-0 6-1 6-2 6-3 6-4 6-5 6-6 6-7 7-0 7-1 7-2 7-3 7-4 7-5 7-6 7-7 8-0 8-1 8-2 8-3 8-4 8-5 8-6 8-7 9-0 9-1 9-2 9-3 9-4 9-5 9-6 9-7
Error No. not assigned not assigned not assigned 321 not assigned not assigned not assigned not assigned not assigned not assigned 339 340 341 342 343 344 345 346 347 348 349 350 351 352 353 354 355 356 357 358 359 360 361 362 not assigned not assigned not assigned not assigned not assigned not assigned not assigned not assigned not assigned
Short error description ( Page 90 ff. ) Coil current of the sensor is outside the tolerance.
Flow buffer: The temporarily buffered flow portions (measuring mode for pulsating flow) could not be cleared or output within 60 seconds.
Frequency buffer: The temporarily buffered flow portions (measuring mode for pulsating flow) could not be cleared or output within 60 seconds.
Pulse buffer: The temporarily buffered flow portions (measuring mode for pulsating flow) could not be cleared or output within 60 seconds.
Current output: flow is out of range.
Frequency output: flow is out of range.
Pulse output: the pulse output frequency is out of range.
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Byte Bit 10-0 10-1 10-2 10-3 10-4 10-5 10-6 10-7 11-0 11-1
11-2
11-3
11-4
11-5 11-6 11-7 12-0 12-1 12-2 12-3 12-4 12-5 12-6
12-7
13-0 13-1 13-2 13-3 13-4 13-5 13-6 13-7 14-0 14-1 14-2 14-3 14-4 14-5 14-6
Error No. not assigned not assigned not assigned not assigned not assigned not assigned not assigned 401 not assigned not assigned
461
not assigned
463
not assigned not assigned not assigned not assigned 474 not assigned not assigned not assigned not assigned not assigned
501
502 not assigned not assigned not assigned not assigned not assigned not assigned not assigned not assigned not assigned not assigned 601 not assigned not assigned not assigned
Short error description ( Page 90 ff. ) Measuring tube partially filled or empty EPD calibration not possible because the fluid's conductivity is either too low or too high. The EPD calibration values for empty pipe and full pipe are identical, therefore incorrect. Maximum flow value entered is overshot. New amplifier software version is loaded. Currently no other commands are possible. Upload and download of device files. Currently no other commands are possible. Positive zero return active
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Byte Bit 14-7 15-0 15-1 15-2 15-3 15-4 15-5 15-6 15-7 16-0 16-1 16-2 16-3 16-4 16-5 16-6 16-7 17-0 17-1 17-2 17-3 17-4 17-5 17-6 17-7 18-0 18-1 18-2 18-3 18-4 18-5 18-6 18-7
Error No. 611 612 613 614 621 622 623 624 631 632 633 634 641 642 643 644 not assigned not assigned not assigned not assigned not assigned not assigned not assigned not assigned 671 672 673 674 691 692 not assigned not assigned not assigned
Short error description ( Page 90 ff. )
Simulation current output active
Simulation frequency output active
Simulation pulse output active
Simulation status output active
Simulation status input active Simulation status input active Simulation status input active Simulation status input active Simulation of response to error (outputs) active Simulation of volume flow active
5 Operation
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6 Commissioning
6 Commissioning
6.1 Function check
Make sure that all final checks have been completed before you start up your measuring point: · Checklist for "Installation check" Page 46 · Checklist for "Electrical connection check" Page 60
6.1.1 Switching on the measuring device
Once the connection checks (see Page 60) have been successfully completed, it is time to switch on the power supply. The device is now operational. The measuring device performs a number of post switch-on self-tests. As this procedure progresses the following sequence of messages appears on the local display:
!
PROMAG 50 START UP ...
DEVICE SOFTWARE V XX.XX.XX
SYSTEM OK
OPERATION
Start-up message Current software version Beginning of normal measuring mode
Normal measuring mode commences as soon as start-up completes. Various measured-value and/or status variables (HOME position) appear on the display.
Note! If start-up fails, an error message indicating the cause is displayed.
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6.2 Application-specific commissioning
In the case of measuring devices without a local display, the individual parameters and functions must be configured via the configuration program, e.g. ToF Tool - Fieldtool Package. If the measuring device is equipped with a local display, all the important device parameters for standard operation can be configured quickly and easily by means of the "Commissioning" Quick Setup menu. · Quick Setup "Commissioning", Page 3 ff.
6.2.1 "Commissioning" Quick Setup menu
This Quick Setup menu guides you systematically through the setup procedure for all the major device functions that have to be configured for standard measuring operation.
Note! In the case of measuring devices without a local display, the individual parameters and functions must be configured by means of a configuration program, such as ToF Tool - Fieldtool Package from Endress+Hauser.
ENDRESS+HAUSER
-
+
E
ESC
E
++
HOME-POSITION
Quick Setup E+
QS Commission
Language
Defaults
Unit Volume flow Measuring
Mode
Current Output
Freq.-/ Pulse Output
Quit
Operation Mode
Assign Current
Current Span
Value 20 mA
Time Constant
Failsafe Mode
Frequency
Assign Frequency
End Value Freq.
Value f max Output Signal
Time Constant
Failsafe Mode
Pulse
Assign Pulse
Pulse Value
Pulse Width Output Signal
Failsafe Mode
Automatic parameterization of the display
Quit Quick Setup
Fig. 46: Quick Setup for commissioning
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F06-50xxxxxx-19-xx-xx-en-000
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6 Commissioning
"
!
6.2.2 Empty-pipe/full-pipe adjustment
Flow cannot be measured correctly unless the measuring tube is completely full. This status can be permanently monitored using the Empty Pipe Detection: · EPD = Empty Pipe Detection (with the help of an EPD electrode) · OED = Open Electrode Detection (Empty Pipe Detection with the help of the measuring electro-
des, if the sensor is not equipped with an EPD electrode or the orientation is not suitable for using EPD).
Caution! A detailed description and other helpful hints for the empty-pipe/full-pipe adjustment procedure can be found in the separate "Description of Device Functions" Manual: · EPD/OED ADJUSTMENT Carrying out the adjustment. · EPD Switching on and off EPD/OED. · EPD RESPONSE TIME Input of the response time for EPD/OED.
Note! · The EPD function is not available unless the sensor is fitted with an EPD electrode. · The devices are already calibrated at the factory with water (approx. 500 µS/cm).
If the fluid conductivity differs from this reference, empty-pipe/full-pipe adjustment has to be performed again on site. · The default setting for EPD/OED when the devices are delivered is OFF; the function has to be activated if required. · The EPD/OED process error can be output by means of the configurable status output.
Performing empty-pipe and full-pipe adjustment (EPD/OED)
1. Select the appropriate function in the function matrix: HOME F R PROCESS PARAMETER F R EPD/OED ADJUSTMENT
2. Empty the piping. In case of an EPD adjustment, the wall of the measuring tube should be wetted with fluid for the adjustment procedure but this is not the case with an OED adjustment.
3. Start empty-pipe adjustment: Select "EMPTY PIPE ADJUST" or "OED EMPTY ADJUST" and press F to confirm.
4. After empty-pipe adjustment, fill the piping with fluid. 5. Start full-pipe adjustment: Select "FULL PIPE ADJUST" or "OED FULL ADJUST" and press F
to confirm. 6. Having completed the adjustment, select the setting "OFF" and exit the function by pressing
F . 7. Now select the "EPD" function. Switch on Empty Pipe Detection by selecting the
following settings: EPD Select ON STANDARD or ON SPECIAL and press F to confirm. OED Select OED and confirm with F .
" Caution!
The adjustment coefficients must be valid before you can activate the EPD/OED function. If adjustment is incorrect the following messages might appear on the display: FULL = EMPTY
The adjustment values for empty pipe and full pipe are identical. In cases of this nature you must repeat empty-pipe or full-pipe adjustment! ADJUSTMENT NOT OK Adjustment is not possible because the fluid's conductivity is out of range.
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6.2.3 Current output: active/passive
The current output is configured as "active" or "passive" by means of various jumpers on the I/O board.
Warning! · Risk of electric shock. Exposed components carry dangerous voltages. Make sure that the power
supply is switched off before you remove the cover of the electronics compartment. · Wait at least 10 minutes for heat to dissipate before opening an Ex-rated device.
1. Switch off power suppy. 2. Remove the I/O board Page 98, 100 3. Position the jumper according to Fig. 47.
" Caution!
Risk of destroying the measuring device. Set the jumpers exactly as shown in Fig. 47. Incorrectly set jumpers can cause overcurrents that would destroy either the measuring device or external devices connected to it.
4. Installation of the I/O board is the reverse of the removal procedure.
1 2
Fig. 47: Configuring the current output (I/O board)
1 Active current output (Factory setting) 2 Passive current output
A0001044
6.3 Data storage device (HistoROM)
At Endress+Hauser, the term HistoROM refers to various types of data storage modules on which process and measuring device data are stored.
6.3.1 HistoROM/S-DAT (sensor-DAT)
The S-DAT is an exchangeable data storage device in which all sensor relevant parameters are stored, i.e., diameter, serial number, calibration factor, zero point.
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7 Maintenance
7 Maintenance
The Promag 50 flow measuring system requires no special maintenance.
7.1 Exterior cleaning
When cleaning the exterior of measuring devices, always use cleaning agents that do not attack the surface of the housing and the seals.
7.2 Seals
The seals of the Promag H sensor must be replaced periodically, particularly in the case of gasket seals (aseptic version). The period between changes depends on the frequency of cleaning cycles, the cleaning temperature and the fluid temperature. Replacement seals (accessories) Page 85.
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8 Accessories
8 Accessories
Various accessories, which can be ordered separately from Endress+Hauser, are available for the transmitter and the sensor. The Endress+Hauser service organisation can provide detailed information on the order codes of your choice.
8.1 Device-specific accessories
Accessory
Transmitter Promag 50
Description
Transmitter for replacement or for stock. Use the order code to define the following specifications:
Approvals Degree of protection / version Cable type for the remote version Cable entries Display / power supply / operation Software Outputs / inputs
Order code
50XXX - XXXXX * * * * * * * *
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8.2 Measuring principle-specific accessories
Accessory
Description
Mounting kit for transmitter Promag 50/53
Mounting kit for wall-mounted housing (remote version). Suitable for: Wall mounting Post mounting Installation in control panel
Order code
DK5WM - *
Cable for remote version Ground cable for Promag W, P Ground disk for Promag W, P Mounting kit for Promag H
Adapter connection for Promag A, H
Ground rings for Promag H
Set of seals for Promag H
Wall-mounting kit for Promag H Welding jig for Promag H
Mounting set for aluminium housings. Suitable for pipe mounting (3/4"...32")
Coil and signal cables, various lengths. Reinforced cable on request.
A set consists of two ground cables.
DK5CA - * * DK5GC - * * *
Ground disk for potential equalisation
DK5GD - * * *
Mounting kit for Promag H, comprising: 2 process connections Threaded fasteners Seals
DKH * * - * * *
Adapter connections for installing Promag 50 H instead of Promag 30/33 A or Promag 30/33 H DN 25.
DK5HA - * * * * *
If the process connections are made of PVC or PVDF, ground rings are necessary to ensure that potential is matched. Set of ground rings, comprising: 2 ground rings
DK5HR - * * *
For regular replacement of the seals of the Promag H DK5HS - * * *
sensor.
Wall-mounting kit for the Promag H sensor
DK5HM - * *
Weld nipple as process connection: welding jig for installation in pipe.
DK5HW - * * *
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8.3 Communication-specific accessories
Accessory
HART Communicator DXR 375 hand-held terminal
Description
Order code
Hand-held terminal for remote parameterisation and for fetching measured values via the current output HART (4...20 mA).
DXR375 - * * * *
Contact your Endress+Hauser representative for more information.
8.4 Communication-specific accessories
Accessory Applicator ToF Tool - Fieldtool Package
Fieldcheck
Description
Order code
Software for selecting and configuring flowmeters. Applicator can be downloaded from the Internet or ordered on CD-ROM for installation on a local PC. Contact your Endress+Hauser representative for more information.
DKA80 - *
Modular software package consisting of the service program "ToF Tool" for configuration and diagnosis of ToF level measuring devices (time-of-flight measurement) and the "Fieldtool" service program for the configuration and diagnosis of Proline flow measuring devices. The Proline flow measuring devices are accessed via a service interface or via the service interface FXA 193.
DXS10 - * * * * *
Contents of the "ToF Tool - Fieldtool Package": Commissioning, maintenance analysis Configuring flowmeters Service functions Visualisation of process data Trouble-shooting Controlling the "Fieldcheck" tester/simulator
Contact your Endress+Hauser representative for more information.
Tester/simulator for testing flowmeters in the field. When used in conjunction with the "ToF Tool Fieldtool Package" software package, test results can be imported into a database, printed and used for official certification.
DXC10 - * *
Contact your Endress+Hauser representative for more information.
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9 Trouble-shooting
9.1 Trouble-shooting instructions
Always start trouble-shooting with the checklist below, if faults occur after start-up or during operation. The routine takes you directly to the cause of the problem and the appropriate remedial measures.
Check the display
No display visible and no output signals present.
1. Check the power supply terminals 1, 2 2. Check the power line fuse Page 102
85...260 V AC: 0.8 A slow-blow / 250 V
20...55 V AC and 16...62 V DC: 2 A slow-blow / 250 V
3. Measuring electronics defective order spare parts Page 97
No display visible, but output signals are present.
1. Check whether the ribbon-cable connector of the display module is correctly
plugged into the amplifier board Page 99, 101 2. Display module defective order spare parts Page 97 3. Measuring electronics defective order spare parts Page 97
Display texts are in a foreign lan- Switch off power supply. Press and hold down both the OS buttons and switch on
guage.
the measuring device. The display text will appear in English (default) and is dis-
played at maximum contrast.
Measured value indicated, but no signal at the current or pulse output
Measuring electronics defective order spare parts Page 97
Error messages on display
Errors which occur during commissioning or measuring operation are displayed immediately. Error messages consist of a variety of icons: the meanings of these icons are as follows (example):
Error type: S = system error, P = process error
Error message type: $ = fault message, ! = notice message
EMPTY PIPE = Type of error, e.g. measuring tube is only partly filled or completely empty 03:00:05 = duration of error occurrence (in hours, minutes and seconds) # 401 = error number
" Caution!!
· See the information on Page 64! · The measuring system interprets simulations and positive zero return as system errors, but displays them as notice
message only.
Error number: No. 001 399 No. 501 699
System error (device error) has occurred Page 90
Error number: No. 401 - 499
Process error (application error) has occurred Page 93
Other error (without error message)
Some other error has occurred. Diagnosis and rectification Page 94
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!
9.2 System error messages
Serious system errors are always recognised by the instrument as "Fault message", and are shown as a lightning flash ( $) on the display. Fault messages immediately affect the inputs and outputs. Simulations and positive zero return, on the other hand, are classed and displayed as notice messages.
Caution! In the event of a serious fault, a flowmeter might have to be returned to the manufacturer for repair. The procedures on Page 8 must be carried out before you return a flowmeter to Endress+Hauser. Always enclose a duly completed "Declaration of contamination" form. You will find a preprinted blank of the this form at the back of this manual.
Note! The listed error message types below correspond to the factory setting. Also observe the information on Page 64 and 95.
No. Error message / Type Cause
Remedy / spare part
S = System error
$ = Fault message (with an effect on the outputs)
! = Notice message (without an effect on the outputs)
No. # 0xx Hardware error
001 S: CRITICAL FAILURE
$: # 001
Serious device error
Replace the amplifier board. Spare parts Page 97
011 S: AMP HW EEPROM
$: # 011
Amplifier: Defective EEPROM
Replace the amplifier board. Spare parts Page 97
012 S: AMP SW EEPROM
$: # 012
Amplifier: Error accessing EEPROM data
The EEPROM data blocks in which an error has occurred are displayed in the "TROUBLESHOOTING" function. Press Enter to acknowledge the errors in question; default values are automatically inserted instead of the errored parameter values.
! Note!
The measuring device has to be restarted if an error has occurred in a totalizer block (see error No. 111 / CHECKSUM TOTAL).
031 S: SENSOR HW DAT
$: # 031
Sensor DAT: 1. S-DAT is defective. 2. S-DAT is not plugged into the amplifier board
or is missing.
1. Replace the S-DAT. Spare parts Page 97 Check the spare part set number to ensure that the new, replacement DAT is compatible with the measuring electronics.
2. Plug the S-DAT into the amplifier board Page 99, 101
032 S: SENSOR SW DAT
$: # 032
Sensor: Error accessing the calibration values stored in the S-DAT.
1. Check whether the S-DAT is correctly plugged into the amplifier board Page 99, 101
2. Replace the S-DAT if it is defective. Spare parts Page 97. Before replacing the DAT, check that the new, replacement DAT is compatible with the measuring electronics. Check the: Spare part set number Hardware revision code
3. Replace measuring electronics boards if necessary. Spare parts Page 97
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No.
Error message / Type
No. # 1xx Software error
Cause
Remedy / spare part
101 S: GAIN ERROR AMP
$: # 101
Gain deviation compared to reference gain is grea- Replace amplifier board.
ter than 2%.
Spare parts Page 97
111 S: CHECKSUM TOTAL
$: # 111
Totalizer checksum error
1. Restart the measuring device 2. Replace the amplifier board if necessary.
Spare parts Page 97
121 S: A / C COMPATIB. !: # 121
Due to different software versions, I/O board and amplifier board are only partially compatible (possibly restricted functionality).
Module with lower software version has either to be actualizied by FieldTool with the required software version or the module has to be replaced.
! Note!
The indication on the display as notice message appears only for 30 seconds (with listing in "Previous system condition" function).
This condition can occur if only one electronics board has been exchanged; the extended software functionality is not available. The previously existing software functionality is still working and the measurement possible.
Spare parts Page 97
No. # 2xx Error in DAT / no communication
251 S: COMMUNICATION I/O Internal communication error on the amplifier
$: # 251
board.
Remove the amplifier board. Spare parts Page 97
261 S: COMMUNICATION I/O No data reception between amplifier and I/O
$: # 261
board or faulty internal data transfer.
No. # 3xx System limits exceeded
Check the BUS contacts
321 S: TOL. COIL CURR.
$: # 321
Sensor: Coil current is out of tolerance.
1. Remote version: Switch off the power supply before connecting or discon-necting the cable of the coil (terminals 41/42).
2. Remote version: Switch off power supply and check wiring of terminals 41/42 Page 47 ff.
3. Switch off the power supply and check the connectors of the coil cable Page 99, 101
4. Replace measuring electro-nics boards if necessary. Spare parts Page 97
339 S: STACK CUR OUT n ... !: # 339...342 342
343 S: STACK FREQ. OUT n ... !: # 343...346 346
The temporarily buffered flow portions (measuring mode for pulsating flow) could not be cleared or output within 60 seconds.
1. Change the upper or lower limit setting, as applicable. 2. Increase or reduce flow, as applicable.
Recommendations in the event of fault category = FAULT MESSAGE ($): Configure the fault response of the output to "ACTUAL
VALUE" (see Page 95), so that the temporary buffer can be cleared. Clear the temporary buffer by the measures described under Item 1.
347 S: STACK PULSE OUT n ... !: # 347...350 350
The temporarily buffered flow portions (measuring mode for pulsating flow) could not be cleared or output within 60 seconds.
1. Increase the setting for pulse weighting 2. Increase the max. pulse frequency, if the totalizer can handle
a higher number of pulses. 3. Reduce flow
Recommendations in the event of fault category = FAULT MESSAGE ($): Configure the fault response of the output to "ACTUAL
VALUE" (see Page 95), so that the temporary buffer can be cleared. Clear the temporary buffer by the measures described under Item 1.
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No. Error message / Type
351 S: CURRENT RANGE n ... !: # 351...354 354
355 S: FREQ. RANGE n ... !: # 355...358 358
359 S: PULSE RANGE n ... !: # 359...362 362
Cause Current output: Flow is out of range.
Frequency output: Flow is out of range.
Pulse output: Pulse output frequency is out of range.
Remedy / spare part
1. Change the upper or lower limit setting, as applicable. 2. Increase or reduce flow, as applicable.
1. Change the upper or lower limit setting, as applicable. 2. Increase or reduce flow, as applicable.
1. Increase the setting for pulse weighting 2. When selecting the pulse width, choose a value that can still
be processed by a connected counter (e.g. mechanical counter, PLC etc.).
Determine the pulse width: Variant 1: Enter the minimum duration that a pulse must be
present at the connected counter to ensure its registration. Variant 2: Enter the maximum (pulse) frequency as the half
"reciprocal value" that a pulse must be present at the connected counter to ensure its registration.
Example: The maximum input frequency of the connected counter is 10 Hz. The pulse width to be entered is:
----------1----------2 10 Hz
=
50 ms
No. # 5xx Application error
3. Reduce flow.
501 S: SW.-UPDATE ACT. !: # 501
New amplifier or communication (I/O module) software version is loaded. Currently no other functions are possible.
Wait until the procedure is finished. The device will restart automatically.
502 S: UP-/DOWNLOAD ACT Up- or downloading the device data via configura- Wait until the procedure is finished.
!: # 502
tion program. Currently no other functions are
possible.
No. # 6xx Simulation mode active
601 S: POS. ZERO-RETURN !: # 601
Positive zero return active
" Caution!!
This message has the highest display priority!
Switch off positive zero return
611 S: SIM. CURR. OUT. n ... !: # 611...614 614
Simulation current output active
Switch off simulation
621 SIM. FREQ. OUT. n ... !: # 621...624 624
Simulation frequency output active
Switch off simulation
631 S: SIM. PULSE n ... !: # 631...634 634
Simulation pulse output active
Switch off simulation
641 S: SIM. STAT. OUT n ... !: # 641...644 644
Simulation status output active
Switch off simulation
671 S: SIM. STATUS IN ... !: # 671...674 674
Simulation status input active
Switch off simulation
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No.
Error message / Type
691 S: SIM. FAILSAFE !: # 691
692 S: SIM. VOL. FLOW !: # 692
698 S: DEV. TEST ACT. !: # 698
Cause Simulation of response to error (outputs) active
Remedy / spare part Switch off simulation
Simulation of volume flow active
Switch off simulation
The measuring device is being checked on site via the test and simulation device.
!
9.3 Process error messages
Process errors can be defined as either "Fault" or "Notice" messages and can thereby be weighted differently. Determination of this is done via the function matrix (see the "Description of Device Functions" Manual).
Note! The error types listed in the following correspond to the factory settings. Also observe the information on Page 64 ff. and 95.
No. Error message / Type
Cause
Remedy
P = Process error
$ = Fault message (with an effect on the outputs)
! = Notice message (without an effect on the outputs)
401 EMPTY PIPE
$: # 401
Measuring tube partially filled or empty
1. Check the process conditions of the plant 2. Fill the measuring tube
461 ADJ. NOT OK !: # 461
EPD/OED calibration not possible because the fluid's conductivity is either too low or too high.
The EPD/OED function cannot be used with fluids of this nature.
463 FULL = EMPTY
$: # 463
The EPD/OED calibration values for empty pipe and full pipe are identical, therefore incorrect.
Repeat calibration, making sure procedure is correct Page 81
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9.4 Process errors without messages
Symptoms
Rectification
Remark: You may have to change or correct certain settings in functions in the function matrix in order to rectify the fault. The functions outlined below, such as DISPLAY DAMPING, for example, are described in detail in the "Description of Device Functions" manual.
Flow values are negative, even though the fluid is flowing forwards through the pipe.
1. Remote version: Switch off the power supply and check the wiring
Page 47 ff.
If necessary, reverse the connections at terminals 41 and 42 2. Change the setting in the "INSTALLATION DIRECTION SENSOR" function
accordingly
Measured-value reading fluctuates even though flow is steady.
1. Check grounding and potential equalization Page 56 ff.
2. Check the fluid for presence of gas bubbles.
3. In the "TIME CONSTANT" function (current output) increase the value 4. In the "DISPLAY DAMPING" function increase the value
Measured-value reading shown on display, even though the fluid is at a standstill and the measuring tube is full.
1. Check grounding and potential equalization Page 56 ff.
2. Check the fluid for presence of gas bubbles. 3. Activate the "LOW FLOW CUTOFF" function, i.e. enter or increase the value
for the switching point.
Measured-value reading on display, even though measuring tube is empty.
1. Perform empty-pipe/full-pipe adjustment and then switch on Empty Pipe detec-
tion Page 81 2. Remote version: Check the terminals of the EPD cable Page 47 ff.
3. Fill the measuring tube.
The current output signal is always 4 mA, irrespective of the flow signal at any given time.
1. Select the "BUS ADDRESS" function and change the setting to "0". 2. Value for creepage too high. Reduce corresponding value in the "Low flow
cutoff" functions (ON-/OFF-VALUE).
The fault cannot be rectified or some other fault not described above has arisen.
In these instances, please contact your Endress+Hauser service organization.
The following options are available for tackling problems of this nature:
Request the services of an Endress+Hauser service technician If you contact our service organization to have a service technician sent out, please be ready to quote the following information: Brief description of the fault Nameplate specifications (Page 9 ff.): order code, serial number
Returning devices to Endress+Hauser The procedures on Page 8 must be carried out before you return a flowmeter requiring repair or calibration to Endress+Hauser. Always enclose a duly completed "Declaration of Conformity" form with the flowmeter. You will find a preprinted form at the back of this manual.
Replace transmitter electronics
Components in the measuring electronics defective order spare parts Page 97
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9.5 Response of outputs to errors
Note! The failsafe mode of totalizers, current, pulse and frequency outputs can be customized by means of various functions in the function matrix. You will find detailed information on these procedures in the "Description of Device Functions" manual.
Positive zero return and failsafe mode: You can use positive zero return to set the signals of the current, pulse and frequency outputs to their fallback value, for example when measuring has to be interrupted while a pipe is being cleaned. This function takes priority over all other device functions: simulations, for example, are suppressed.
Failsafe mode of outputs and totalizers
Process/system error is current
Positive zero return is activated
" Caution!!
System or process errors defined as "Notice messages" have no effect whatsoever on the
inputs and outputs. See the information on Page 64 ff.
Current output
MINIMUM CURRENT The current output will be set to the lower value of the signal on alarm level depending on the setting selected in the CURRENT SPAN (see the "Description of Device Functions" manual).
Output signal corresponds to "zero flow"
MAXIMUM CURRENT The current output will be set to the higher value of the signal on alarm level depending on the setting selected in the CURRENT SPAN (see the "Description of Device Functions" manual).
HOLD VALUE Measured value display on the basis of the last saved value preceding occurrence of the fault.
ACTUAL VALUE Measured value display on the basis of the current flow measurement. The fault is ignored.
Pulse output
FALLBACK VALUE
Signal output no pulses
Output signal corresponds to "zero flow"
ACTUAL VALUE Fault is ignored, i.e. normal measured-value output on the basis of ongoing flow measurement.
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Failsafe mode of outputs and totalizers
Process/system error is current
Positive zero return is activated
Frequency output
FALLBACK VALUE
Signal output 0 Hz
Output signal corresponds to "zero flow"
FAILSAFE LEVEL Output of the frequency specified in the FALÌLSAFE VALUE function.
HOLD VALUE Last valid value (preceding occurrence of the fault) is output.
ACTUAL VALUE Fault is ignored, i.e. normal measured-value output on the basis of ongoing flow measurement.
Totalizer
STOP The totalizers are paused until the error is rectified.
Totalizer stops
ACTUAL VALUE The fault is ignored. The totalizers continue to count in accordance with the current flow value.
HOLD VALUE The totalizers continue to count the flow in accordance with the last valid flow value (before the error occurred).
Status output
In the event of a fault or power supply failure:
Status output non-conductive
No effect on status output
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9.6 Spare parts
Chap. 9.1 contains a detailed trouble-shooting guide. The measuring device, moreover, provides additional support in the form of continuous self-diagnosis and error messages. Fault rectification can entail replacing defective components with tested spare parts. The illustration below shows the available scope of spare parts.
Note! You can order spare parts directly from your Endress+Hauser service organisation by providing the serial number printed on the transmitter's nameplate (Page 9 ff.).
Spare parts are shipped as sets comprising the following parts: · Spare part · Additional parts, small items (threaded fasteners, etc.) · Mounting instructions · Packaging
1 2 3
4
5
Fig. 48: Spare parts for Promag 50 transmitter (field and wall-mounted housings)
1 Power supply board (85...260 V AC, 20...55 V AC, 16...62 V DC) 2 Amplifier board 3 I/O board 4 S-DAT (sensor data memory) 5 Display module
F06-50xxxxxx-03-06-06-xx-000
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#
9.7 Removing and installing printed circuit boards
Field housing: removing and installing printed circuit boards (Fig. 49)
Warning! · Risk of electric shock. Exposed components carry dangerous voltages. Make sure that the power
supply is switched off before you remove the cover of the electronics compartment. · Risk of damaging electronic components (ESD protection). Static electricity can damage electronic
components or impair their operability. Use a workplace with a grounded working surface purpose-built for electrostatically sensitive devices! · If you cannot guarantee that the dielectric strength of the device is maintained in the following steps, then an appropriate inspection must be carried out in accordance with the manufacturer's specifications. · When connecting Ex-certified devices, see the notes and diagrams in the Ex-specific supplement to these Operating Instructions.
1. Unscrew cover of the electronics compartment from the transmitter housing. 2. Remove the local display (1) as follows:
Press in the latches (1.1) at the side and remove the display module. Disconnect the ribbon cable (1.2) of the display module from the amplifier board. 3. Remove the screws and remove the cover (2) from the electronics compartment. 4. Remove power supply board and I/O board (4, 6): Insert a suitable tool into the holes (3) provided for the purpose and pull the board clear of its holder. 5. Remove amplifier board (5): Disconnect the plug of the electrode signal cable (5.1) including S-DAT (5.3) from the board. Loosen the plug locking of the coil current cable (5.2) and gently disconnect the plug from
the board, i.e. without moving it to and fro. Insert a thin pin into the hole (3) provided for the purpose and pull the board clear of its
holder.
6. Installation is the reverse of the removal procedure.
" Caution!
Use only original Endress+Hauser parts.
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4
5
3
6
5.1
3 5.3
5.2
3
2
1.2
1
1.1
Fig. 49: Field housing: removing and installing printed circuit boards 1 Local display 1.1 Latch 1.2 Ribbon cable (display module) 2 Screws of electronics compartment cover 3 Aperture for tool, removal/installation 4 Power supply board 5 Amplifier board 5.1 Electrode signal cable (sensor) 5.2 Coil current cable (sensor) 5.3 S-DAT (sensor data memory) 6 I/O board
A0002657
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Proline Promag 50
#
Wall-mounted housing: removing and installing printed circuit boards (Fig. 50)
Warning! · Risk of electric shock. Exposed components carry dangerous voltages. Make sure that the power
supply is switched off before you remove the cover of the electronics compartment. · Risk of damaging electronic components (ESD protection). Static electricity can damage electronic
components or impair their operability. Use a workplace with a grounded working surface, purpose-built for electrostatically sensitive devices. · If you cannot guarantee that the dielectric strength of the device is maintained in the following steps, then an appropriate inspection must be carried out in accordance with the manufacturer's specifications. · When connecting Ex-certified devices, see the notes and diagrams in the Ex-specific supplement to these Operating Instructions.
1. Remove the screws and open the hinged cover (1) of the housing. 2. Remove screws of the electronics module (2). Then push up electronics module and pull it as
far as possible out of the wall-mounted housing. 3. Disconnect the following cable plugs from amplifier board (7):
Electrode signal cable plug (7.1) including S-DAT (7.3) Plug of coil current cable (7.2). To do so, loosen the plug locking of the coil current cable
and gently disconnect the plug from the board, i.e. without moving it to and fro. Ribbon cable plug (3) of the display module 4. Remove the screws and remove the cover (4) from the electronics compartment. 5. Remove the boards (6, 7, 8): Insert a suitable tool into the hole (5) provided for the purpose and pull the board clear of its holder. 6. Installation is the reverse of the removal procedure.
" Caution!
Use only original Endress+Hauser parts.
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Proline Promag 50
9 Trouble-shooting
1
2
6
3
4
7
5
8
7.1
7.3
5
3
7.2
5
Fig. 50: Wall-mounted housing: removing and installing printed circuit boards
1 Housing cover 2 Electronics module 3 Ribbon cable (display module) 4 Cover of electronics compartment (3 screws) 5 Aperture for tool, removal/installation 6 Power supply board 7 Amplifier board 7.1 Electrode signal cable (sensor) 7.2 Coil current cable (sensor) 7.3 S-DAT (sensor data memory) 8 I/O board
F06-50xxxxxx-03-03-06-xx-000
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Proline Promag 50
#
9.8 Replacing the device fuse
Warning! Risk of electric shock. Exposed components carry dangerous voltages. Make sure that the power supply is switched off before you remove the cover of the electronics compartment.
The main fuse is on the power supply board (Fig. 51). The procedure for replacing the fuse is as follows:
1. Switch off power supply. 2. Remove the power supply board Page 98, 100 3. Remove cap (1) and replace the device fuse (2).
Use only fuses of the following type: Power supply 20...55 V AC / 16...62 V DC 2.0 A slow-blow / 250 V;
5.2 x 20 mm Power supply 85...260 V AC 0.8 A slow-blow / 250 V; 5.2 x 20 mm Ex-rated devices see the Ex documentation.
4. Assembly is the reverse of the disassembly procedure.
" Caution!
Use only original Endress+Hauser parts.
2 1
Fig. 51: Replacing the device fuse on the power supply board 1 Protective cap 2 Device fuse
A0001148
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Proline Promag 50
9 Trouble-shooting
9.9 Replacing exchangeable measuring electrodes
The Promag W sensor (DN 350...2000) is available with exchangeable measuring electrodes as an option. This design permits the measuring electrodes to be replaced or cleaned under process conditions (see Page 104).
F06-5xWxxxxx-00-05-xx-xx-000
Fig. 52: Apparatus for replacing exchangeable measuring electrodes (Replacing Page 104)
a Allen screw b Handle c Electrode cable d Knurled nut (locknut) e Measuring electrode f Stop cock g Retaining cylinder h Locking pin (for handle) i Ball-valve housing j Seal (retaining cylinder) k Coil spring
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Proline Promag 50
Removing the electrode 1 Loosen Allen screw (a) and remove the cover.
Installing the electrode
1 Insert new electrode (e) into retaining cylinder (g) from below. Make sure that the seals at the tip of the electrode are clean.
2 Remove electrode cable (c) secured to handle (b).
2 Mount handle (b) on the electrode and insert locking pin (h) to secure it in position.
". Caution!!
Make sure that coil spring (k) is inserted. This is essential to ensure correct electrical contact and correct measuring signals.
2 Loosen knurled nut (d) by hand. This knurled nut acts as a locknut.
2 Pull the electrode back until the tip of the electrode no longer protrudes from retaining cylinder (g).
3 Remove electrode (e) by turning handle (b). The 3 Screw the retaining cylinder (g) onto ball-valve
electrode can now be pulled out of retaining cylin-
housing (i) and tighten it by hand. Seal (j) on the
der (g) as far as a defined stop.
cylinder must be correctly seated and clean.
#. Warnung!
Risk of injury. Under process conditions (pressure in the piping system) the electrode can recoil suddenly against its stop. Apply counter-pressure while releasing the electrode.
! Note!
Make sure that the rubber hoses on retaining cylinder (g) and stop cock (f) are of the same color (red or blue).
4 Close stop cock (f) after pulling out the electrode as far as it will go.
#. Warnung!
Do not subsequently open the stop cock, in order to prevent fluid escaping.
4 Open stop cock (f) and turn handle (b) to screw the electrode all the way into the retaining cylinder.
5 Remove the electrode complete with retaining cylinder (g).
5 Screw knurled nut (d) onto the retaining cylinder. This firmly locates the electrode in position.
6 Remove handle (b) from electrode (e) by pressing out locking pin (h). Take care not to lose coil spring (k).
6 Use the Allen screw to secure electrode cable (c) to handle (b).
". Caution!!
Make sure that the machine screw securing the electrode cable is firmly tightened. This is essential to ensure correct electrical contact and correct measuring signals.
7 Remove the old electrode and insert the new elec- 7 Reinstall the cover and tighten (a) Allen screw. trode. Replacement electrodes can be ordered separately from Endress+Hauser.
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9 Trouble-shooting
9.10 Software history
Date
Software version
Changes to software
03.2005 2.00.XX
Software expansion: New / revised functionalities
New functionalities: DEVICE SOFTWARE Device software
displayed (NAMUR-recommendation 53) Unit US Kgal
11.2004
Amplifier: 1.06.01 Communication module: 1.04.00
Software update relevant only for production
10.2003
Amplifier: 1.06.00 Communication module: 1.03.00
Software expansion: Language groups Flow direction pulse output selectable
New functionalities: Second Totalizer Adjustable backlight (display) Operation hours counter Simulation function for pulse output Access code for counter Reset function (fault history) Up-/download with FieldTool
08.2003
Communication module: 1.02.01
Software expansion: New / revised functionalities
Special documentation: Current span NAMUR NE 43 Failsafe mode function Trouble-shooting function System and process error messages Response of status output
08.2002 Amplifier: 1.04.00
Software expansion: New / revised functionalities
Special documentation: Current span NAMUR NE 43 EPD (new mode) Failsafe mode function Acknowledge fault function Trouble-shooting function System and process error messages Response of status output
03.2002 Amplifier: 1.03.00
Software expansion: Suitability for custody transfer
measurement Promag 50/51
06.2001
Amplifier: 1.02.00 Communication module: 1.02.00
Software expansion: New functionalities:
New functionalities: General instrument functions "OED" software function "Pulse width" software function
Operating Instructions 50097090/03.05 50097090/10.03 50097090/10.03
50097090/08.03
50097090/08.02
none 50097090/06.01
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Proline Promag 50
Date
Software version
Changes to software
09.2000
Amplifier: 1.01.01 Communication module: 1.01.00
Software expansion: Functional adaptations
08.2000 Amplifier: 1.01.00
Software expansion: Functional adaptations
04.2000
Amplifier: 1.00.00 Communication module: 1.00.00
Original software
Compatible with: FieldTool Commuwin II (version 2.05.03 and higher) HART Communicator DXR 275
(from OS 4.6) with Rev. 1, DD 1.
Operating Instructions none
none 50097090/04.00
!
Note! Usually, an upload or download between the different software versions is only possible with a special service software.
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Proline Promag 50
10 Technical data
10 Technical data
Application
Measuring principle Measuring system
Measured variable Measuring range Operable flow range Input signals
10.1 Technical data at a glance
10.1.1 Application
· Measuring the flow rate of fluids in closed piping systems. · A minimum conductivity of 5 µS/cm is required for measuring; the minimum conductivity
required in the case of demineralised water is 20 µS/cm. · Applications in measuring, control and regulation technology
Liner specific applications: · Promag W (DN 25...2000):
Polyurethane lining for applications with cold water and for slightly abrasive fluids. Hard rubber lining for all applications with water (especially for trinking water) · Promag P (DN 15...600): PTFE lining for standard applications in chemical and process industries. PFA lining for all applications in chemical and process industries; especially for high process
temperatures and applications with temperature shocks. · Promag H (DN 2...100):
PFA lining for all applications in chemical, process and food industries; especially for high process temperatures, for applications with temperature shocks and for applications with CIP or SIP cleaning processes.
10.1.2 Function and system design
Electromagnetic flow measurement on the basis of Faraday's Law.
The measuring system consists of a transmitter and a sensor. Two versions are available: · Compact version: transmitter and sensor form a single mechanical unit. · Remote version: transmitter and sensor are installed separately.
Transmitter: · Promag 50
Sensor: · Promag W (DN 25...2000) · Promag P (DN 15...600) · Promag H (DN 2...100)
10.1.3 Input
Flow rate (proportional to induced voltage)
Typically v = 0.01...10 m/s with the specified measuring accuracy
Over 1000 : 1
Status input (auxiliary input): U = 3...30 V DC, Ri = 5 k, galvanically isolated Configurable for: totalizer reset, positive zero return
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10 Technical data Output signal
Signal on alarm Load Switching output Low flow cutoff Galvanic isolation Electrical connections Cable entry
Cable specifications Supply voltage
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Proline Promag 50
10.1.4 Output
Current output: active/passive selectable, galvanically isolated, time constant selectable (0.01...100 s), full scale value selectable, temperature coefficient: typically 0.005% o.f.s./ °C; resolution: 0.5 µA · active: 0/4...20 mA, RL < 700 (for HART: RL 250 ) · passive: 4...20 mA, supply voltage Vs: 18...30 V DC, Ri 150
Pulse / frequency output: passive, open collector, 30 V DC, 250 mA, galvanically isolated · Frequency output: full scale frequency 2...1000 Hz (fmax = 1250 Hz),
on/off ratio 1:1, pulse width max. 10 s · Pulse output: pulse value and pulse polarity selectable, pulse width configurable (0.5...2000 ms)
· Current output failsafe mode selectable (e.g. to NAMUR recommendation NE 43) · Pulse/frequency output failsafe mode selectable · Status output "non-conductive" by fault or power supply failure
Details Page 95
see "output signal"
Status output: Open collector, max. 30 V DC / 250 mA, galvanically isolated Configurable for: error messages, Empty Pipe Detection (EPD/OED), flow direction, limit values
Switch points for low flow cutoff are selectable
All circuits for inputs, outputs, and power supply are galvanically isolated from each other.
10.1.5 Power supply
see Page 47 ff.
Power-supply and signal cables (inputs/outputs): · Cable entry M20 x 1.5 (8...12 mm) · Sensor cable entry for armoured cables M20 x 1.5 (9.5...16 mm) · Threads for cable entries 1/2" NPT, G 1/2"
Connecting cable for remote version: · Cable entry M20 x 1.5 (8...12 mm) · Sensor cable entry for armoured cables M20 x 1.5 (9.5...16 mm) · Threads for cable entries 1/2" NPT, G 1/2"
see Page 51
85...260 V AC, 45...65 Hz 20...55 V AC, 45...65 Hz 16...62 V DC
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Proline Promag 50
10 Technical data
Power consumption
Power supply failure Potential equalisation Reference operating conditions
Maximum measured error
AC: <15 VA (including sensor) DC: <15 W (including sensor)
Switch-on current: · max. 13.5 A (< 50 ms) at 24 V DC · max. 3 A (< 5 ms) at 260 V AC
Lasting min. 1 power cycle · EEPROM saves measuring system data if power supply fails · S-DAT: exchangeable data storage chip which stores the data of the sensor (nominal diameter,
serial number, calibration factor, zero point, etc.)
see Page 56 ff.
10.1.6 Performance characteristics
To DIN EN 29104 and VDI/VDE 2641: · Fluid temperature: +28 °C ± 2 K · Ambient temperature: +22 °C ± 2 K · Warm-up time: 30 minutes
Installation: · Inlet run >10 x DN · Outlet run > 5 x DN · Sensor and transmitter grounded. · Sensor centered relative to the pipe.
Pulse output: · ± 0.5% o.r. ± 1 mm/s (o.r. = of reading) · Option: ± 0.2% o.r. ± 2 mm/s (o.r. = of reading)
Current output: plus typically ± 5 µA
Supply-voltage fluctuations have no effect within the specified range.
Repeatability
[%] 2.5
2.0 0.5 %
1.5 0.2 %
1.0
0.5
0
0
1
2
4
6
v [m/s]
Fig. 53: Max. measured error in % of reading
max. ± 0.1% o.r. ± 0.5 mm/s (o.r. = of reading)
8
10
F06-5xxxxxxx-05-xx-xx-xx-000
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10 Technical data
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Proline Promag 50
10.1.7 Operating conditions
Installation
Installation instructions
Any orientation (vertical, horizontal) Restrictions and additional installation instructions see Page 15 ff.
Inlet and outlet runs
Inlet run: typically 5 x DN Outlet run: typically 2 x DN
Length of connecting cable
For the remote version the permissible cable length Lmax depends on the conductivity of the medium Page 25. A minimum conductivity of 20 µS/cm is required for measuring demineralized water.
Environment
Ambient temperature
!
"
Transmitter: · Standard: 20...+60 °C · Optional: 40...+60 °C
Note! At ambient temperatures below 20 °C the readability of the display may be impaired.
Sensor: · Flange material carbon steel: 10...+60 °C · Flange material stainless steel: 40...+60 °C
Caution! It is not allowed to use the device beyond the min. and max. lining specified temperature values ( "Medium temperature range").
Note the following points: · Install the device at a shady location. Avoid direct sunlight, particularly in warm climatic regions. · If both fluid and ambient temperatures are high, install the transmitter at a remote location from
the sensor ( "Medium temperature range").
Storage temperature
The storage temperature corresponds to the operating temperature range of the measuring transmitter and the appropriate measuring sensors.
Degree of protection
· Standard: IP 67 (NEMA 4X) for transmitter and sensor · Optional: IP 68 (NEMA 6P) for remote version of Promag W and P sensor
Shock and vibration resistance Acceleration up to 2 g by analogy with IEC 60068-2-6 (high-temperature version: no data available)
CIP cleaning
Promag W: not possible Promag P: possible (note max. temperature) Promag H: possible (note max. temperature)
SIP cleaning
Promag W: not possible Promag P: possible with PFA (note max. temperature) Promag H: possible (note max. temperature)
Electromagnetic compatibility (EMC)
To EN 61326/A1 and NAMUR recommendation NE 21.
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Proline Promag 50
10 Technical data
Process
Medium temperature range
The permissible fluid temperature depends on the lining of the measuring tube:
Promag W 0...+80 °C for hard rubber (DN 65...2000) 20...+50 °C for polyurethane (DN 25...2000)
Promag P 40...+130 °C for PTFE (DN 15...600), for restrictions refer to diagrams 20...+180 °C for PFA (DN 25...200), for restrictions refer to diagrams
HT TA [°C]
60
40
20
0
PFA -20
m
PTFE -40
-40 -20 0 20 40 60 80 100 120 140 160 180
TF [°C]
Fig. 54: Compact version Promag P (with PFA or PTFE lining)
TA = ambient temperature, TF = fluid temperature, HT = high-temperature version, with insulation = Temperature range from 10 °C to 40 °C is valid for stainless steel flanges only
A0002660
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HT TA [°C]
60
40
20
0
PFA -20
m
PTFE -40
-40 -20 0 20 40 60 80 100 120 140 160 180
TF [°C]
Fig. 55: Remote version Promag P (with PFA or PTFE lining)
TA = ambient temperature, TF = fluid temperature, HT = high-temperature version, with insulation = Temperature range from 10 °C to 40 °C is valid for stainless steel flanges only
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10 Technical data
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Proline Promag 50
Conductivity
Limiting medium pressure range (nominal pressure)
Promag H Sensor: · DN 2...25: 20...+150 °C · DN 40...100: 20...+150 °C
Seal: · EPDM: 20...+130 °C · Silicone: 20...+150 °C · Viton: 20...+150 °C · Kalrez: 20...+150 °C
Minimum conductivity: · 5 µS/cm for fluids generally · 20 µS/cm for demineralised water
Note that in the case of the remote version, the requisite conductivity is also influenced by the length of the connecting cable Page 25.
Promag W · EN 1092-1 (DIN 2501): PN 6 (DN 1200...2000), PN 10 (DN 200...2000),
PN 16 (DN 65...2000), PN 25 (DN 200...1000), PN 40 (DN 25...150) · ANSI B16.5: Class 150 (1...24"), Class 300 (1...6") · AWWA: Class D (28...78") · JIS B2238: 10K (DN 50...300), 20K (DN 25...300)
Promag P · EN 1092-1 (DIN 2501): PN 10 (DN 200...600), PN 16 (DN 65...600),
PN 25 (DN 200...600), PN 40 (DN 15...150) · ANSI B16.5: Class 150 (1/2...24"), Class 300 (1/2...6") · JIS B2238: 10K (DN 50...300), 20K (DN 15...300)
Promag H: The permissible nominal pressure depends on the process connection and seal: · 40 bar: flange, weld nipple (with O-ring seal) · 16 bar: all other process connections
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Proline Promag 50
10 Technical data
Pressure tightness (liner)
Promag W Nominal diameter
[mm]
[inch]
25...1000 1...40"
65...2000 3...78"
Measuring tube lining
Polyurethane Hard rubber
Resistance of measuring tube lining to partial vacuum Limit values for abs. pressure [mbar] at various fluid temperatures
25 °C 50 °C 80° C 100 °C 130 °C 150 °C 180 °C
0
0
-
-
-
-
-
0
0
0
-
-
-
-
Promag P Nominal diameter
Measuring tube lining
[mm]
[inch]
15
1/2"
PTFE
25
1"
PTFE / PFA
32
-
PTFE / PFA
40
1 1/2" PTFE / PFA
50
2"
PTFE / PFA
65
-
PTFE / PFA
80
3"
PTFE / PFA
100
4"
PTFE / PFA
125
-
PTFE / PFA
150
6"
PTFE / PFA
200
8"
PTFE / PFA
250
10"
PTFE
300
12"
PTFE
350
14"
PTFE
400
16"
PTFE
450
18"
PTFE
500
20"
PTFE
600
24"
PTFE
* No value can be quoted.
Resistance of measuring tube lining to partial vacuum Limit values for abs. pressure [mbar] at various fluid temperatures
25 °C
80 °C 100 °C 130 °C 150 °C 180 °C
0
0
0
100
0 / 0
0 / 0
0 / 0
100 / 0
/ 0
/ 0
0 / 0
0 / 0
0 / 0
100 / 0
/ 0
/ 0
0 / 0
0 / 0
0 / 0
100 / 0
/ 0
/ 0
0 / 0
0 / 0
0 / 0
100 / 0
/ 0
/ 0
0 / 0
*
40 / 0 130 / 0
/ 0
/ 0
0 / 0
*
40 / 0 130 / 0
/ 0
/ 0
0 / 0
*
135 / 0 170 / 0
/ 0
/ 0
135 / 0
*
240 / 0 385 / 0
/ 0
/ 0
135 / 0
*
240 / 0 385 / 0
/ 0
/ 0
200 / 0
*
290 / 0 410 / 0
/ 0
/ 0
330
*
400
530
400
*
500
630
470
*
600
730
540
*
670
800
Partial vacuum is impermissible
Limiting flow Pressure loss
Promag H Nominal diameter
[mm]
[inch]
2...100 1/12...4"
Measuring tube lining
PFA
Resistance of measuring tube lining to partial vacuum Limit values for abs. pressure [mbar] at various fluid temperatures
25 °C
80 °C 100 °C 130 °C 150 °C 180 °C
0
0
0
0
0
0
see Page 20
· No pressure loss if the sensor is installed in a pipe of the same nominal diameter (Promag H: only DN 8 and larger).
· Pressure losses for configurations incorporating adapters according to DIN EN 545 Page 20
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10 Technical data
Design / dimensions Weight
WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
Proline Promag 50
10.1.8 Mechanical construction
All the dimensions and lengths of the sensor and transmitter are provided in the separate documentation "Technical Information".
Weight data of Promag W in kg
Nominal diameter
Compact version
Remote versin (without cable)
[mm]
[inch]
EN (DIN) /AS*
JIS
ANSI/AWWA EN (DIN)
/AS*
Sensor
JIS
ANSI / AWWA
Wall housin
g
25
1"
7.3
7.3
7.3
5.3
5.3
5.3
6.0
PN 40
PN 40
32 1 1/4"
8.0
7.3
6.0
5.3
6.0
40 1 1/2"
9.4
8.3
9.4
7.4
6.3
7.4
6.0
50
2"
10.6
9.3
10.6
8.6
7.3
8.6
6.0
65 2 1/2"
12.0
11.1
10.0
9.1
6.0
80
3"
14.0
12.5
14.0
12.0
10.5
12.0
6.0
PN 16 10K
Class 150
PN 16 10K
Class 150
100
4"
16.0
14.7
16.0
14.0
12.7
14.0
6.0
125
5"
21.5
21.0
19.5
19.0
6.0
150
6"
25.5
24.5
25.5
23.5
22.5
23.5
6.0
200
8"
45
41.9
45
43
39.9
43
6.0
250
10"
65
69.4
75
63
67.4
73
6.0
300
12"
70
72.3
110
68
70.3
108
6.0
350
14"
115
175
113
173
6.0
400
16"
135
205
133
203
6.0
450
18"
175
255
173
253
6.0
PN 10 PN 10
500
20"
175
285
173
283
6.0
600
24"
235
405
233
403
6.0
700
28"
355
400
353
398
6.0
30"
460
458
6.0
800
32"
435
550
433
548
6.0
900
36"
575
800
573
798
6.0
1000 40"
700
900
698
898
6.0
42"
1100
1098
6.0
1200 48"
850
1400
848
1398
6.0
PN 6 Class D
PN 6 Class D
54"
2200
2198
6.0
1400
1300
1298
6.0
60"
2700
2698
6.0
1600
1700
1698
6.0
66"
3700
3698
6.0
1800 72"
2200
4100
2198
4098
6.0
78"
4600
4598
6.0
2000
2800
2798
6.0
Transmitter Promag (compact version): 3.4 kg (Weight data valid for standard pressure ratings and without packaging material) * Flanges according AS are only available for DN 80, 100, 150...400, 500 and 600
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Proline Promag 50
10 Technical data
Weight data of Promag P in kg
Nominal diameter
Compact version
Remote version (without cable)
[mm] [inch] EN (DIN)
JIS
/AS*
ANSI
EN (DIN) /AS*
Sensor JIS
ANSI
Wall housing
15 1/2"
6.5
6.5
6.5
4.5
4.5
4.5
6.0
25
1"
7.3
7.3
7.3
5.3
5.3
5.3
6.0
PN 40
PN 40
32 1 1/4"
8.0
7.3
6.0
5.3
6.0
40 1 1/2"
9.4
8.3
9.4
7.4
6.3
7.4
6.0
50
2"
10.6
9.3
10.6
8.6
7.3
8.6
6.0
65 2 1/2"
12.0
11.1
10.0
9.1
6.0
PN 16 10K
Class 150
PN 16 10K
Class 150
80
3"
14.0
12.5
14.0
12.0
10.5
12.0
6.0
100
4"
16.0
14.7
16.0
14.0
12.7
14.0
6.0
125
5"
21.5
21.0
19.5
19.0
6.0
150
6"
25.5
24.5
25.5
23.5
22.5
23.5
6.0
200
8"
45
41.9
45
43
39.9
43
6.0
250 10"
65
69.4
75
63
67.4
73
6.0
300 12"
70
72.3
110
68
70.3
108
6.0
PN 10 PN 10
350 14"
115
175
113
173
6.0
400 16"
135
205
133
203
6.0
450 18"
175
255
173
253
6.0
500 20"
175
285
173
283
6.0
600 24"
235
405
233
403
6.0
Transmitter Promag (compact version): 3.4 kg High-temperature version: +1.5 kg (Weight data valid for standard pressure ratings and without packaging material) * Flanges according AS are only available for DN 25 and 50
Weight data of Promag H in kg
Nominal diameter
Compact version
Remote version (without cable)
[mm]
[inch]
DIN
Sensor
Wall housing
2
1/12"
5.2
2.5
6.0
4
5/32"
5.2
2.5
6.0
8
5/16"
5.3
2.5
6.0
15
1/2"
5.4
2.6
6.0
25
1"
5.5
2.8
6.0
40
1 1/2"
6.5
4.5
6.0
50
2"
9.0
7.0
6.0
65
2 1/2"
9.5
7.5
6.0
80
3"
19.0
17.0
6.0
100
4"
18.5
16.5
6.0
Transmitter Promag (compact version): 3.4 kg (Weight data valid for standard pressure ratings and without packaging material)
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Promag W
Transmitter housing: · Compact housing: powder coated die-cast aluminium · Wall-mounted housing: powder coated die-cast aluminium
Sensor housing: · DN 25...300: powder-coated die-cast aluminium · DN 350...2000: painted steel (Amerlock 400)
Measuring tube: · DN < 350: stainless steel 1.4301 or 1.4306/304L; non-stainless flange material with
Al/Zn protective coating · DN > 300: stainless steel 1.4301/304; non-stainless flange material with
Amerlock 400 paint
Flange: · EN 1092-1 (DIN 2501): 316L / 1.4571; RSt37-2 (S235JRG2) / C22 / FE 410W B
(DN < 350: with Al/Zn protective coating; DN > 300 with Amerlock 400 paint) · ANSI: A105, F316L
(DN < 350 with Al/Zn protective coating, DN > 300 with Amerlock 400 paint) · AWWA: 1.0425 · JIS: RSt37-2 (S235JRG2) / H II / 1.0425 / 316L
(DN < 350 with Al/Zn protective coating, DN > 300 with Amerlock 400 paint) · AS 2129: (DN 150, 200, 250, 300, 600) A105 or RSt37-2 (S235JRG2)
(DN 80, 100, 350, 400, 500) A105 or St44-2 (S275JR) · AS 4087: A105 or St44-2 (S275JR)
Ground disks: : 1.4435/316L or Alloy C-22 Electrodes: 1.4435 or Alloy C-22, tantalum Seals: Seals to DIN EN 1514-1
Promag P
Transmitter housing: · Compact housing: powder coated die-cast aluminium or stainless steel field housing · Wall-mounted housing: powder coated die-cast aluminium
Sensor housing: · DN 15...300: powder-coated die-cast aluminium · DN 350...600: painted steel (Amerlock 400)
Measuring tube: · DN < 350: stainless steel 1.4301 or 1.4306/304L; non-stainless flange material with
AI/Zn protective coating · DN > 300: stainless steel 1.4301/304; non-stainless flange material with
Amerlock 400 paint
Flange: · EN 1092-1 (DIN 2501): 316L / 1.4571; RSt37-2 (S235JRG2) / C22 / FE 410W B
(DN < 350: with Al/Zn protective coating, DN > 300 with Amerlock 400 paint) · ANSI: A105, F316L
(DN < 350 with Al/Zn protective coating, DN > 300 with Amerlock 400 paint) · JIS: RSt37-2 (S235JRG2) / H II / 1.0425 / 316L
(DN < 350 with Al/Zn protective coating, DN > 300 with Amerlock 400 paint) · AS 2129: (DN 25) A105 or RSt37-2 (S235JRG2)
(DN 50) A105 oder St44-2 (S275JR) · AS 4087: A105 or St44-2 (S275JR)
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Material load diagram Fitted electrodes
Ground disks: 1.4435/316L or Alloy C-22 Electrodes: 1.4435, platinum/rhodium 80/20 or Alloy C-22, tantalum Seals: Seals to DIN EN 1514-1
Promag H
Transmitter housing: · Compact housing: powder coated die-cast aluminium or
stainless-steel field housing 1.4301/316L · Wall-mounted housing: powder coated die-cast aluminium
Sensor housing: 1.4301 Wall mounting (holder panel): 1.4301
Measuring tube: stainless steel 1.4301 or 1.4306/304L
Flange: · All connections stainless-steel 1.4404/316L · Flanges (EN (DIN), ANSI, JIS) made of PVDF · Adhesive fitting made of PVC
Ground rings: 1.4435/316L, Option: tantalum, Alloy C-22
Electrodes: · Standard: 1.4435 · Option: Alloy C-22, tantalum, platinum/rhodium 80/20 (up to DN 25 only)
Seals: · DN 2...25: O-ring (EPDM, Viton, Kalrez) or gasket seal (EPDM, silicone, Viton) · DN 40...100: gasket seal (EPDM, silicone)
The material load diagrams (pressure-temperature graphs) for the process connections are to be found in the following documents: · Technical Information "Promag 50/53W" (TI 046D/06/en) · Technical Information "Promag 50/53P" (TI 047D/06/en) · Technical Information "Promag 50/53H" (TI 048D/06/en)
Promag W: Measuring, reference and EPD electrodes · Standard available with 1.4435, Alloy C-22, tantalum · Optional: exchangeable measuring electrodes made of 1.4435 (DN 350...2000)
Promag P: Measuring, reference and EPD electrodes · Standard available with 1.4435, Alloy C-22, tantalum, platinum/rhodium 80/20 · Optional: measuring electrodes made of platinum/rhodium 80/20
Promag H: Measuring electrodes and EPD electrodes · Standard available with 1.4435, Alloy C-22, tantalum, platinum/rhodium 80/20 · DN 2...4: without EPD electrode
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Surface roughness
Display elements Operating elements Language group
Remote operation Ex Approvals
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Promag W: Flange connection: EN 1092-1 (DIN 2501); DN 65 PN 16 and DN 600 PN 16 exclusively to EN 1092-1, ANSI, AWWA, JIS, AS
Promag P: Flange connection: EN 1092-1 (DIN 2501); DN 65 PN 16 and DN 600 PN 16 exclusively to EN 1092-1, ANSI, JIS, AS
Promag H: · With O-ring: weld nipples (DIN EN ISO 1127, ODT / SMS), flanges (EN (DIN), ANSI, JIS),
PVDF flanges (EN (DIN), ANSI, JIS), external pipe thread, internal pipe thread, hose connection, PVC adhesive fittings · With gasket seal: weld nipples (DIN 11850, ODT / SMS), clamps (ISO 2852, DIN 32676, L14 AM7), threaded fasteners (DIN 11851, DIN 11864-1, ISO 2853, SMS 1145), flanges (DIN 11864-2
· PFA liner: 0.4 µm · Electrodes:
1.4435, Alloy C-22: 0.3...0.5 µm Tantalum, platinum/rhodium: 0.3...0.5 µm · Process connection Promag H: 0.8 µm
(all data relate to parts in contact with medium)
10.1.9 Human interface
· Liquid-crystal display: illuminated, two lines with 16 characters per line · Custom configurations for presenting different measured values and status variables · 2 totalizers · At ambient temperatures below 20 °C the readability of the display may be impaired
· Local operation with three push buttons (, +, E) · "Quick Setup" menus for straightforward commissioning
Language groups available for operation in different countries: · Western Europe and America (WEA):
English, German, Spanish, Italian, French, Dutch and Portuguese · Eastern Europe and Scandinavia (EES):
English, Russian, Polish, Norwegian, Finnish, Swedish and Czech · South and east Asia (SEA):
English, Japanese, Indonesian You can change the language group via the operating program "ToF Tool - Fieldtool Package."
Operation via HART protocol
10.1.10 Certificates and approvals
Information about currently available Ex versions (ATEX, FM, CSA) can be supplied by your Endress+Hauser Sales Center on request. All explosion protection data are given in a separate documentation which is available upon request.
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Sanitary compatibility
Promag W: No applicable approvals or certification
Promag P: No applicable approvals or certification
Promag H: · 3A authorization and EHEDG-tested · Seals in conformity with FDA (except Kalrez seals)
Pressure Equipment Directive
Measuring devices with a nominal diameter smaller than or equal to DN 25 correspond to Article 3(3) of the EC Directive 97/23/EC (Pressure Equipment Directive) and have been designed and manufactured according to good engineering practice. Where necessary (depending on the medium and process pressure), there are additional optional approvals to Category II/III for larger nominal diameters.
CE mark
The measuring system is in conformity with the statutory requirements of the EC Directives. Endress+Hauser confirms successful testing of the device by affixing to it the CE mark.
Other standards and guidelines
EN 60529 Degrees of protection by housing (IP code)
EN 61010 Protection Measures for Electrical Equipment for Measurement, Control, Regulation and Laboratory Procedures
EN 61326/A1 (IEC 6326) Electromagne8tic compatibility (EMC requirements)
NAMUR NE 21 Electromagnetic compatibility (EMC) of industrial process and laboratory control equipment.
NAMUR NE 43 Standardisation of the signal level for the breakdown information of digital transmitters with analogue output signal.
NAMUR NE 53 Software of field devices and signal-processing devices with digital electronics.
10.1.11 Ordering information
The Endress+Hauser service organisation can provide detailed ordering information and information on specific order codes on request.
10.1.12 Accessories
Various accessories, which can be ordered separately from Endress+Hauser, are available for the transmitter and the sensor (see Page 85). The Endress+Hauser service organisation can provide detailed information on request.
10.1.13 Supplementary documentation
· System Information Promag (SI 028D/06/en) · Technical Information Promag 50/53W (TI 046D/06/en) · Technical Information Promag 50/53P (TI 047D/06/en) · Technical Information Promag 50/53H (TI 048D/06/en) · Description of Device Functions Promag 50 (BA 049D/06/en) · Supplementary documentation on Ex-ratings: ATEX, FM, CSA, etc.
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11 Index
A
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Adapters (installation of sensors) . . . . . . . . . . . . . . . . . . . . 20 Ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Applicator (selection and configuration software) . . . . . . . 87 Auxiliary input
see Status input
B
Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97, 99, 101
C
Cable entries degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . 59 technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Cable specifications (remote version) cable length, conductivity . . . . . . . . . . . . . . . . . . . . . . 25 Cable termination of Promag H . . . . . . . . . . . . . . . . . . 50 Cable termination Promag W, P . . . . . . . . . . . . . . . . . 49 technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Calibration factor (default) . . . . . . . . . . . . . . . . . . . . . . . . 10 Cathode protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 CE mark (declaration of conformity) . . . . . . . . . . . . . . . . . 11 CIP cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Cleaning
CIP /SIP cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 exterior cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Code entry (function matrix) . . . . . . . . . . . . . . . . . . . . . . 63 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Commissioning Quick Setup menu . . . . . . . . . . . . . . . 80 configure current output (active/passive) . . . . . . . . . . 82 empty pipe and full pipe calibration (EPD/OED) . . . . . 81 Commubox FXA 191, electrical connection . . . . . . . . . . . 55 Communication (HART) . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Conditions for operation . . . . . . . . . . . . . . . . . . . . . . . . . 110 Conductivity of fluid, minimum . . . . . . . . . . . . . . . . . . . 112 Connection see Electrical connection Current output configuration (active/passive) . . . . . . . . . . . . . . . . . . . 82 electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . 54 technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
D
Data storage (S-DAT) . . . . . . . . . . . . . . . . . . . . . . . . 82, 97 Declaration of conformity (CE mark) . . . . . . . . . . . . . . . . 11 Declaration of contamination . . . . . . . . . . . . . . . . . . . . . . . 8 Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . 59, 110 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Device description files . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Device designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Device functions
see "Description of Device Functions" manual Device fuse, replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Display
display and operating elements . . . . . . . . . . . . . . . . . . 61 turning the display . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Documentation for hazardous areas (Ex) . . . . . . . . . . . . . . . 7 Down pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
E
Electrical connection cable specifications (remote version) . . . . . . . . . . . . . . 51 Commubox FXA 191 . . . . . . . . . . . . . . . . . . . . . . . . . 55 degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . 59 HART handheld communicator . . . . . . . . . . . . . . . . . . 55 length of connecting cable . . . . . . . . . . . . . . . . . . . . . . 25 post-connection check (checklist) . . . . . . . . . . . . . . . . 60 potential equalisation . . . . . . . . . . . . . . . . . . . . . . . . . 56 remote version (connecting cable) . . . . . . . . . . . . . . . . 47 terminal assignment, transmitter . . . . . . . . . . . . . . . . . 54 transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Electrode Cleaning Circuitry see "Description of Device Functions" manual
Electrodes EPD electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . 17, 81 exchanging replaceable electrodes . . . . . . . . . . . . . . . 103 fitted electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 measuring electrode plane . . . . . . . . . . . . . . . . . . . . . . 17 reference electrode (potential equalisation) . . . . . . . . . 56
Electromagnetic compatibility (EMC) . . . . . . . . . . . 51, 110 Electronics board . . . . . . . . . . . . . . . . . . . . . . . 97, 99, 101 Empty Pipe Detection (EPD/OED)
empty-pipe/full-pipe adjustment . . . . . . . . . . . . . . . . . 81 EPD electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 general information . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Error limits see Measuring accuracy Error messages display mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 error message types . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 process errors (application errors) . . . . . . . . . . . . . . . . 94 system errors (device errors) . . . . . . . . . . . . . . . . . . . . 90 Error response of outputs / totalizers . . . . . . . . . . . . . . . . 95 Error types (system and process errors) . . . . . . . . . . . . . . . 64 Ex certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Ex documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Exchange device fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 measuring electrodes . . . . . . . . . . . . . . . . . . . . . . . . . 103 printed circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . 98
F
Failsafe mode (failure response) . . . . . . . . . . . . . . . . . . . . . 95 Fieldcare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 FieldCheck (tester and simulator) . . . . . . . . . . . . . . . . . . . 87 Flow rate / nominal diameter . . . . . . . . . . . . . . . . . . . . . . 20 Fluid conductivity, minimum . . . . . . . . . . . . . . . . . . . . . . 25 Fluid pressure range . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Fluid temperature ranges . . . . . . . . . . . . . . . . . . . . . . . . 111 Foundations (for sensors with DN > 300) . . . . . . . . . . . . . 19
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Frequency output electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . 54 technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Function descriptions see "Description of Device Functions" manual
Function matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Functions, function groups . . . . . . . . . . . . . . . . . . . . . . . 62 Fuse, replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
G
Galvanic isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Ground cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Ground disks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
mounting (Promag P) . . . . . . . . . . . . . . . . . . . . . . . . . 34 mounting (Promag W) . . . . . . . . . . . . . . . . . . . . . . . . 27 potential equalisation . . . . . . . . . . . . . . . . . . . . . . . . . 58 Ground rings (Promag H) mounting, application area . . . . . . . . . . . . . . . . . . . . . 40 potential equalisation . . . . . . . . . . . . . . . . . . . . . . . . . 56
H
HART command groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . 55 Handheld terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Hazardous substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 High-temperature version (Promag P)
installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 temperature ranges . . . . . . . . . . . . . . . . . . . . . . . . . 111 HOME position (operating mode) . . . . . . . . . . . . . . . . . . 61
I
Incoming acceptance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Inlet runs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Input signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Input variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation dimensions . . . . . . . . . . . . . . . . . 15, 27, 41 Installation check (checklist) . . . . . . . . . . . . . . . . . . . . . . 46 Installation conditions
adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 down pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 foundations (DN > 300) . . . . . . . . . . . . . . . . . . . . . . . 19 inlet and outlet runs . . . . . . . . . . . . . . . . . . . . . . . . . . 18 installation of pumps . . . . . . . . . . . . . . . . . . . . . . . . . 15 location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 orientation (vertical, horizontal) . . . . . . . . . . . . . . . . . 17 partially filled pipes, drains . . . . . . . . . . . . . . . . . . . . . 16 vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Installing sensor adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 foundations (DN > 300) . . . . . . . . . . . . . . . . . . . . . . . 19 ground disks (Promag P) . . . . . . . . . . . . . . . . . . . . . . 34 ground disks (Promag W) . . . . . . . . . . . . . . . . . . . . . . 27 ground rings (Promag H) . . . . . . . . . . . . . . . . . . . . . . 40 Promag H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Promag H with weld nipples . . . . . . . . . . . . . . . . . . . 41 Promag P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Promag P, high-temperature version . . . . . . . . . . . . . . 35 Promag W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Installing the wall-mount housing . . . . . . . . . . . . . . . . . . 44 Insulation of pipes (Promag P) . . . . . . . . . . . . . . . . . . . . . 35
L
Limiting flow see Measuring range . . . . . . . . . . . . . . . . . . . . . . . . . 113
Local display see Display
Low flow cutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
M
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Material load curves . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Measured variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Measuring accuracy
deviation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 reference conditions . . . . . . . . . . . . . . . . . . . . . . . . . 109 repeatability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Measuring electrodes see electrodes Measuring principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Measuring range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Measuring tube lining, resistance to partial vacuum . . . . . . . . . . . . . . 113 lining, temperature range . . . . . . . . . . . . . . . . . . . . . 111 Medium see Fluid ...
N
Nameplate Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Nominal diameter / flow rate . . . . . . . . . . . . . . . . . . . . . 20 Nominal pressure
see Fluid pressure range
O
OED (Open Electrode Detection) see Empty Pipe Detection . . . . . . . . . . . . . . . . . . . . . . 81
Operable flow range . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Operation
device description files . . . . . . . . . . . . . . . . . . . . . . . . 67 display and operating elements . . . . . . . . . . . . . . . . . . 61 Fieldcare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 function matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 HART commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 HART handheld terminal . . . . . . . . . . . . . . . . . . . . . . 66 ToF Tool - Fieldtool Package (configuration and service software) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Order code Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Ordering code accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Ordering information . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
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Outlet runs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Output signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Output variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Outputs, response to errors . . . . . . . . . . . . . . . . . . . . . . . . 95
P
Partial vacuum, lining . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Performance characteristics
see Measuring accuracy Positive zero return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Potential equalisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Power consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Power supply failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Pressure loss
adapters (reducers, expanders) . . . . . . . . . . . . . . . . . . 20 general information . . . . . . . . . . . . . . . . . . . . . . . . . . 113 resistance to partial vacuum, lining . . . . . . . . . . . . . . 113 Printed circuit boards, removing and installing . . . . . . . . . 98 Process connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Process error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 process errors without message . . . . . . . . . . . . . . . . . . 94 Programming mode disable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Pumps, location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Q
Quick Setup menu for "Commissioning" . . . . . . . . . . . . . 80
R
Registered trademarks . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Registrierte Warenzeichen . . . . . . . . . . . . . . . . . . . . . . . . 12 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Repeatability (measuring accuracy) . . . . . . . . . . . . . . . . . 109 Returning devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
S
Safety icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Safety of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Safety regulation form (e.g. for repairs)
see Declaration of contamination Sanitary compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Screw tightening torques
for Promag H (with plastic process connections) . . . . . 39 for Promag P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 for Promag W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 S-DAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 S-DAT (HistoROM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Seals Promag H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Promag P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Promag W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 temperature ranges (Promag H) . . . . . . . . . . . . . . . . . 112 Sensor installation see Installing sensor Serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9, 10, 11 Shock resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Signal on alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 SIP cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Software
amplifier display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 versions (history) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Status input electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . 54 technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Status output electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . 54 technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Switching output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 System error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
T
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Temperature ranges
ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . 110 fluid temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 storage temperature . . . . . . . . . . . . . . . . . . . . . . . . . 110 ToF Tool - Fieldtool Package . . . . . . . . . . . . . . . . . . . 66, 87 Transmitter electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . 52 installing the wall-mount housing . . . . . . . . . . . . . . . . 44 length of connecting cable (remote version) . . . . . . . . . 25 turning the field housing (aluminum) . . . . . . . . . . . . . . 42 turning the field housing (stainless steel) . . . . . . . . . . . 42 Transporting the sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Trouble-shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
V
Vibrations measures to prevent vibrations . . . . . . . . . . . . . . . . . . 18 shock resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
W
Wall-mount housing, installing . . . . . . . . . . . . . . . . . . . . . 44 Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Welding work
grounding welding equipment . . . . . . . . . . . . . . . . . . . 41 Promag H with weld nipples . . . . . . . . . . . . . . . . . . . . 41 Wiring see Electrical connection
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Declaration of Contamination Erklärung zur Kontamination
Because of legal regulations and for the safety of our employees and operating equipment, we need the "declaration of contamination", with your signature, before your order can be handled. Please make absolutely sure to include it with the shipping documents, or - even better - attach it to the outside of the packaging. Aufgrund der gesetzlichen Vorschriften und zum Schutz unserer Mitarbeiter und Betriebseinrichtungen, benötigen wir die unterschriebene "Erklärung zur Kontamination", bevor Ihr Auftrag bearbeitet werden kann. Legen Sie diese unbedingt den Versandpapieren bei oder bringen Sie sie idealerweise außen an der Verpackung an.
Type of instrument / sensor
Geräte-/Sensortyp
_______________________________________
Serial number Seriennummer ___________________
Process data/Prozessdaten
Medium and warnings Warnhinweise zum Medium
Temperature / Temperatur _________ [°C] Pressure / Druck __________ [ Pa ] Conductivity / Leitfähigkeit _________ [ S ] Viscosity / Viskosität __________ [mm2/s]
Medium /concentration Identification flammable toxic Medium /Konzentration CAS No. entzündlich giftig
Process medium Medium im Prozess Medium for process cleaning Medium zur Prozessreinigung
corrosive ätzend
harmful/ irritant gesundheitsschädlich/ reizend
other * harmless sonstiges* unbedenklich
Returned part cleaned with Medium zur Endreinigung
* explosive; oxidising; dangerous for the environment; biological risk; radioactive * explosiv; brandfördernd; umweltgefährlich; biogefährlich; radioaktiv Please tick should one of the above be applicable, include security sheet and, if necessary, special handling instructions. Zutreffendes ankreuzen; trifft einer der Warnhinweise zu, Sicherheitsdatenblatt und ggf. spezielle Handhabungsvorschriften beilegen.
Reason for return / Grund zur Rücksendung _____________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________
Company data /Angaben zum Absender
Company /Firma ________________________________ ______________________________________________ Address / Adresse ______________________________________________ ______________________________________________
Contact person / Ansprechpartner ______________________ Department / Abteilung ______________________________ Phone number/ Telefon ______________________________ Fax / E-Mail _______________________________________ Your order No. / Ihre Auftragsnr. _______________________
We hereby certify that the returned parts have been carefully cleaned. To the best of our knowledge they are free from any residues in dangerous quantities. Hiermit bestätigen wir, dass die zurückgesandten Teile sorgfältig gereinigt wurden, und nach unserem Wissen frei von Rückständen in gefahrbringender Menge sind.
_____________________________________________
(place, date / Ort, Datum)
______________________________________________
(Company stamp and legally binding signature) (Firmenstempel und rechtsverbindliche Unterschrift)
P/SF/Konta VIII
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www.endress.com/worldwide
BA046D/06/en/03.05 50097090 FM+SGML6.0
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual J & P Richardson Industries Pty Ltd
5 Generator
SUPPLIER: MODEL:
Eneraque 1937 Ipswich Road Rocklea QLD 4106
Ph: 1800 636 744 Fax: (07) 3434 3593
TRAILER MOUNTED DPAS50 GENSET PERKINS/LEROY SOMER 34941
C63100-WB065_Manual_DRAFT.doc Revision 0
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J&P RICHARDSON
TRAILER MOUNTED DPAS 50 GENSET
PERKINS / LEROY SOMER 34941
OPERATION & MAINTENANCE MANUAL
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Document Control
REVISION A
DATE 19/03/2013
PREPARED BY Noel Rosario
APPROVED BY Ray Verburgt
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STANDBY SERIES GENERATOR SET
USERS MANUAL
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1.0
WELCOME ...................................................................................................................3
2.0
BASIC SAFETY RULES
................................................................................ 4
3.0
DESCRIPTION OF GENERATOR SET .......................................................................6
3.1 SOUND INSULATION ......................................................................................................9
3.2 CONTROL PANEL .........................................................................................................10
3.3 ELECTRICAL CONFIGURATION ..................................................................................11
3.4 RETENTION BATH ........................................................................................................12
4.0
INSTALLATION OF THE GENERATOR SET............................................................13
4.1 UNLOADING AND TRANSPORT ..................................................................................13
4.2 INSTALLATION PRINCIPLES .......................................................................................14
4.3 VENTILATION AND COOLING......................................................................................16
4.4 FUEL 16
4.4.1 Automatic fuel transfer system ............................................................................16
4.5 EXHAUST.......................................................................................................................16
4.6 GENERATOR SET STARTUP.......................................................................................17
4.7 ELECTRICAL CONNECTION
............................................................................. 18
4.7.1.1 Installation of CONTROL section: ............................................................20
4.7.1.2 Installation of ELECTRICAL POWER section:.........................................22
4.7.1.3 Earthing: ...................................................................................................23
4.7.1.4 Motorized changeover switches: ..............................................................23
STORAGE ............................................................................................................................. 24
5.0
STARTUP ...................................................................................................................25
5.1 POWER FACTOR AND GENERATOR SETS ...............................................................26
5.2 LIGH LOAD OPERATION ON DIESEL ENGINES ........................................................26
6.0
OPERATION MANUAL ..............................................................................................27
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6.1 CONTROL PANEL COMPONENTS ..............................................................................27
6.2 GECO ANALOG CONTROL MODULE..........................................................................29
6.3 GPM-2 ANALOG CONTROL MODULE .........................................................................36
6.4 DEEP SEA 7310/7320 DIGITAL CONTROL MODULE .................................................42
6.5 DEEP SEA 5510/5520 DIGITAL CONTROL MODULE .................................................59 6.6 INTELIGENNT DIGITAL CONTROL MODULE ...............................................................77
7.0
MAINTENANCE OF GENERATOR SET ...................................................................86
7.1 PRIOR TO MAINTENANCE...........................................................................................86
7.2 DURING MAINTENANCE ..............................................................................................86
7.3 MAINTENANCE CHART ................................................................................................88
8.0
TROUBLESHOOTING ...............................................................................................89
9.0
PROTECTION FROM THE ENVIRONMENT ............................................................90
10.0
WARRANTY ...............................................................................................................91
11.0
NOISE LEVEL ............................................................................................................91
12.0
DECLARATION OF CONFORMITY
................................................................. 92
13.0
APPENDIX 1: FIGURES ............................................................................................92
14.0
APPENDIX 2: IMAGE INDEX.....................................................................................95
15.0
APPENDIX 3: PRE-DELIVERY INSPECTION DOCUMENT .....................................97
16.0
APPENDIX 4: FIGURES IN DEEP SEA CONTROL CARDS. ...................................99
17.0
APPENDIX 5: NOISE EMISSIONS ..........................................................................101
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1.0 WELCOME
Thank you for choosing an Eneraque generator set.
The purpose of this manual is to familiarize the user on how to use and work with the electrical generator, its components and maintenance. We recommend a carefully reading this document prior to working with the equipment to ensure its correct use. Save this manual for future reference and if the generator set is resold be sure to include the manual along with the unit. The following is a general description of the unit and the information necessary for installation, operation and preventive maintenance. Additionally, you should have received a specific user manual for the Engine and Alternator, electrical setup, a set of keys, ATS (upon order), silencer or exhaust tube and flexible tube (supplied separately for open-skid units). Should you have any problem with the equipment provided, please contact the distributor directly. Eneraque, in a constant effort towards product improvement, shall revise its manuals and include improvements made to the supplied units. Thus the information contained in this document is subject to change without prior notice and without obligation to update.
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2.0 BASIC SAFETY RULES
Safety precautions and recommendations for handling the Electrical Generator supplied by Eneraque
1. Do not allow the unit to be used by non-authorized personnel or minors not accompanied by an adult.
2. Use the necessary individual protection equipment.
3. Ground the machine and ATS panel.
4. Make sure there is sufficient lighting on the genset and on the control panels.
5. Do not install the open-skid electrical generator outdoors: risk of electrocution and non-functioning.
6. The connection should be made by a qualified electrician in accordance with current norms and regulations. An incorrectly made connection can cause electrical feedback with electrocution hazards for anyone working with the mains power supply. The mains connection should always be made using an automatic transfer switch (ATS); if none has been supplied, contact your distributor or Eneraque.
7. The supply line between the generator set and the consumers should be protected by means of a differential relay for protection against earth leakage.
8. The electrical installation between the generator unit and ATS should be protected using electromagnetic circuit breaker for protection against short circuits and overcurrents. The circuit breaker is supplied optionally by Eneraque.
9. Do not operate the unit with the doors open: risk of electrocution, burns or entrapment.
10. The exhaust system produces enough heat to ignite certain materials.
11. Do not inhale exhaust gases produced by the unit.
12. Do not touch the engine or the exhaust while the generator set is operating as this could produce serious burns.
13. Ensure proper ventilation in the area where the generator is installed in order to guarantee sufficient flow of cooling air.
14. Do not refuel while the engine is running or in poorly ventilated areas.
15. Know how to stop the unit in case of emergency.
16. The fuel used is flammable and volatile.
17. Do not overfill the tank and make sure it is closed properly after filling. Use extreme precaution if fuel is spilled: the vapors and the fuel itself are flammable. Clean the area completely before starting up the unit.
18. Do not smoke or bring any flames or sparks in the vicinity of the electrical generator: risk of explosions.
19. If you notice abnormal behavior by the generator set, stop the unit, locate, examine and resolve the potential failure of the unit prior to restarting. Contact our technical services department if needed.
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20. Keep the unit at least one meter away from buildings or other units. 21. Be cautious when switching or installing batteries as they contain acids which are highly hazardous. Avoid
spills and use protection to avoid contact with the skin and eyes. In case of contact, rinse thoroughly with water and contact a doctor immediately. 22. In case of ingestion of battery acid, drink large amounts of water and milk and contact a doctor immediately. 23. Use only distilled water in the battery: tap water reduces its life expectancy. 24. If a battery is filled above the maximum level, the electrolytes will spill out; if this happens, clean the area quickly to avoid corrosion of the parts it has come in contact with. 25. Frequently clean the unit to avoid obstructions or the entry of foreign elements into the unit (dust, moisture, etc.). 26. Regularly inspect the unit's electrical cables. 27. Prolonged contact with used oil can cause skin cancer. Wash your hands after working with the generator. 28. Avoid oil spills on both the inside and outside of the generator. In case of an oil spill on the inside of the unit, clean it properly as it could potentially become a flammable material.
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3.0 DESCRIPTION OF GENERATOR SET
General overview of the generator set and its different configurations manufactured by Eneraque.
Image 1- Generator set with sound proof canopy.
Image 2- Generator set without canopy
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Image 3- Detailed view of Image 1
1) Coolant tank hatch 2) Side access door 3) Fuel tank cap 4) Exhaust silencer 5) Engine 6) Shock absorbers 7) Base frame 8) Base support
9) Canopy 10) Electrical Panel Doors 11) Ventilation grill 12) Lifting frame and eyebolt 13) Control panel 14) Alternator 15) Electrical power panel 16) Battery 17) Fuel tank 7
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Image 4- Detailed view of Image 2
1) Lifting frame 2) Engine 3) Shock absorbers 4) Base frame 5) Fuel tank
6) Base support 7) Control panel 8) Electrical power panel (optional) 9) Alternator 10) Battery
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3.1
SOUND INSULATION
The supplied unit may be:
Soundproofed. Includes sound-insulating canopy.
Open skid. Please keep in mind that in compliance with current regulations may require that proper room sound insulation will be provided for this model. (See 4.2 INSTALLATION)
Each Electrical Generator is provided with a sticker indicating the level of noise output produced and the need to use hearing protection.
Noise output 90 dBA
Noise output 114 dBA
Use of hearing protection required.
The noise level has been measured according to the European directive 2000/14/EC and in compliance with the maximum levels established by directive 2005/88/EC.
Please consider the local and national regulations that could be more restribe. In any case it the intaller and owner responsabity to comply with the current legislation
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3.2
CONTROL Panel
The unit provided may be controlled by different modules depending on the type of function it has been designed to
perform.
The following is an example of a control panel with Inteligen NT which contains all of the electrical and mechanical options available.
Image 5- Generic Control Panel
1-3 .Electrical Gaugues
6 Indication lamps (green, red, yellow)
4 Hour meter
7 Mode Swicht
5 Earth elakage relay (It may be installed inside the electrical panel)
8-> Engien Gaugues
10
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3.3
ELECTRICAL CONFIGURATION
The supplied unit may be one of three types:
The generator unit is supplied with automatic transfer switch (ATS).
The generator unit is supplied without ATS. Note that its installation is required.
Image 6- Load Transfer diagram
Note: PCCB = Power Control Circuit Breaker
ATS may be with contactors, motorized changeover switch or motorized circuit breakers
Standby by signal. The Electrical Generator is supplied without ATS stands idle until it receives a signal
from an autonomous external system which monitors the mains and controls the automatic transfer switch for startup.
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3.4
retention bath
The generator set may include a built-in retention bath to prevent spills from the unit--such as fuel, oil or coolant--with a capacity of 110% with respect to the total volume of liquids.
It is the responsibility ot the installer and the owner to take the
1
2 2
3 1
Image 7- Retention Bath 1) 4 drain plugs, 2 on each side of the pan 2) Slots for inserting forklift arms 3) Retention bath level senders (optional)
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4.0 INSTALLATION OF THE GENERATOR SET
In this part of the manual it is described how to install a "generic" generator set composed of a diesel engine, alternator and electrical panel. Please follow the current regulations when installing a generator set.
4.1
UNLOADING AND TRANSPORT
When unloading an generator set, certain minimum conditions should be observed in terms of safety and
efficiency. The loading and transport of the unit should be done by qualified personnel.
The floor must be capable of supporting the full weight of the Generator and the forklift.
Make sure that the battery is disconnected.
Make sure that the fuel tank is empty.
Place the arms of the forklift below the chassis at an equal distance with respect to the lifting frame.
With a hoist, raise the unit using the lifting frame eyebolt.
The image below shows a drawing of a generator unit which includes a frame with a single lifting point.
Image 8- Lifting frame
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4.2
Installation Principles
Premises
The following considerations must be kept in mind: the fuel supply, ventilation of the premises, the output and direction of the exhaust gases and the noise produced.
Dimensions
The dimensions should allow for the various required maintenance or disassembly operations. A minimum of one meter should be left on all sides of the generator to allow for the doors to be opened.
Openings
The premises should have an entrance that is large enough for the generator to pass through and openings large enough for ventilation (fresh-air intake and radiator hot air outlet), with the appropriate surface area based on the generator's output, the premises' cooling system and the soundproofing system used.
Eneraque does not recommend installing canopied units in closed spaces.
If the unit must be installed in a enclosed space, it is recommended to use an open-skid model and soundproof the work area, in keeping with the current fire-prevention regulations.
The following image shows a typical installation of an open-skid unit in a closed space.
Image 9- Detailed view of installation of an open-skid unit
Air intake grill. Will be at least 1.4 times the surface area of the engine's radiator panel. Smoke exhaust line. This will be explained in more detail later.
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Silencer. Must be firmly installed and fastened to a stable structure. Smoke exhaust outlet. Smoke must flow out through a point which impedes its reentry into the space where
the working unit is installed. Radiator air outlet grill. Will be at least 1.25 times the surface area of the engine's radiator panel. Cooling air channel. Prevents re-entry of hot air into the space where the unit is installed. Optional external fuel tank. The tank may or may not be supplied by Eneraque. Auxiliary fuel pump, SAB-BE-EV system. Optional accessory for filling of the generator set day tank from
an external large-capacity tank. Fuel line, adequate for transporting fuel and complies with current regulations.
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4.3
Ventilation and cooling
The heat produced by the generator's thermal engine must be evacuated from the premises.
The heat is generated by the cooling of the cylinders, the radiation from the engine block, the exhaust pipe, the cooling of the alternator and the radiator air output.
Insufficient ventilation could produce an increase in the ambient temperature of the premises and cause the generator to lose engine power or even shut down.
4.4
Fuel
In keeping with current regulations, special attention should be paid to the storage of fuel, which is classified as a
hazardous product. The installation of the generator will include a day tank and an optional fuel storage tank.
Depending on the output of the generator, the fuel tank may be external instead of being built into the base frame.
The tank should be installed within a maximum distance (see the Engine manufacturer's manual). The installation will be carried out according to current regulations.
4.4.1 Automatic fuel transfer system The unit may include a self-suction, eccentric fuel transfer pump (SAB-BE) with self-adjusting blades. Includes a recirculation bypass valve. The pump has an internal removable 352 micron filter, which must be used.
If the unit is positioned beyond the recommended distance to the fuel storage tank, the pump should be dismounted and placed near the external tank.
The pump will function if the generator set is running; it has an OFF/AUTO switch located on the door of the unit's control panel.
4.5
Exhaust
Pressure drop, insulation, suspension and sound levels should all be taken into account.
The compensators and flexible pipes used in the installation will absorb the displacement of the unit (due to dilations and vibrations).
The units supplied by ENerqaue may or may not include a rain cap. The units are equipped with two holes on the underside to prevent internal water accumulation.
The optimun muffler locations are, first, directly behind the exhaust manifold, and secondly at 2/5 or 4/5 of the total exhaust system length. The reason for this are the existing standing waves, especially for long exhaust systems, when the natural pipe frequency is in resonance with the fundamental engine frequency or one of its harmonics. The worst muffler locations in order of valve are 1/3, 3/5 or at the end of the system.
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The best muffler locations in order of values are
The worst muffler locations in order of value are
exhaust system length (elbows may be considered as straight portions).
L = total
Note: In installations where it is required, the exhaust pipe diameter must be increased. If the installation isn´t correct, seriously engine damage can be caused.
4.6
Generator set startup
The startup system used by the generator set is electrical and consists of a 12 or 24 V electric engine powered by
one or more batteries, usually lead.
Low temperatures make engine cranking difficult. Startup failure (three attempts without success) entails the stopping of the motor and, as a result, of the entire generator unit. In order to avoid it, and to ensure correct startup of the generator set at any temperature, preheating of the entire unit is made (heating of coolant water) by means of a boiler powered by mains. This system will work automatically, by a thermostat (setup in factory from 40 to 60ºC) and it will be correctly indicated on the control panel by a lamp..
Sometimes the unit can be supplied with dry batteries. The placement into service of the this batteries should be done by removing the vent caps and filling each cell using sulfuric acid with a density of 1.28 (or 1.23 in tropical countries). Let it sit for at least 20 minutes and check the electrolyte level (25 mm above the plates; never fill to the brim). Finally put the caps back on.
It is recommended that protective eyewear and gloves be worn when adding battery acid. Make sure that there is nearby access to tap water in order to wash any areas that come into contact with the acid.
All operations must be performed with the utmost precaution and safety as indicated in this Manual. (Be especially careful with potential short circuits that could occur when coming in contact with the unit's metallic objects).
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4.7
Electrical connection
These connections should be made while following a number of safety measures:
Use the proper individual protection equipment to ensure complete safety while performing the electrical installation.
Set the control module switch to the OFF position.
Make sure the emergency button has been pressed.
Verify that the battery is disconnected.
Swich off main power
Before beginning the installation of the unit provided, make sure that it meets your particular needs for voltage and frequency.
Handle cables with maximum precaution as they could be live voltaged.
The ground installation of the generator set and ATS must be performed correctly. Ground onnections should be identified by the following icon: .
The unit manufactured by Eneraque may or may not be supplied with ATS (depends on electrical configuration: see section 3.3); if it is not supplied, it must be added by the customer.
The ATS is comprised of electrical switchgear. The ATS will prevent simultaneous supply by the mains and the generator set.
There are three kinds of different control switchgear used in GESAN automatic transfer switch systems:
Contactors: mechanically and electrically interlocked to control mains and generator set output. They are manufactured from 40A to 125A.
Motor operated changeover switches: built by two mechanical interlocked switches. They are manufactured from 160A to 3150A.
Motor operated circuit breakers: two mechanical and electrical interlocked circuit breakers. They are supplied only on customer request.
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The following diagram shows a basic ATS setup.
GENERATOR SET MAINS
AUTOMATIC TRANSFER SWITCH (ATS)
Image 10- ATS setup The electrical installation of the ATS is performed in two separate steps: first, the installation of the CONTROL section (control and management of mains and ATS) and second, the ELECTRICAL POWER section (transmission of electrical energy). The following diagram shows the connections of a typical ATS manufactured by Eneraque.
LOADS
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CONTROL CONNECTIONS ON ATS PANEL
GECO module only
Image 11- Diagram of ATS Panel
4.7.1.1 Installation of CONTROL section:
The installation of the Control section can be done in three different ways: 1) ATS supplied by Eneraque. 2) ATS not supplied by Eneraque. 3) Unit is a "Standby by signal" type.
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POWER CONNECTIONS ON ATS PANEL
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1) ATS provided by Eneraque. Connect the terminals R S T N on the control panel installed on the generator and the terminals numbered 37, 40, 41 and 44 (for the GECO module, also connect 45, 46 and 47) to the terminals on the ATS panel with the same numbering.
CAUTION: Do not mistake control terminals R S T N with the electrical power terminals R S T N (see the connections diagram preceding the installation instructions for the control and electrical power sections).
In making these connections, you must use an 8-wire conductor (or 11-wire for the GECO module) of 1.5mm²,. This cable is not provided with the generator set. The maximum distance between the control panel and the ATS panel should be 25m for a 1.5mm² cross section and a generator set power of 650 kVA. In case of higher power or distance, increase the cross section to avoid excessive voltage drop.
2) ATS not supplied by Eneraque. Check the user manual of the corresponding ATS and follow these steps:
Connect the terminals R S T N of the control panel (referential mains voltage) to the input of the electric company mains.
Connect the terminals numbered 37 to 47 to the ATS control panel (check the electrical setup on the generator set control panel).
Make sure that the electrical and mechanical interlocking is completed correctly. Also make sure that the ATS that you want to install is compatible with the generator unit provided. Assembly is typically done with contactors; for motorized switches please check with Enerque.
The cable cross section must be appropriate for your installation.
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3) Generator unit is "Standby by signal" type: Neither the generator set will monitor the mains nor control the ATS: these must be controlled by the user's management system. The terminals through which the generator set receives the startup signal are 184 and 185, which should be voltfree. The generator set uses terminals 120 and 121 to return a volt-free signal when the voltage and frequency of the generator set are correct. Terminals R S T N should be connected to a mains input prior to the ATS, as these terminals provide the power supply for the engine block heater and battery maintainer. The cable cross section should be appropriate for your installation.
4.7.1.2 Installation of ELECTRICAL POWER section:
A diagram of a connection can be seen in image 17. The ELECTRICAL POWER installation may be done in two ways:
1) ATS supplied by Eneraque Connect the generator's current output terminals U V W N to the ATS terminals U V W N. Connect the electric company's power control switch (PCS) to terminals R S T N. Then connect terminals X Y Z N to the installation for which you want to guarantee electrical power.
2) ATS not supplied by Eneraque or the generator set is the "Standby via signal" type. Connect the generator's current output terminals U V W N to the input of the ATS on the generator set.
Check the manual of your ATS. This installation should be performed by qualified personnel, who should determine the conductor section to be used. Remember that you must ground the unit according to the current regulations in effect where the installation is performed.
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4.7.1.3 Earthing: Ensure that the generator set, including mobile ones, is effectively grounded (earthed) in accordance with every relevant regulation, electrical code, standard or other requirement, prior to start operations.
The electrical resistant of earthing installation must be enough low in order to allow earth leakage protection systems to work properly and to limit the voltage in exposed conductive parts, to avoid dangers to people or goods. Check regularly this value to avoid its increasing.
To avoid the transfer of currents or voltages from other electrical systems (for example, high voltage network), independence between grounding systems must be guaranteed.
4.7.1.4 Motorized changeover switches: Mototized changeover switches are a kind of special designed control switchgear for electrical networks transfer, which simplify the equipment and control wiring needed.
Motorized changeover switches can also be manually operated. They include a handle key to network switching in case of emergency when any power source is available.
For security purposes, the changeover switch can be padlocked in position 0 (then manual operations are impossible and electrical controls are disabled).
For additional information, please consult manufacturer manual.
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STORAGE
If you think your generator will be inactive for a long period of time, follow these instructions: Switch the control module to the OFF position. Press the emergency stop button to avoid future involuntary startups when connecting. Empty the fuel tank. Leave the battery disconnected. Avoid storing the unit in spaces with high dust accumulation or excessive humidity. Do not use pressurized water when cleaning the unit. Check your engine manual for care instructions; the manual has been provided together with this document. Check your alternator manual for maintenance instructions; the manual has been provided together with this document.
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5.0 STARTUP
Prior to start up the generator set, follow these steps listed below: Check levels: oil, coolant and fuel. Turn the battery isolator switch to the ON position. Release the emergency push button if it has been pressed. Connect to the mains power and verify that the voltage indicator is giving an adequate reading. Check circuit breaker is on After completing the pre-startup tasks, make sure that the generator's control module switch is in the desired position. For this reason, the user should carefully read about the operation of the control module in section 6 of the OPERATION MANUAL. It is recommendable to run a simulation of mains failure to verify that the unit is functioning properly.
Prior to start up the generator set or after changing generator set location, follow these steps listed below: Check the genset right mechanical balance and the right contact of every base support with the floor. Check and retighten, when necessary, engine-alternator coupling to base frame screws. Check and retighten, when necessary, radiator to base frame and radiator to motor screws. Check and adjust, when necessary, the fan belt and battery charger alternator belt alignment. If generator set output is over 750 kVA, this recommendation turns into mandatory. Please, contact with your distributor to request specific information to make this task. Check canopy sealing material, especially in the roof. Clean and reseal when necessary. Check battery connections, and retighten, clean and grease when necessary.
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5.1
POWER FACTOR AND GENERATOR SETS
The power factor (cos ) of the generator set loads must be determined. Lagging power factor below 0,8 can
overload the generator. It can work properly from 0,8 to 1 lagging power factor.
Special attention must be given to installation with power factor corrections equipment (based on capacitors) in order to avoid leading power factor. This could prompt the generator set to voltage instability and could result in dangerous overvoltages. Whenever generator set is supplying the load, any power factor correction equipment must be switched off.
5.2
LIGH LOAD OPERATION ON DIESEL ENGINES
If an engine is operated on a load less than 25-30% of it's rated output, certain symptoms will be observed which
may be cause for concern. The engine is designed to run up to a maximum power and so the size of the piston, the
wall loading of the piston rings, etc., are designed for this.
When an engine is run at light load then the energy put into the cylinder is low and cnsequently the cylinder pressure is lower and so is the temperature. The result is the piston to bore clearance is increased allowing more oil to pass the piston and be burnt, which is indicated by high oil consumption.
With lower preasures the sealing capacity of the rings is lower, also it is not ideal for bedding in the rings and can cause bore glazing, which reduces oil control.
Oil will start to appear from the manifolds from the bearing arrangement in the turbocharger.
Turbochargers are fitted to an engine to increase power by supplying more air to the cylinders. When running a turbocharger, air is sucked in, which can have vacuum levels up to 500 mm H2O, with pressure ratios of 3:1. The compressor seals are designed to work most efficiently when the turbocharger compressor is operating at its' most efficient point. If the engine is running at low powers then the turbocharger is running at low speed (no energy from the exhaust because the fuel inlet to the engine is low) and the inlet vacuum is low resulting in poor turbocharger seal loading and pull over of oil from the bearing assembly. This oil is mixed with the air and pumped into the manifolds where some separates from the air when it collides with the inside of the manifold. The manifold gaskets will become impregnated with oil, eventually this will show as an oil leak from the manifold mating surfaces.
Black smoke will be produced from the exhaust outlets, due to poor combustion at light load, as excess fuel is pumped through into the exhaust system, resulting in soot being expelled into the exhaust system.
A further result is that of abnormal carbon build-up on the valves, piston crowns and exhaust ports. Thus the normal service interval of 2500 hours between top overhauls may be reduced. Fuel dilution of the lubricating oil will also occure.
It is therefore recommended that the following precautions are observed :-
Running on light load should be avoided or reduced to a minimum period. If weekly exercising on no load is carried out, the running period should be kept down to maximum 15 minutes or until the battery charge rate returns to normal.
Every year the engine / generating set should be run on full load for four (4) hours, to burn off accumulations of carbon in the engine and exhaust system. This may require a "dummy" load. The load should be built-up gradually from zero over the four hour run.
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6.0 OPERATION MANUAL
The generator set you purchased was designed for standby use, which means that it will mainly be operational when the mains voltage is inadequate.
Therefore it is necessary to connect the mains to the unit's ATS as well as to the generator set (see section 4 Installation).
The following is a description of the different variable elements, according to the generator set chosen.
6.1
CONTROL panel components
Ammeter: Measures the current (A), by means of a switch, of the different phases of the generator set.
Frequency meter: Indicates the frequency of the generator set (Hz).
Voltmeter: Indicates the voltage (V) of the main power supply or generator set, depending on the position of the voltmeter switch (Ph-Ph, Ph-N).
Voltmeter Switch This switch allows for voltage measurement by phase of the main power supply or the generator set.
Hour meter: Indicates number of hours worked by the generator set. The two digits in red on the right indicate hundredths of hours. Hours are indicated in white from the third digit on.
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Battery voltmeter. Indicates current voltage of battery.
Engine block heater lamp (warming up): Amber light. Indicates engine block heating system is turned on. Turns on and off automatically according to the setup of the thermostat.
Battery voltage failure lamp (GECO module only). Red light. Indicates alternator battery charge failure.
Emergency stop button:
Pressing this button brings the generator set to an immediate stop. To cancel, turn to the left, when the end of the emergency situation has been confirmed.
Gauges indicating engine parameters:
Oil Pressure
Battery charger current Engine Temperature Fuel Level
Activated by temperature and fuel button when generator set is stopped. When the generator is operating, the gauges show the corresponding levels.
Diagnostic Button: Allows engine parameters to be checked when generator set is stopped (electronically controlled engines). Also gives a readout of the generator's different alarms.
Differential: Protection against earth leakage of one phase, switching off the generator set circuit breaker.
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6.2
GECO Analog Control Module
Image 12- GECO Digital Control Module
The following is an explanation of each of the items shown on the GECO control module; this module is for generator units with/without ATS:
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NUMBER (1)
(2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)
(13)
(14)
(15)
SYMBOL
DESCRIPTION
IDENTIFICATION
Startup failure/No voltage
or frequency detected/Emergency button
Red LED
pushed
Low oil pressure
Red LED
High temperature/Low coolant level
Red LED
Overload
Red LED
Low fuel level Load test mode Test mode Automatic mode OFF/RESET mode SERV-1/START mode SERV-2/START mode Battery voltage OK
Battery charging
Red LED
Different module operational modes
Green LED Constant red: batteries charging/Flashing red light: batteries fully charged.
Mains correct
Green LED
Mains contactor
Yellow LED on indicates contactor closed
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Yellow LED on indicates
(16)
Power supply to loads
supply to loads
Yellow LED on indicates
(17)
Generator Contactor
contactor closed
(18) (19)
Generator voltage and frequency correct
Green LED indicates correct voltage and frequency
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The GECO module has six operating modes, differentiated in automatic mode (AUTO) and manual mode (MAN), which can be configured using the module switch (numbers 6-11 on the control module's descriptive panel).
AUTOMATIC mode (8), (normal operating mode):
When mains failure occurs, the GECO module registers this by turning off LED indicators
(13)
and
(14), at which point the mains contactor closes, LED indicator
(15) turns off and the
command is sent to turn on the unit. There will be a maximum of three startup attempts lasting 20 seconds each,
with a 10 second pause between each.
Once the unit has started up, if the generator set voltage is correct LED indicators
(18) and
(19) will be turned on, at which point the electrical generator's contactor closes and LED indicators
(16) and
(17) will be turned on, and the customer's installation receives a power supply until the
mains power returns.
If all three startup attempts have been unsuccessful, LED indicator will be given, lasting 120 seconds.
(1) will be lit and an acoustic signal
Upon return of the mains power, LED indicator
(14) on the control module will be lit and the unit's shutdown
sequence begins, which lasts approximately 60 seconds (in order to check the stability of the mains power)
following the return of the mains power, the generator set contactor will be disconnected, which in turn shuts off
LED indicators
(16) and
(17), followed by the closing of the mains power contactor
and the illuminating of LED indicators
(16) and
(17).
From this moment, the unit will continue operating for 120 seconds at no load before stopping completely to cool the engine.
If the mains power fails during the shutdown sequence, the operating cycle will be repeated, thus guaranteeing adequate electrical supply.
On this control module in automatic mode, two additional selections can be made (in addition to the automatic
option, seen previously): 32
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LOAD TEST mode (6): with the switch turned to this position, a simulation is made of mains failure and the load is transferred to the generator set. If the switch is turned to another option while correct voltage and frequency levels exist, the loads will be transferred to the mains power.
NO LOAD TEST mode (7): this option simulates a mains failure: no loads are transferred to the generator set. If a mains failure occurs during this operation, the loads will be transferred to the generator unit. This mode will terminate if another option is selected.
Note: For terminating test modes, it is recommendable to turn the switch to OFF/RESET and then turn the switch to the AUTO position.
MANUAL mode (3 different modes)
OFF/RESET mode performs two functions, the first of which is to stop the unit whether it is in manual mode (MAN) or automatic mode (AUTO); the second function is to cancel the active alarms, allowing for a new startup of the generator set.
SERV-1/START mode (10): when turning the switch to this option, the unit startup is ordered (manual operation of the generator unit); if it is operating in this mode and a mains failure occurs, the generator set will not supply energy to the loads.
SERV-2/START mode (11): when turning the switch to this option, the unit startup is ordered (manual operation of the generator unit) and LED (17) is lit. If the generator stops in this mode, the loads would not be transferred to the mains power. The alarms are automatically set.
If a TEST has been run, both in automatic mode (AUTO) or in manual mode (MAN), to stop the generator set turn the control module switch to the OFF mode (9); once the engine is stopped the switch can be set to a new operating mode.
Finally, if the red STOP button is pressed, an emergency stop will take place. If the switch is turned to a position
other than OFF, LED indicators activated.
(1) and
(15) will light up and an acoustic signal will be
Note: If the emergency stop button is pushed while the generator unit is stopped (in the OFF position of the control module), the GECO control module will not give any indication of this, however the unit will not start up.
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INDICATOR LIGHTS:
(12) This control module includes a 2 ampere battery charger; receives power supply from external transformer connected to the mains power. LED will turn on when battery voltage is correct.
(13) LED is lit while batteries are charging. Lit only when connection with the mains power exists. LED illuminated intermittently when battery voltage is correct.
ALARMS: The alarms of the GECO module are showed by means of LED indicators. There are two alarm types, one which issues the stop command and one which does not; if it is the first of these, move the switch to the OFF position (9) and fix whatever caused the alarm and select the desired option.
(1) Indicates startup failure. Either voltage or frequency is not detected or the emergency stop button has been pressed; in both cases the LED indicator (1) will turn on and the control module will issue a stop command to the generator unit. To stop the alarm, turn the control module switch to the OFF/RESET position (9).
(2) Indicates low oil pressure. LED indicator (2) will turn on and the control module will issue a stop command to the generator unit. To stop the alarm, turn the control module switch to the OFF/RESET position (9).
(3) Indicates high engine coolant temperature or low coolant level. LED indicator (3) will turn on and the control module will issue a stop command to the generator unit. To stop the alarm, turn the control module switch to the OFF/RESET position (9).
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(4) Indicates overload of the generator unit. LED indicator (4) will light up and the control module will issue a stop command to the generator unit. To stop the alarm, turn the control module switch to the OFF/RESET position (9). Open the electrical panel door and check the status of the circuit breaker. Check the reason for the overload and reset. Close the electrical panel door. Put the module in AUTO mode.
(5) Indicates low fuel level; LED indicator (5) will be lit. System warning; must respond accordingly.
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6.3
GPM-2 Analog Control Module
This module is for "Standby by signal" type generators.
Image 13- GPM-2 Control Module
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NUMBER (1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
(11) (12) (13) (14)
SYMBOL
DESCRIPTION Unit startup failure / Alternator failure
Battery charge failure
IDENTIFICATION
Flashing red light: three startup failures. Continuous red light: voltage failure or low frequency.
Flashing red light: charge failed. Continuous red light: unit stopped.
Low oil level
Flashing red light: low oil level. Continuous red light: unit stopped.
Low level / High coolant temperature
Flashing red light: high temperature. Continuous red light; low level.
Overload
Flashing red light: unit overload.
Low fuel level
Flashing red light: low fuel level.
Emergency stop / Overspeed
Flashing red light: emergency stop. Continous red light: overspeed.
Remote startup mode Green LED
Unit warming up
Yellow LED
Stop signal Maintenance signal
Flashing red light: cool-down time.
Continuous red light: stop command issued.
Flashing blue light: maintenance required
Maintenance reset button / Ignition button
Button
Unit startup button Manual Mode
Button MAN
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(15)
Key position for stopping unit
STOP
(16)
Automatic mode
AUTO
(17)
Programmable alarm
Flashing or continuous red light: user-defined.
The GPM-2 control module has three positions: STOP, automatic (AUTO) and manual (MAN). Key selectable (numbers 14 through 16 of the descriptive chart on the control module).
AUTOMATIC mode
(AUTO):
When key is turned to the automatic mode position, unit will sit idle until receiving an external startup command. If mains failure occurs, the external mains monitoring system will issue a signal to the generator set, which will begin to operate, supplying the necessary electric power..
At the moment in which the external startup signal is received, while the key is in the AUTO position, the LED
indicator for low oil level
will light up, as well as the alternator battery voltage indicator
and AUTO
TEST LED
(numbers 3, 2 and 8 of the descriptive panel on the control module, respectively).
There will be a maximum of three startup attempts lasting 10 seconds each, with a 10 second pause between each.
After three unsuccessful startup attempts, LED indicator (1) will turn on.
If the unit was operating in automatic mode and the mains failure is resolved, once the external signal disappears
60 seconds will pass in order for the engine to be cooled; during these 60 seconds the LED indicator (10) will flash and later it will be continuously displayed and the engine will stop, with the LED indicator light remaining for 20 seconds.
If the mains power fails during the shutdown sequence, the operating cycle will be repeated, thus guaranteeing adequate electrical supply.
NO LOAD TEST mode (Manual):
When key is turned to the manual mode, LED indicators for low oil level
(3) and alternator battery charge
indicator
(2) will be turned on. To start up the unit, press the START button
(13). If the key selection
has been made on the generator unit and this button is not pushed in 20 seconds, the control module will shut off
the system; the startup signal will be cut off when LED indicators for low oil level
(3) and alternator battery
charge
(2) turn on; the startup signal will also be cut off when the frequency exceeds 20 Hz. 38
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LOAD TEST mode (Manual): It must be done using the external ATS controller with the control module in automatic mode.
INDICATOR LIGHTS:
(8) Indicates remote startup; continuous green light turns on when unit is operating remotely.
(9) Indicates unit is warming up; continuous yellow light turns on when unit is being heated.
(10) Indicates stop signal.
Flashing: indicates engine cooling time.
Continuous: control module issues a stop command to the Engine; stays lit for 20 seconds following the complete stopping of the engine.
(11)
Indicates maintenance. Flashing light; the first time the light turns on after 50 operating hours and afterwards every 150 hours.
To reset the maintenance hour meter, the generator set must be running; turn the key to the STOP position while
pressing down the button
(12) until the control module becomes completely deactivated.
(12)
Ignition button.
When key is turned to manual mode and START button is not pushed before 20 seconds, the control module will shut off the system in order to avoid battery discharging. But some engine maintenance tasks require electrical supply from battery to electronic engine components when the engine is not running. To get it, with the key in
STOP position, press the button
(12) and without releasing it turn the key to the MAN position
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ALARMS: The following is a chart describing the possible alarms of the GPM-2 module:
NUMBER (1) (2) (3) (4) (5) (6) (7)
SYMBOL
DESCRIPTION
IDENTIFICATION
Unit startup failure / Alternator failure
If the light is flashing, generator is shut down.
If light is continuous, indicates low frequency. If it unit runs below rated frequency for more than 30 seconds, it is shut down.
Alternator battery charge failure
If light is continuous and the engine is stopped, indicates ignition.
If light is flashing, indicates failure and the control module issues unit stop command.
Low oil pressure
If light is continuous and the engine is stopped, indicates ignition.
If light is flashing, indicates failure and the control module issues unit stop command.
Low level / High coolant temperature
If light is continuous, indicates low coolant level and module issues unit stop command.
If light is flashing, indicates high coolant temperature and the control module issues unit stop command.
Overload
Light will flash and indicate that the circuit breaker is tripped; module issues stop unit command.
Low fuel level
If light is flashing, indicated WARNING.
If light is continuous, module issues unit stop command.
Emergency stop / Overspeed
If light is continuous, module issues unit stop command, indicating an emergency stop (emergency button activated).
If the light is flashing, module issues unit stop command, indicating engine high speed.
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If the light is continuous, indicates
WARNING.
(17)
Programmable alarm
If light is flashing, module issues unit stop
command.
Note: If at any point 3 or more LED indicators turn on, it could indicate low battery level.
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6.4
DEEP SEA 7310/7320 Digital Control Module
MODULE 7320
9
10 8
11
12
7
1
2
3
4
5
6
Image 14- Deep Sea 7320 Control Module
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MODULE 7310
A
NUMBER (1)
SYMBOL
Image 15- Deep Sea 7310 Control Module
DESCRIPTION
IDENTIFICATION
Stop button.
Red LED
(2)
MANUAL mode button Red LED
(3)
TEST mode button
Green LED (available on model 7320 only)
(4)
AUTOMATIC mode button
Red LED
(5)
Mute alarm / Lamp test button
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(6)
Generator set start up button
(7)
"Transfer to generator" button
Green LED on when generator set is available
(8)
Configurable LED indicators.
Red LED
(9)
Status generator set display.
(10)
Menu navigator
(11)
"Transfer to mains" button
Green LED (available on Model 7320 only)
(12)
Status of ATS for mains Left LED on: mains closed / Right
and generator set.
LED on: generator closed.
(A)
"Open generator" button
LED on: generator set is supplying loads.
Deep Sea 7320 is an automatic control module that monitors the main power supply; if a mains failure occurs, generator set will start up and loads are transferred. This control module also allows the option of manual startup. The user can also control all of the generator unit's parameters as well as the status of mains power supply. This model is supplied with standby generator sets with or without ATS.
Deep Sea 7310 control module is supplied with "standby by signal" type units.
AUTOMATIC mode (AUTO):
This is the normal operating mode.
The automatic mode is activated by pressing the button will turn on, indicating that it is operational.
(4), at which point the LED at the top of the button
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(7320) If the mains power supply fails for longer than the unit's programmed period, the LED that the mains power is available will be turned off.
(11) indicating
(7310) If a mains failure occurs, the external management system should send a startup signal to the generator set, at which point the LED indicating remote startup active (8) turns on and the startup process of the generator set begins.
The engine will start; if it should fail, there will be a maximum number of startup attempts (3). If all three startup
attempts have been unsuccessful, the information screen will display a startup alarm:
When mains power is restored (or when the remote startup signal disappears) there will be a period of time in which the engine will continue operating at no load to cool down before stopping completely.
If a mains failure occurs or remote startup signal appears again during the no-load operating period (cool-down period), the generator set would begin the startup process again.
Press
(1) or the emergency stop button to intentionally stop the unit.
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MANUAL mode:
The manual mode is activated by pressing the button turn on, indicating that it is operational.
(2), at which point the LED at the top of the button will
Press
(6) to start up the unit.
If a mains failure occurs, a remote startup signal is received or "transfer to generator" button (7)
is pressed,
loads will be transferred to the generator set. Once the load has been transferred to the generator, It will not be
automatically transferred back to the mains supply.
Loads can be manually transfer back to mains pressing "transfer to mains" button
(11) (7320) or pressing
"open generator" button
(A) (7310).
To terminate this mode, press the button
(4).
Once button (4) is pressed and there is adequate mains power supply (without the remote startup signal activated), the shutdown sequence will begin as described in the automatic mode.
Press
(1) or the emergency stop button to intentionally stop the unit.
LOAD TEST mode (7320):
A test for proper functioning of the generator set can be done pressing
(3).
To start up, press the start button
(6).
In this operating mode, a mains failure is simulated, with the loads being transferred to the generator set.
To terminate this mode, press the button
(4).
Once button
(4) is pressed and there is adequate mains power supply (without the remote startup signal
activated), the shutdown sequence will begin as described in the automatic mode. After this period of time, the load
will be carried by the mains power.
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Press
(1) or the emergency stop button to intentionally stop the unit.
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ALARMS:
Press
(5) to silence the audible alarm and acknowledge the common alarm LED.
By default, the information screen will show the status screen and if an alarm occurs, the screen will display the following:
Alarm 1 of a total of 2 present alarms
Alarm type (shutdown or warning)
Alarm description. Example: High engine temperature
If shutdown occurs while a warning is active, the screen will cycle through the active alarms:
The warnings do not entail generator unit shutdown.
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INCIDENT
ALARM Warning Charge failure ALARM Warning Battery under voltage ALARM Warning Battery over voltage ALARM Warning Fail to Stop ALARM Warning Auxiliary inputs
ALARM DESCRIPTIONS Charge alternator voltage not detected
Battery voltage beyond established limits
After shutdown command, engine continues running. Could also indicate faulty oil pressure sender Auxiliary inputs can be configured and will display the message as written by the user
ALARM Warning Low fuel level ALARM Warning CAN ECU error ALARM Warning kW overload ALARM Warning Earth fault ALARM
Fuel level below established limits
Engine ECU has detected a warning alarm. The exact error is also indicated on module display (only for electronic engines).
The total kW are above the warning setting.
The earth fault current is above alarm settings (only under customer request) Indicates "out of balance" current loading of the generator set.
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Warning Negative phase sequence
ALARM Warning Low oil Pressure ALARM Warning Engine high temperature ALARM Warning Engine low temperature ALARM Warning Underspeed ALARM Warning Overspeed ALARM Warning Generator over frequency ALARM Warning Generator under frequency ALARM Warning Generator over voltage ALARM Warning Generator under voltage ALARM Warning
Low oil pressure, below established limit Engine temperature beyond established limits Engine speed beyond established limits Generator set frequency beyond established limits Generator set voltage beyond established limit Current of the generator set output beyond established limits
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High Current
INCIDENT
ALARM Shutdown Earth fault ALARM Shutdown Failed to Start ALARM Shutdown Emergency stop ALARM Shutdown Low oil pressure ALARM Shutdown High temperature ALARM Shutdown Phase rotation ALARM Shutdown Overspeed ALARM Shutdown Underspeed
ALARM Shutdown Generator over frequency
DESCRIPTION OF SHUTDOWNS The earth fault current is above shutdown settings (only under customer request) Engine does not start, three attempts made. Controlled shutdown of the unit. It will not be functional until the emergency stop button has been reset. Oil pressure below established limit Engine temperature above established limit The phase rotation is different to the configured direction
Engine speed beyond established limits
Generator set frequency beyond established limits 51
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ALARM
Shutdown
Generatp
or under frequency
ALARM
Shutdown
Generator over voltage ALARM
Generator set voltage beyond established limit
Shutdown
Generator under voltage
ALARM
Shutdown
Faulty oil pressure sender
Oil pressure sender open circuit
ALARM Shutdown Auxiliary input
An active auxiliary input configured as a shutdown will cause the engine to shutdown. The display shows the text as configured by the user.
ALARM Shutdown Loss o speed signal
The speed signal from magnetic pick up as not received by the module.
ALARM Shutdown ECU data fail
The module conficured for CAN operation and doesn´t detect data on datalink
ALARM Shutdown ECU shutdown
Engine ECU has detected a shutdown alarm. The exact error is also indicated on module display (only for electronic engines).
ALARM
Shutdown
The total kW are above the shutdown setting.
kW overload
ALARM
Shutdown
Indicates "out of balance" current loading of the generator set.
Negative phase sequence
ALARM
Current of the generator set output beyond established limits
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Shutdown
High Current trip
Note: If the established limit for shutdown is exceeded, a corresponding alarm screen will be displayed and on the configurable LED indicator (8) the Common Shutdown alarm will appear.
INCIDENT
DESCRIPTION OF ELECTRICAL TRIPS
ALARM Electrical trip Generator over current
Generator set current above electrical trip setting.
ALARM Electrical trip Auxiliary inputs
Auxiliary inputs can be configured and will display the message as written by the user
ALARM Electrical trip kW overload
The total kW are above electrical trip setting.
ALARM Electrical trip
Earth fault
The earth fault current is above electrical trip settings (only under customer request)
ALARM Electrical trip Negative phase sequence
Indicates "out of balance" current loading of the generator set.
Note: Electrical trips are latching and stop the generator set but in a controlled manner. Firstly de-energise the "close generator" output to remove the load from the generator set, and later, cool down and shutdown the unit.
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Typical LCD Display Screens
Indicates that the generator set will respond to either a mains failure or an active remote start.
Indicates that generator set is in automatic mode and has been initiated after a mains failure has been detected.
Indicates generator set running normally in automatic mode. Also indicates the average line to neutral voltage (L-N), the highest of the three phase currents, the rated frequency, average line-to-line voltage (LL) and total kilowatts.
Measurement Parameter Display Screens:
Coolant temperature in degrees (ºC) Celsius and degrees Fahrenheit (ºF)
Displays engine oil pressure in Bar, PSI and kPa.
All three generator line currents.
Event Log:
To view the event log, press the following button repeatedly
until the LCD display the event log.
It registers the shutdown alarms occurring in the generator unit. A screen similar to this is shown:
"On September 12, 2007, at 08:25:46, the unit detected that the oil pressure was below the minimum level and has shut down the generator. It´s the event 1 of a total of 50 logged events"
To move from one event to the next, press
.
To exit the main screen, press
.
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Note: Warning alarms are not logged.
Displaying information:
Pressing this button:
.
Page order:
Status display
Instrument display (engine, generator and mains)
Alarms display
ECU DTCs (electronic engines only)
Event Log
Scheduler (if enabled)
About
It is possible to scroll through the different display screens by pressing the next page button:
. Once selected,
the page will remain on the screen until the user selects a different page or after a period of inactivity for the control
module, at which point the status display appears.
If no buttons are pressed upon entering an instrumentation page, the instruments will be displayed automatically.
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Alternatively, by pressing on
or
buttons, the user can scroll through all the instruments on a particular
screen. This disables autoscroll. When autoscroll is disabled, if no buttons are pressed the display will return to the
status page. To re-enable autoscroll, press on
or
buttons to scroll to the title of the instrument page.
If an alarm becomes activated while viewing instruments, the Alarms page will be automatically displayed. Instrument page content: Engine
Engine speed Oil pressure Coolant temperature Engine battery volts Run time Oil temperature* Coolant temperature* Inlet temperature* Exhaust temperature* Fuel temperature* Turbo pressure* Fuel pressure* Fuel consumption* Fuel used* Fuel level* Auxiliary sensors (if fitted and configured) Engine mantenience due (if configured) Engine ECU link*
* When connected to suitably configured and compatible engine ECU.
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Generator Generator AC voltage L-N Generator AC voltage L-L Generator frequency Generator current Generator earth current (under customer request) Generator load (kW) Generator load (kVA) Generator power factor Generator load (kVAr) Generator load (kWh, kWAh, kVArh) Generator phase sequence
Mains (DSE 7320 only) Mains voltage L-N Mains voltage L-L Mains frequency
About Module type Application version USB ID unique identifier for PC USB connection Analogue measurements version Firmware update bootloader version
If the following appears in an instrument display: *****, this means that the engine can't provide this parameter; the control module, however, does provide this option.
If the following appears in an instrument display: ####### with the generator set in OFF/AUTOMATIC mode (with the engine stopped), this means that the control module is not connected to the engine. Press this button
(6) to display the given value. 57
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Alarm LED:
Remote start on load Overload pre-alarm Common alarms Common shutdown
Editing the current Date and Time:
The date and time are adjustable. When the battery is disconnected, the date and time are frozen; when the battery is reconnected, the date and time shown will be from the last time the battery was disconnected. The date and time reflected in the Event Log will be taken from the configuration according to the following steps:
Press
and
simultaneously, then enter the correct PIN number using
or
buttons to select
the right figure, and using
and
to move from one figure to another. Finally press
button
Press
until the Display seccion. Press
until "Current date and time".
When "Current Date and Time" appears, press the
button. The figures will start to flash. Press
or
to adjust to the desired values.
Press the
button to confirm the value entered.
Press and hold
to exit the editor at any time.
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6.5
DEEP SEA 5510/5520 Digital Control Module
9
10 8
11
12
7
1
2
3
4
5
6
Image 16- Deep Sea 5520 Control Module
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A
NUMBER (1)
SYMBOL
Image 17- Deep Sea 5510 Control Module
DESCRIPTION
IDENTIFICATION
Stop button.
Red LED
(2)
MANUAL mode button Red LED
(3)
TEST mode button
Green LED (available on Model 7320 only)
(4)
AUTOMATIC mode button
Red LED
(5)
Mute alarm button
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(6)
Generator set start up button
(7)
"Transfer to generator" button
Green LED on when generator set is available
(8)
Configurable LED indicators.
Red LED
(9)
Status generator set display.
(10)
Menu navigator
(11)
"Transfer to mains" button
Green LED (available on Model 7320 only)
(12)
Status of ATS for mains Left LED on: mains closed / Right
and generator set.
LED on: generator closed.
(A)
"Open generator" button
LED on: generator set is supplying loads.
Deep Sea 5520 is an automatic control module that monitors the main power supply; if a mains failure occurs, generator set will start up and loads are transferred to generator, synchronising and paralleling with mains when it is correct again. This control module also allows the option of manual startup. The user can also control all of the generator unit's parameters as well as the status of mains power supply. This model is supplied with standby generator sets which need synchronise and parallel with mains, with or without ATS.
Deep Sea 5510 control module is supplied with generator set design for multi-set systems (several genset working in parallel. Another control device must monitor the mains and order the switch.
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AUTOMATIC mode (AUTO):
This is the normal operating mode.
The automatic mode is activated by pressing the button will turn on, indicating that it is operational.
(4), at which point the LED at the top of the button
(5520) If the mains power supply fails for longer than the unit's programmed time, the LED that the mains power is available will be turned off.
(11) indicating
(5510) If a remote start signal gets to the generator set, the LED indicating remote startup active (8) turns on and the startup process of the generator set begins.
The engine will start; if it should fail, there will be a maximum number of startup attempts (3). If all three startup
attempts have been unsuccessful, the information screen will display a startup alarm:
Once the engine is running and stabilized the mains breaker is opened and generator breaker is closed (5520).
Once the engine is running and stabilized, the generator set will first synchronise to the bus before closing generator breaker (5510).
When mains power is restored, the generator set is synchronised and paralleled with the mains. When parallel time is expired, the generator set will ramp the remaining load to the mains, and generator breaker is opened. There will be a period of time in which the engine will continue operating at no load to cool down before stopping completely (5520).
When remote start is removed the generator set will ramp the load to remaining sets. The generator breaker will be opened. There will be a period of time in which the engine will continue operating at no load to cool down before stopping completely (5510).
If a mains failure occurs or remote startup signal appears again during the no-load operating period (cool-down period), the generator set would begin the startup process again.
Press
(1) or the emergency stop button to intentionally stop the unit.
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MANUAL mode:
The manual mode is activated by pressing the button turn on, indicating that it is operational.
(2), at which point the LED at the top of the button will
Press
(6) to start up the unit. When engine is running and stabilized, the generator available led is on.
If a mains failure occurs or "transfer to generator" button
(7) is pressed, the generator set is synchronized
and paralleled with mains. If "transfer to generator" button
(7) is pressed while in parallel, the loads will be
ramped to the generator set and mains breaker will be opened. If later "transfer to mains" button
(11) is
pressed, the generator set is re-synchronised with the mains and return to parallel operation. If "transfer to mains"
button
(11) is pressed while in parallel, the generator breaker will be open and loads transferred to the
mains (5520).
If a remote start signal is applied or "transfer to generator" button
(7) is pressed, the generator is
synchronised to the bus and then generator breaker is closed. If "open generator" button pressed, the load is ramped on the remaining generators and the generator circuit is opened (5510).
(A) is
To terminate this mode, press the button
(4).
Once button (4) is pressed and there is adequate mains power supply or without the remote startup signal activated, the shutdown sequence will begin as described in the automatic mode.
Press
(1) or the emergency stop button to intentionally stop the unit.
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LOAD TEST Mode (5520):
Press
(3) to test for proper functioning of the generator set.
To start up, press the start button
(6). When the engine is running and stabilized, the generator set is
synchronized with the mains and the generator breaker is closed. The loads will then be ramped from mains to the
generator set.
To terminate this mode, press the button
(4).
Once button
(4) is pressed and there is adequate mains power supply, the shutdown sequence will begin
as described in the automatic mode. After this period of time, the load will be carried by the mains power.
Press
(1) or the emergency stop button to intentionally stop the unit.
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ALARMS:
Press
(5) to silence the audible alarm and acknowledge the common alarm LED.
By default, the information screen will show the status screen and if an alarm occurs, the screen will display the following:
Alarm 1 of a total of 2 present alarms
Alarm type (shutdown or warning)
Alarm description. Example: High engine temperature
If shutdown occurs while a warning is active, the screen will cycle through the active alarms:
The warnings do not entail generator unit shutdown.
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INCIDENT ALARM Warning
Charge failure ALARM Warning
Battery low voltage ALARM Warning
Battery high voltage
ALARM Warning Auxiliary inputs
ALARM DESCRIPTIONS Charge alternator voltage not detected
Battery voltage beyond established limits
After shutdown command, engine continues running. Could also indicate faulty oil pressure sender Auxiliary inputs can be configured and will display the message as written by the user
Fuel level below established limits
ALARM Warning Engine low temperature ALARM Warning Generator failed to open ALARM Warning Mains failed to open ALARM Warning
Engine coolant temperature below warning setting.
Feedback doesn´t confirm that generator breaker is opened.
Feedback doesn´t confirm that mains breaker is opened. Feedback doesn´t confirm that mains breaker is closed.
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Mains failed to close
ALARM
Warning
The setting time without maintenance has been exceed.
Maintenance due
ALARM
Warning
The generator set can´t synchronise
Failed to synchronise
ALARM
Warning
Generator phase sequence wrong
A bus phase rotaion error has been detected.
ALARM
Warning
A mains phase rotation error has been detected.
Mains phase sequence wrong
ALARM Warning Negative phase sequence
Indicates "out of balance" current loading of the generator set.
ALARM
Warning
MSC link doesn´t allow modules communicate correctly.
MSC data error
ALARM Warning MSC too few sets
The number of modules on the MSC link is below the warning setting.
ALARM Warning CAN ECU error
Engine ECU has detected a warning alarm. The exact error is also indicated on module display (only for electronic engines).
Low oil pressure, below established limit
ALARM Warning Engine high temperature
Engine temperature beyond established limits
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ALARM Warning Engine low temperature
Engine speed beyond established limits
ALARM Warning Generator over frequency ALARM Warning Generator under frequency ALARM Warning Generator over voltage ALARM Warning Generator under voltage ALARM Warning Loss of excitation
Generator set frequency beyond established limits Generator set voltage beyond established limit Loss of excitation on the alternator
ALARM Warning Insufficient capacity
The generator set is overloaded when paralleling with mains.
Current of the generator set output beyond established limits
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INCIDENT
DESCRIPTION OF SHUTDOWNS Engine does not start, three attempts made.
Controlled shutdown of the unit. It will not be functional until the emergency stop button has been reset.
Oil pressure below established limit
Engine temperature above established limit
Engine speed beyond established limits
ALARM
Shutdown
Generator over frequency ALARM
Generator set frequency beyond established limits
Shutdown
Generator under frequency
ALARM
Shutdown
Generator over voltage ALARM
Generator set voltage beyond established limit
Shutdown
Generator under voltage
ALARM
Shutdown
Faulty oil pressure sender
Oil pressure sender open circuit
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ALARM Shutdown Auxiliary input ALARM Shutdown Magnetic pickup open circuit ALARM Shutdown Loss of speed signal ALARM Shutdown CAN data fail ALARM Shutdown CAN ECU fail ALARM Shutdown kW overload ALARM Shutdown Generator earth fault ALARM Shutdown Air flap closed ALARM Shutdown Negative phase sequence ALARM Shutdown MSC old units on bus ALARM Shutdown
An active auxiliary input configured as a shutdown will cause the engine to shutdown. The display shows the text as configured by the user. The speed signal from magnetic pick up as not received by the module. The speed signal is not received by the module during cranking. The module conficured for CAN operation and doesn´t detect data on datalink Engine ECU has issued a shutdown alarm. The total kW are above the shutdown setting. Earth fault current is above the shutdown settings. Engine air intake flap is closed. Inbalance in the load current of each phase above shutdown setting. An incompatible module on the MSC link. ID error on MSC link.
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MSC ID error
ALARM
Shutdown
MSC link is not detected.
MSC failure
ALARM
Shutdown
Loss of excitation on alternator.
Loss of excitation
Note: If the established limit for shutdown is exceeded, a corresponding alarm screen will be displayed and on the configurable LED indicator (8) the Common Shutdown alarm will appear.
INCIDENT ALARM
Electrical trip Auxiliary inputs
ALARM Electrical trip Generator high current
ALARM Electrical trip Generator reverse power
ALARM Electrical trip Generator short circuit
ALARM Electrical trip Mains reverse power
ALARM Electrical trip
DESCRIPTION OF ELECTRICAL TRIPS Auxiliary inputs can be configured and will display the message as written by th user Output current above the electrical trip setting.
Reverse power current above the electrical trip setting.
A generator short circuit has been detected.
The power exported to the mains is above the setting. Loss of excitation on alternator.
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Loss of excitation ALARM
Electrical trip Insufficient capacity
The generator set is overloaded when paralleling with mains.
ALARM Electrical trip Generator failed to close
Feedback doesn´t confirm that generator breaker is closed.
ALARM Electrical trip Negative phase sequence
Indicates "out of balance" current loading of the generator set.
Note: Electrical trips are latching and stop the generator set but in a controlled manner. Firstly de-energise the "close generator" output to remove the load from the generator set ,and later, cool down and shutdown the unit.
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Typical LCD Display Screens
Indicates that the generator set will respond to either a mains failure or an active remote start.
Indicates that generator set is in automatic mode and has been initiated after a mains failure has been detected.
L) and total kilowatts.
Indicates generator set running normally in automatic mode. Also indicates the average line to neutral voltage (L-N), the highest of the three phase currents, the rated frequency, average line-to-line voltage (L-
Measurement parameter display screens:
Coolant temperature In degrees (ºC) celsius and degrees fahrenheit (ºF)
Displays engine oil pressure in Bar, PSI and
kPa.
All three generator line currents.
Event Log:
To view the event log, press the page button be automatically scrolled down.
repeatedly until the LCD display the event log. The records will
The event log registers the shutdown alarms occurring in the generator unit. A screen similar to this is shown:
"On September 12, 2007, at 08:25:46, the unit detected that the oil pressure was below the minimum level and has
shut down the generator. It´s the event 1 of a total of 50 logged events". To exit the another page, press
.
Note: Warning alarms are not logged.
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Displaying Information:
Press the button
to move to the required page. The LCD display the page title and then automatically start
scrolling the various instruments until the user change to another page. It is also possible to scroll to different
instruments using
or
buttons.
Instrument page content:
Engine speed
Oil pressure
Coolant temperature
Fuel level
Battery voltage/charge alt volts
Engine run time/number of starts
Next maintenance (if enable)
Generator AC voltage L-N
Generator AC voltage L-L
Generator frequency
Generator current
Generator earth current (under customer request)
Generator load (kW)
Generator load (kVA)
Generator power factor
Generator load (kVAr)
Generator load (kWh, kWAh, kVArh)
Generator phase sequence
Mains voltage L-N
Mains voltage L-L
Mains frequency
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Enhance engine instrumentation (when supported by electronic engine ECU):
Oil temperature* Coolant temperature* Inlet manifold temperature* Exhaust temperature* Turbo pressure* Fuel pressure* Fuel consumption* Total fuel used*
Alarm LED:
Remote start on load Overload pre-alarm Common alarms Common shutdown
Editing the current Date and Time:
The date and time are adjustable. When the battery is disconnected, the date and time are frozen; when the battery is reconnected, the date and time shown will be from the time the battery was disconnected. The date and time reflected in the Event Log will be taken from the configuration according to the following steps:
Press
and
simultaneously, then enter the correct PIN number using + or - buttons and then press
to select the next figure.
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The LCD will then display: CONFIGURATION. To view the different configuration functions press the + or
buttons. Pressing the
button will enter in edit mode. The parameter being changed will flash. Pressing +
or buttons will change the parameter to the desired value. Press
to save the change.
Press and hold
to exit the editor at any time.
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6.6
INTELIGENNT Digital Control Module
Image 18- INTELIGENNT Digital Control Module
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#
SYMBOL
DESCRIPTION
IDENTIFICATION
(1)
Scrolls
through OFFMANAUTTEST
different operating
(2)
modes
OFFMANAUTTEST
(3)
Deactivates audible alarm
(4)
Fault reset
Acknowledges faults and alarms
(5)
Start button
In manual mode
(6)
Stop button
In manual mode
(7)
MCB ON/OFF
Opens and closes MCB in manual mode
(8)
GCB ON/OFF
Opens and closes GCB in manual mode
Exit from atual screen
(9)
(without save changes
if editing)
(10)
Selects on-screen Increases value
value, setpoint, history
record
or
(11)
increase/decrease
Decreases value
setpoint value
(12)
Moves history record Increases value
displayed columns to
the right/left, 5%
increase/decrease of
(13)
edited setpoint,s value Decreases value
or go out/into alarm
list
(14)
Enter button
Confirms on-screen value
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(15)
Mains power status Green if mains power correct
Red light flashes if mains failure occurs
(16)
Mains failure
and generator set doesn´t run; continuous if generator is operating, turns off when
Mains power restored.
(17)
Generator present
voltage Green led is on if unit voltage is present and within limits.
(18)
Generator set failure Flashing Red LED indicates alarm
(19)
State of GCB
Green led is on if GCB is closed. Flashes during synchronization with mains.
(20)
State of MCB
Green led is on if MCB is closed Flashes during reverse synchronization with mains.
(21)
State of bus
Green led is on if bus voltage is correct
NOTE: GCB = Generator Circuit Breaker; MCB = Mains Circuit Breaker.
The InteliGenNT module contains a main menu screen and the following seven submenu screens: Alarmlist Measurement Measurement I/O History Setpoints User/Password Languages
Pressing several times the main menu is displayed. To enter in a submenu, scroll up and down using
(10)
or
(11) buttons and press
(14) button. To display the different instruments or parameters on each 79
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screen menu, press (9) button.
(10) or
(11) buttons. To come back to a previous menu screen, press .
The alarmlist screen display the alarms detected by the module. Pressing aknowledged.
button (4) faultls and alarms are
The measurement screen displays the parameters measured on the engine; if the engine uses an electronic management system, many additional parameters can be displayed. In addition to these parameters, measurements can be displayed for fuel level, oil pressure, current, voltage, frequency, run hours and battery charge level.
The measurement I/O screen display the status of digital inputs and outputs and the measured parameter of analogue inputs (senders).
The history screen menu displays the log of alarms that have occurred in the generator unit. It also logs the opening and closing of the mains circuit breaker as well as the starting and shutting down of the generator unit.
The setpoints menu screen displays the adjustment parameters already configured; it is not necessary to edit any of these.
The users/password screen allows to define users and passwords. The languages screen allows to change the display language
AUTOMATIC mode (AUTO):
If a mains failure is detected, the InteliGenNT module will open the MCB (main circuit breaker). Startup command is
issued to generator set. If generator voltage is within the established limits, the LED indicator
(17) will be on
and the control module closes the GCB (generator circuit breaker). Once mains power has been restored,
synchronization between mains and generator occurs; then the MCB is closed, causing the generator to discharge,
followed by the opening of the GCB. When mains power is restored, there will be a period of time during which the
engine continues operating at no load to cool down before stopping completely.
Note: If
(4) is pressed following a disconnection alarm, the engine could automatically start without any warning.
NO-LOAD TEST mode (MANUAL):
Press the START button
(5) to start up the generator set. When the generator voltage is within the
established limits, the LED indicator
(17) will be on. To stop the unit, press STOP
(6).
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LOAD TEST mode (TEST):
This operating mode is used for generator set start test is the mains is OK or to transfer the load to the generator set when a mains failure is announced in advance. To stop this mode, change to another mode by means of the
buttons
(1) or (2).
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OFF mode:
The generator set will not start. Even if we press the buttons START
ON/OFF
(8), the generator will not respond.
(5), STOP (6)
, GCB
ALARMS: The InteliGenNT control module includes the following warnings:
INCIDENT
STORED IN HISTORY RECORD
Startup sequence initiated
Startup of Gen-Set
Shutdown of the Gen-Set
Gen-Set stops
Electrical Generator circuit breaker closed
GCB connected
Electrical Generator circuit breaker opened
GCB disconnected
Some GCB in group was opened (in MINT)
Other GCB trip
Mains circuit breaker closed
MCB connected
Mains circuit breaker opened
MCB disconnected
Time mode has been changed
TimeModeChngd
STARTUP INFO
AMF Startup
GenSetMF start
AMF Stop
GenSetMF stop
Remote startup by binary input (SPM, SPtM)
GenSetRemStart
Remote stop by binary input (SPM, SPtM)
GenSetRemStop
System startup by binary input (MINT, MEXT) GenSetSysStart
System stop by binary input (MINT, MEXT)
GenSetSysStop
Peak start (SPtM)
GenSet PKstart
Peak stop (SPtM)
GenSet PKstop
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ENGINE
EVENT SPECIFICATION
ALARM
Electrical Generator Startup failure Sd Start Fail
Electrical Generator Overspeed Sd Overspeed
Electrical Generator Underspeed Sd Underspeed
SD Stop fail
Sd Stop Fail
Emergency Stop
Emergency Stop
RPM Pickup fail
SdPickupFail
Battery voltage warning
Wrn Batt volt
Battery is discharged
Sd Batt flat
HISTORY Sd Start Fail Sd Overspeed Sd Underspeed Sd Stop Fail Emergency Stop SdPickupFail Wrn Batt volt 0
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GENERATOR
EVENT SPECIFICATION
HISTORY
Generator phase 1 overvoltage
Unl Vg1 Over
Generator phase 1 undervoltage
Unl Vg1 Under
Generator phase 2 overvoltage
Unl Vg2 Over
Generator phase 2 undervoltage
Unl Vg2 Under
Generator phase 3 overvoltage
Unl Vg3 Over
Generator phase 3 undervoltage
Unl Vg3 Under
Generator Overfrequency
Unl Fgen Over
Generator Underfrequency
Unl Fgen Under
Generator voltage unbalance
Unl Vgen Unbal
Generator overload
UnlGen Overload
Load surge protection
LoadSurge
Reverse power
Unl Rev Pwr
Synchronization timeout
Stp SyncTO
Ground fault protection
Unl EarthFltC
Failure of generator circuit breaker
GCB fail
Generator short circuit protection
Unl Short Igen
Generator IDMT protection
Unl IDMT
Generator current unbalance
Unl Igen Unbal
Voltage on mains terminals (SPM)
UnlCounterVolt
Bus voltage error (MINT)
Unl BusMeasErr
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PHASE SEQUENCE
EVENT SPECIFICATION
ALARM
Generator phase L1 is inverted
GEN L1 neg
Generator phase L2 is inverted
GEN L2 neg
Generator phase L3 is inverted
GEN L3 neg
Wrong generator phase sequence G ph opposed
Wrong generator phase sequence and phase L1 is inverted
G ph + L1 neg
Wrong generator phase sequence and phase L2 is inverted
G ph + L2 neg
Wrong generator phase sequence and phase L3 is inverted
G ph + L3 neg
Mains phase L1 is inverted
B L1 neg
Mains phase L2 is inverted
B L2 neg
Mains phase L3 is inverted
B L3 neg
Wrong mains phase sequence
B ph opposed
Wrong mains phase sequence and phase L1 is inverted
B ph + L1 neg
Wrong mains phase sequence and phase L2 is inverted
B ph + L2 neg
Wrong mains phase sequence and phase L3 is inverted
B ph + L3 neg
HISTORY 0 0 0 0 0
0
0 0 0 0 0 0
0
0
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7.0 MAINTENANCE OF GENERATOR SET
You must make sure that the person who will perform this duty is qualified to do so and uses the appropriate individual protection equipment.
7.1
prior to maintenance
You must first:
Switch Control Module to the OFF position.
Press the emergency stop button.
Disconnect the battery; use the battery isolator switch.
To cut Mains voltage, switch off the 10 A circuit breaker in the ATS panel supplied by Eneraquw. If made by another manufacturer, make sure that this cut is done properly before handling the unit.
7.2
during maintenance
Preventive maintenance tasks are necessary to preserve the unit; doing so will result in optimum performance. Be
sure to verify the following items:
While the engine is cold, the oil level should be between the minimum and maximum values. If it is below the minimum, add Engine oil. NOTE: With the GPM-2 and InteliGenNT modules, at 50 hours run notice will be given to change
the oil. The recommended oil is 15W40.
The radiator water level should be adequate.
The fuel level in the tank should be sufficient for the service to be performed. The generator control panel is equipped with a fuel gauge, which will be functional whenever the electrical panel is receiving power.
Always refuel in a well ventilated area with the engine stopped.
Closely inspect the connections and the electrical circuit, for both the mechanical and electrical sections.
Check carefully for possible liquid leaks. If a leak is detected, find its source and resolve the problem. If your unit has a retention bath, drain it (see section 3.4 RETENTION BATH).
The air inlet and outlet vents should be completely unobstructed to allow for free circulation of cooling air.
Check the state of the unit's radiator and clean if necessary.
Make sure the exhaust tube is not obstructed.
Check the battery's connection terminals and electrolyte level (if necessary, add demineralized or distilled water). Acid should never be added. The battery should be recharged if the terminal voltage is below 12.3 V.
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If the battery needs recharging after being taken out of the unit, remove the vent caps and charge battery with direct current only. Connect the charger's positive (+) cable to the battery's positive (+) terminal and the charger's negative (-) cable to the battery's negative (-) terminal. Recharge battery with a current equivalent to 1/10 the rated capacity (Ah). Battery is fully charged when acid density is 1.28. Before completing recharging process: turn off charger before disconnecting battery and check electrolyte level.
If the battery is discharged and you want to perform an emergency startup with the battery from another generator, first check the tightness of the discharged battery's terminals. Stop the engines of both units and connect the two positive terminals of the batteries first and then connect the negative terminal of the charged battery to a metal area on the disabled unit (ground). Start up the auxiliary unit and then the unit being repaired. Disconnect the cables in reverse order to avoid a short circuit. Finally, fully charge the battery.
While performing preventive maintenance tasks it is advisable to wear protective eyewear and gloves during all operations involving the handling of battery acid. Make sure there is nearby access to tap water in order to wash all potentially affected areas.
Remember to always perform all operations with the utmost precaution and safety as indicated in this Manual. (Pay special attention to the risk of short circuits that could be caused by coming in contact with the unit's metallic objects.)
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7.3
FREQUENCY
maintenance chart
MAINTENANCE OPERATION
Perform a mains failure simulation; the unit should supply power to consumers for one hour.
For parallel units, check the connection and the load sharing.
Review the connections of the startup battery, clean and cover with vaseline.
Make sure the battery charger is functioning properly.
Make sure fuel pump is functioning properly.
MONTHLY
Check fuel level on the main fuel tank. Check coolant and oil levels.
Make sure smoke extractor is functioning properly.
Make sure all of the electrical panel lights are functioning properly.
Make sure the ATS functions properly in transfers.
Check the state of all of the gauges and indicators on the electrical panel.
Check the engine manufacturer's manual for specific tasks.
Start up the engine manually three times, noting each time the voltage and density readings for each of the battery's elements. If any of the voltage readings varies significantly from those of the battery's other elements, do not perform the remaining manual engine startups.
EVERY 6 MONTHS Fully charge the battery and check the electrolyte level. Make sure there are no leaks in the coolant tubes.
Make sure that all of the unit's alarms display correctly.
Check the engine manufacturer's manual for specific tasks.
Clean the outside of the fuel tank and check the diesel pipes.
Clean radiator, change antifreeze.
YEARLY
Clean and lube the water pump and fan. Make sure meters are correct.
Clean control panel and tighten the panel's connections.
Verify that the antivibration feet, fittings and belts are in proper condition.
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Make sure that vibration and noise levels comply with the current regulations. Make sure noise emission level is compliant with the current regulations. Check the engine manufacturer's manual for specific tasks. EVERY 3 YEARS Replace startup batteries.
8.0 TROUBLESHOOTING
Engine does not start
In the electrical panel
Engine starts
INCIDENT Starter does not turn
LIKELY CAUSE 1.-Defective battery
2.-Defective starting system
Starter functioning properly
1.-Faulty voltage detector on control module
2.-Low fuel level
Stops with cause
1.-Emergency has occurred
Stops for no apparent reason
1.-Emergency not indicated due to faulty LED indicator
Does not stop when emergency occurs
1.-Defective stopping system
Generator does not stop when in stop position
1.-Faulty control unit
2.-Defective Stopping System
1.-Overspeed High voltage at no load
2.-Alternator failure
SOLUTION 1.-Replace battery 2.-Replace starting system 3.-Contact technical service.
1.-Contact technical service.
2.-Refill fuel tank 1.-Take appropriate measures
1.-Contact technical service.
1.-Press emergency stop button 2.-Contact technical service. 1.-Press emergency stop button 2.-Contact technical service.
1.-Contact technical service.
1.-Underspeed Low voltage at no load
2.-Alternator failure
Correct voltage but low 1.-Heavy load
when on load
2.-Underspeed on load
1.-Contact technical service.
1.-Reduce power of loads 2.-Contact technical service.
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Originating in engine's interior
Unit in operation
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Voltage unstable
3.-Alternator failure 1.-Voltage meter damaged 2.-Engine unsteady 3.-AVR damaged
Strange noise inside the unit
1.-Various causes
1.-Contact technical service.
1.-Make sure nothing is preventing the unit from functioning properly. 2.-Contact technical service.
9.0 PROTECTION FROM THE ENVIRONMENT
Once the generator set has been installed, it is necessary to remove the packaging, accessories, electrical tools, etc., that were used during the installation process.
When it is time to dispose of the batteries, in keeping with environmental regulations it is advisable to take them to an authorized recycling center.
For a cleaner environment, recycle all possible items and be sure to not throw electrical components in with the regular garbage so as to comply with european directive 2002/96/EC. These items should be stored separately until being taken for ecological recycling.
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10.0 WARRANTY
The electrical generator warranty covers an entire year, starting from the date it is installed. This should be communicated to Eneraque. (hereinafter "the manufacturer"), in writing, via fax or email. The following information must be included: MODEL, SERIAL NUMBER and INSTALLATION DATE.
If the manufacturer is not informed of the installation within a maximum of sixty days from the invoice date, the latter shall be considered the effective start date of the warranty period. If for any reason the installation is not possible within the first sixty days following the invoice date, the manufacturer must be informed thereof in writing. Thus no warranty claims shall be accepted if the manufacturer is not in possession of the aforementioned correspondence.
The warranty of the electrical generator will cover any faulty components or assembly not caused by improper use, handling or modification. The warranty does not cover breakdowns caused by connecting the electrical generator to devices not installed or supplied by the manufacturer. Also excluded are breakdowns and damages caused by prolonged or improper storage; should this occur, please see the manufacturer's user manuals.
The warranty for the electrical generator shall cover ONLY the replacement parts and labor necessary for the repair of the generator by personnel authorized by the manufacturer. Traveling, kilometers traveled and other expenses deriving from the repair of a generator under warranty are excluded from the warranty coverage and in no case shall the manufacturer be responsible for these covering these expenses, which shall be paid in cash.
The decision to accept or reject a warranty shall be made by the manufacturer. In the case of engine and alternator breakdowns, the warranty shall be granted by the provider of said components, according to the particular warranty conditions of those components. The manufacturer reserves the option to request that the faulty element be returned. In such case, all costs related to said return shall be covered by the customer.
The warranty for a repair made during the warranty period shall have the same expiration date as the warranty for the electrical generator.
The warranty does not cover damage caused by terrorist attacks, natural disasters, sabotage or incidents of a similar nature.
If any of the provisions set out does not comply with the legislation of a certain country, the importer is required to notify the manufacturer thereof prior to carrying out the sale transaction.
11.0 NOISE LEVEL
Generator sets manufactured by Eneraque produce different acoustic levels depending on the output and soundproofing of the generator set. The noise output is indicated on a sticker affixed to the unit's base frame.
Note: If you work near the unit for any extended period of time, it is advisable to use hearing protection.
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12.0 DECLARATION OF CONFORMITY
Eneraque shall deliver a CE "declaration of conformity" form along with the unit, in compliance with the referenced regulations or standardized documents.
13.0 APPENDIX 1: FIGURES
Detail of the unit's Identification Label:
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[1] Model DVAS 360 E
[2] Rated output: 260 kW
[3] Power factor: 0.8
[4] Rated frequency: 50Hz
Rated figures reduce in altitudes above 1,000m and surrounding temperatures above 40ºC
[5] Rated voltage:
400Im/23a0Vge 19- Identification Label
[6] Product class: G1
[7] Weight: 4,499 kg
[8] Serial no.: 164936
[9]
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#
LABELED ITEM
DESCRIPTION
D => Engine uses Diesel fuel at 1500/1800 rpm
V => Engine manufacturer is (V)olvo, (P)erkins, (C)ummins, Mitsubis(H)I or M(T)U.
W => The generator set is designed to operate at 60 Hz
(1)
DVAS 360 E
A => The generator set is automatic
S => The generator set is soundproofed
360 => Commercial name
E => Indicates generator set is standby type
(2)
Rated power
Rated power of generator set expressed in kW.
(3)
Power factor
Indicates power factor of generator set
(4)
Rated frequency
Rated frequency of generator set (Hertz)
(5)
Rated voltage
Rated voltage of generator set (Volts)
(6)
Product class
When withstanding a load, engine will perform according to catalogued response times per ISO 8528
(7)
Weight
Total weight of generator set
(8)
Serial no.
Serial number of generator manufacture
(9)
Manufacture date Manufacture date of generator set
(10)
CE marking indicates that generator set complies with the relevant directives
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Image 20 Placing in operation
Image 26:
Image 21 Caution with generatorImsagtea2r7t: up
Image 22 General warning
IMPORTANT
CAUTION
PLACING IN OPERATION:
1.-Make sure "Battery Shutoff" switch is
ImagCeLOS2E3D Undefined Warning Notice
2.-Check engine's water and oil levels.
THIS ELECTRICAL GENERATOR COULD START UP WITHOUT PRIOR WARNING
Image 24ToEpelerfocrmtrMiAcINaTElNHANaCEz, aturrndthe230 Image 25 Electrical Hazard
Volts
400 Volts BATTERY SHUTOFF SWITCH to the OPEN
position.
3.-Connect earth pin to a suitable point on the ground.
4.-Make sure electrical power circuit breaker is OPEN.
Image 26 Lifting point
5.-Connect cables to connection terminals on circuit breaker.
Image 27 Possible battery leakage
Image 28 Electrical grounding
6.-Start up ELECTRICAL GENERATOR.
7.-Make sure Voltage and Frequency are correct.
Imag8e.-Se2t E9lectNricaol Pisoweer sowiutchtpto uCLtOS9E0D dB
position.
Image 30 Noise output 114 dB
Image 31 Use of hearing protection required
BATTERY ISOLATOR
Image 32 Coolant Flush
Image 33 Oil draining
Image 34 Battery Isolator
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14.0 APPENDIX 2: IMAGE INDEX
Image 1- Generator set with sound proof canopy. ............................................................................................6 Image 3- Detailed view of Image 1 ....................................................................................................................7 Image 4- Detailed view of Image 2 ....................................................................................................................8 Image 5- Interior of a soundproofed Electrical Generator ................................ Error! Bookmark not defined. Image 6- Generic Control Panel ......................................................................................................................10 Image 7- Control Panel of GECO Control Module............................................ Error! Bookmark not defined. Image 8- Control Panel of the GPM-2 Control Module..................................... Error! Bookmark not defined. Image 9- Control Panel of the Deep Sea Control Module ................................ Error! Bookmark not defined. Image 10- Control Panel of the InteliGenNT Control Module............................. Error! Bookmark not defined. Image 11- Load Transfer diagram ...................................................................................................................11 Image 13- Lifting frame....................................................................................................................................13 Image 14- Detailed view of installation of an open-skid unit ...........................................................................14 Image 15- SAB-BE Pump ................................................................................. Error! Bookmark not defined. Image 16- ATS setup .......................................................................................................................................19 Image 17- Diagram of ATS Panel....................................................................................................................20 Image 18- GECO Digital Control Module ........................................................................................................29 Image 19- GPM-2 Control Module...................................................................................................................36 Image 20- Deep Sea 7320 Control Module .....................................................................................................42 Image 21- Deep Sea 7310 Control Module .....................................................................................................43 Image 22- Deep Sea 5520 Control Module .....................................................................................................59 Image 23- Deep Sea 5510 Control Module .....................................................................................................60 Image 24- INTELIGENNT Digital Control Module .............................................................................................77 Image 25- Identification Label..........................................................................................................................92 Image 26 Placing in operation .........................................................................................................................94 Image 27 Caution with generator startup ........................................................................................................94 Image 28 General warning ..............................................................................................................................94 Image 29 Undefined Warning Notice...............................................................................................................94 Image 30 Electrical Hazard 230 Volts .............................................................................................................94 Image 31 Electrical Hazard 400 Volts .............................................................................................................94 Image 32 Lifting point ......................................................................................................................................94 Image 33 Possible battery leakage..................................................................................................................94
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Image 34 Electrical grounding .........................................................................................................................94 Image 35 Noise output 90 dB ..........................................................................................................................94 Image 36 Noise output 114 dB ........................................................................................................................94 Image 37 Use of hearing protection required ..................................................................................................94 Image 38 Coolant Flush...................................................................................................................................94 Image 39 Oil draining.......................................................................................................................................94 Image 40 Battery Isolator.................................................................................................................................94
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15.0 APPENDIX 3: PRE-DELIVERY INSPECTION DOCUMENT
ITEMS TO BE CHECKED First checks
Verify the right positioning of the genset Verify that air inlet is enough and according Verify that the hot air outlet from the engine is forwarded outside Verify that the exhaust outlet is piped outside Verify that the genset identifying plate is legible Verify that the alternator identifying plate is legible Verify that the engine identifying plate is legible Verify stickers and warning labels Verify the cabling and genset connexions Verify the earthling of the equipment
Before starting the equipment Verify oil level and its conditions Verify fuel level Verify coolant level Verify air filter conditions Verify bolts, nuts and its tightness Verify lights and LEDs from the control panel Verify Battery isolator Verify and re*tight battery terminals
Starting of the genset Verify exhaust emission colour Verify there is not strange noises from engine/alternator Verify fuel pipes and flanges
OK LP (OK) KO
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Verify that the control card is operating OK
Verify phase sequence from genset is equal to Mains
Mains Failure
Verify the genset start when Mains is cut
Verify the ATS closes genset contactor
Verify that the genset keeps frequency and voltage on load
Verify that, when Mains is back, the control card detects voltage
Verify Mains contactors closed
Verify genset stops after cooling period
END
Working mode and installation is OK
Explain to the user the working mode
Genset Voltage w/o load:
Genset Frequency w/o load
Remarks
Leyend:
Ok = Accepted, OK
LP = Low problem, OK
KO = Remove from service
R = Repaired
N/A = Not applicable
In case that an installation is faulty the client must be informed, so the faults can be solved
Predelivery inspection done by Company:
Final User: Company:
Signed: ID:
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16.0 APPENDIX 4: FIGURES IN DEEP SEA CONTROL CARDS.
Pictograms
DEEP SEA PICTOGRAMS Descripcion Remote Start
Auto Start inhibit Common Alarm Common Shutdown Overcurrent Pre-alarm
GCB Trip Differential Trip GCB-Differential Trip
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Low coolant level Low fuel level
High Engine Temperature Frecuency 60Hz Remote Stop Fuel Filter Alarm
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17.0 APPENDIX 5: NOISE EMISSIONS
Model DCAS 700 E DCAS 860 E DPAS 10 E DPAS 10 E MF DPAS 110 E DPAS 15 E DPAS 15 E MF DPAS 150 E NC DPAS 230 E DPAS 25 E DPAS 25 E MF DPAS 275 E DPAS 35 E MF NC DPAS 400 E DPAS 450 E DPAS 50 E NC DPAS 500 E DPAS 550 E DPAS 65 E NC DPAS 700 E DPAS 90 E NC DVAS 140 E DVAS 165 E
Sound Pressure (dB) at
10 m.
Sound Power (dB)
77
105
77
105
70
90
70
90
69
97
70
90
70
90
69
97
69
97
70
90
70
90
69
97
62
90
69
97
70
98
66
94
66
94
75
103
66
94
77
105
66
94
69
97
69
97
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DVAS 200 E DVAS 220 E DVAS 275 E DVAS 330 E DVAS 360 E DVAS 410 E DVAS 450 E DVAS 505 E DVAS 550 E DVAS 630 E DVAS 700 E DZAS 165 E DZAS 25 E DZAS 35 E DZAS 45 E
69
97
69
97
69
97
69
97
69
97
69
97
70
98
66
94
66
94
69
97
69
97
69
97
66
94
66
94
66
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual
DSECONTROL®
DSE7000 Series Control Module
057-074
Author : Anthony Manton
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual DSE Model 7000 Series Control and Instrumentation System Operators Manual
Deep Sea Electronics Plc Highfield House Hunmanby North Yorkshire YO14 0PH ENGLAND
Sales Tel: +44 (0) 1723 890099 Sales Fax: +44 (0) 1723 893303
E-mail: sales@deepseaplc.com Website: www.deepseaplc.com
DSE Model 7000 series Control and Instrumentation System Operators Manual
© Deep Sea Electronics Plc All rights reserved. No part of this publication may be reproduced in any material form (including photocopying or storing in any medium by electronic means or other) without the written permission of the copyright holder except in accordance with the provisions of the Copyright, Designs and Patents Act 1988. Applications for the copyright holder's written permission to reproduce any part of this publication should be addressed to Deep Sea Electronics Plc at the address above.
The DSE logo and the names DSEUltra, DSEControl, DSEPower, DSEExtra, DSEMarine and DSENet are UK registered trademarks of Deep Sea Electronics PLC.
Any reference to trademarked product names used within this publication is owned by their respective companies.
Deep Sea Electronics Plc reserves the right to change the contents of this document without prior notice.
Amendments since last publication
Amd. No.
Comments
Clarification of notation used within this publication.
NOTE: CAUTION! WARNING!
Highlights an essential element of a procedure to ensure correctness.
Indicates a procedure or practice, which, if not strictly observed, could result in damage or destruction of equipment.
Indicates a procedure or practice, which could result in injury to personnel or loss of life if not followed correctly.
2 Part No. 057-074 7000 Series OPERATING MANUAL ISSUE 1 21/01/2008 ADM
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TABLE OF CONTENTS
Section
Page
1 BIBLIOGRAPHY............................................................................................... 6
2 INTRODUCTION .............................................................................................. 6
3 SPECIFICATIONS ............................................................................................ 7
3.1 PART NUMBERING ........................................................................................................7 3.1.1 MODEL NAMING......................................................................................................7 3.1.2 SHORT NAMES .......................................................................................................7
3.1 POWER SUPPLY REQUIREMENTS...............................................................................8 3.2 TERMINAL SPECIFICATION..........................................................................................8 3.3 GENERATOR AND MAINS VOLTAGE / FREQUENCY SENSING .................................9 3.4 GENERATOR CURRENT SENSING...............................................................................9 3.5 INPUTS ...........................................................................................................................9
3.5.1 DIGITAL INPUTS......................................................................................................9 3.5.2 ANALOGUE INPUTS..............................................................................................10 3.5.3 CHARGE FAIL INPUT ............................................................................................11 3.5.4 MAGNETIC PICKUP...............................................................................................11 3.6 OUTPUTS .....................................................................................................................11 3.6.1 OUTPUTS A & B ....................................................................................................11 3.6.2 OUTPUTS C & D ....................................................................................................11 3.6.3 OUTPUTS E,F,G & H .............................................................................................11 3.7 COMMUNICATION PORTS ..........................................................................................12 3.8 DSENET® .....................................................................................................................12 3.9 ACCUMULATED INSTRUMENTATION ........................................................................12 3.10 DIMENSIONS AND MOUNTING................................................................................13 3.10.1 FIXING CLIPS ........................................................................................................14 3.10.2 CABLE TIE FIXING POINTS ..................................................................................15 3.10.3 SILICON SEALING GASKET..................................................................................15 3.11 APPLICABLE STANDARDS......................................................................................16
4 INSTALLATION.............................................................................................. 17
4.1 USER CONNECTIONS .................................................................................................17 4.2 TERMINAL DESCRIPTION...........................................................................................18
4.2.1 DC SUPPLY, FUEL AND START OUTPUTS..........................................................18 4.2.2 ANALOGUE SENSOR............................................................................................18 4.2.3 MAGNETIC PICKUP, CAN AND EXPANSION........................................................19 4.2.4 LOAD SWITCHING AND GENERATOR VOLTAGE SENSING ..............................20 4.2.5 MAINS VOLTAGE SENSING..................................................................................20 4.2.6 GENERATOR CURRENT TRANSFORMERS.........................................................21 4.2.7 CONFIGURABLE DIGITAL INPUTS .......................................................................22 4.2.8 PC CONFIGURATION INTERFACE CONNECTOR ...............................................22 4.2.9 RS485 CONNECTOR .............................................................................................23 4.2.10 RS232 CONNECTOR .............................................................................................23 4.3 TYPICAL WIRING DIAGRAMS .....................................................................................24 4.3.1 7210 AUTOSTART CONTROLLER ........................................................................24 4.3.2 7220 AMF CONTROLLER ......................................................................................25 4.3.3 7310 AUTOSTART CONTROLLER ........................................................................26 4.3.4 7320 AMF CONTROLLER ......................................................................................27 4.4 ALTERNATIVE TOPOLOGIES .....................................................................................28 4.4.1 3 PHASE, 4 WIRE WITHOUT EARTH FAULT PROTECTION................................28 4.4.2 SINGLE PHASE WITH RESTRICTED EARTH FAULT MEASURING.....................29 4.4.3 SINGLE PHASE WITHOUT EARTH FAULT MEASURING.....................................30 4.4.4 2 PHASE (L1 & L2) 3 WIRE WITH RESTRICTED EARTH FAULT MEASURING ...31
Part No. 057-074 7000 Series OPERATING MANUAL ISSUE 1 21/01/2008 ADM 3
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DSE Model 7000 Series Control and Instrumentation System Operators Manual
4.4.5 2 PHASE (L1 & L2) 3 WIRE WITHOUT EARTH FAULT MEASURING ...................32 4.4.6 2 PHASE (L1 & L3) 3 WIRE WITH RESTRICTED EARTH FAULT MEASURING ...33 4.4.7 2 PHASE (L1 & L3) 3 WIRE WITHOUT EARTH FAULT MEASURING ...................34 4.4.8 3 PHASE 4 WIRE WITH UNRESTRICTED EARTH FAULT MEASURING .............35 4.5 CT LOCATION..............................................................................................................36
5 DESCRIPTION OF CONTROLS.................................................................... 37
5.1 DSE7210 / DSE7310 AUTOSTART CONTROL MODULE............................................37 5.2 DSE7220 / DSE7320 AMF CONTROL MODULE ..........................................................39 5.3 QUICKSTART GUIDE...................................................................................................41
5.3.1 STARTING THE ENGINE.......................................................................................41 5.3.2 STOPPING THE ENGINE ...................................................................................... 41 5.4 VIEWING THE INSTRUMENTS ....................................................................................42 5.4.1 INSTRUMENT PAGE CONTENT ........................................................................... 43 5.4.2 CAN ERROR MESSAGES ..................................................................................... 44 5.5 VIEWING THE EVENT LOG .........................................................................................45 5.6 USER CONFIGURABLE INDICATORS ........................................................................45 5.7 CONTROLS ..................................................................................................................46
6 OPERATION .................................................................................................. 48
6.1 AUTOMATIC MODE OF OPERATION..........................................................................49 6.1.1 WAITING IN AUTO MODE.....................................................................................49 6.1.2 STARTING SEQUENCE......................................................................................... 49 6.1.3 ENGINE RUNNING ................................................................................................ 50 6.1.4 STOPPING SEQUENCE ........................................................................................ 50
6.2 MANUAL OPERATION .................................................................................................51 6.2.1 WAITING IN MANUAL MODE ................................................................................51 6.2.2 STARTING SEQUENCE......................................................................................... 51 6.2.3 ENGINE RUNNING ................................................................................................ 52 6.2.4 STOPPING SEQUENCE ........................................................................................ 52
6.3 TEST MODE OF OPERATION .....................................................................................53 6.3.1 WAITING IN TEST MODE......................................................................................53 6.3.2 STARTING SEQUENCE......................................................................................... 53 6.3.3 ENGINE RUNNING ................................................................................................ 54
7 PROTECTIONS ............................................................................................. 55
7.1 WARNINGS................................................................................................................... 56 7.2 ANALOGUE PRE-ALARMS .......................................................................................... 57 7.3 HIGH CURRENT WARNING ALARM............................................................................57 7.4 SHUTDOWNS...............................................................................................................58 7.5 HIGH CURRENT SHUTDOWN ALARM ........................................................................59 7.6 ELECTRICAL TRIPS ....................................................................................................59
8 FRONT PANEL CONFIGURATION............................................................... 60
8.1 ACCESSING THE MAIN FRONT PANEL CONFIGURATION EDITOR ........................60 8.1.1 EDITING A PARAMETER....................................................................................... 61 8.1.2 ADJUSTABLE PARAMETERS ............................................................................... 62
8.2 ACCESSING THE `RUNNING' CONFIGURATION EDITOR.........................................63 8.2.1 EDITING A PARAMETER....................................................................................... 63 8.2.2 ADJUSTABLE PARAMETERS (RUNNING EDITOR) ............................................. 63
9 COMMISSIONING.......................................................................................... 64
9.1.1 PRE-COMMISSIONING ......................................................................................... 64
10 FAULT FINDING ......................................................................................... 65
11 FACTORY DEFAULT CONFIGURATION .................................................. 67
12 MAINTENANCE, SPARES, REPAIR AND SERVICING ............................. 71
12.1 PURCHASING ADDITIONAL CONNECTOR PLUGS FROM DSE ............................71 12.1.1 DSE7200 SERIES .................................................................................................. 71 12.1.2 DSE7300 SERIES .................................................................................................. 72
12.2 PURCHASING ADDITIONAL FIXING CLIPS FROM DSE .........................................72 12.3 PURCHASING ADDITIONAL SEALING GASKET FROM DSE .................................72
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12.4 EXPANSION MODULES............................................................................................73
13 WARRANTY ................................................................................................ 74
14 DISPOSAL................................................................................................... 74
14.1 WEEE (WASTE ELECTRICAL AND ELECTRONIC EQUIPMENT) ...........................74 14.2 ROHS (RESTRICTION OF HAZARDOUS SUBSTANCES) .......................................74
15 APPENDIX................................................................................................... 75
15.1 IDMT TRIPPING CURVES (TYPICAL) ......................................................................75 15.2 SENSOR WIRING RECOMMENDATIONS ................................................................76
15.2.1 EARTH RETURN SENSORS..................................................................................76 15.2.2 INSULATED RETURN SENSORS..........................................................................76 15.3 CAN INTERFACE .....................................................................................................76 15.4 COMMUNICATIONS OPTION CONNECTIONS ........................................................77 15.4.1 DESCRIPTION .......................................................................................................77 15.4.2 PC TO CONTROLLER (DIRECT) CONNECTION...................................................77 15.5 ENCLOSURE CLASSIFICATIONS ............................................................................78
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1 BIBLIOGRAPHY
This document refers to and is referred to by the following DSE publications which can be obtained from the DSE website www.deepseaplc.com
DSE PART 053-026 053-027 053-028 053-029 057-004 057-077 057-082 057-083 057-084
DESCRIPTION 7210 installation instructions 7220 installation instructions 7310 installation instructions 7320 installation instructions Electronic Engines and DSE wiring manual DSE7000 Series configuration software manual DSE2130 input expansion manual DSE2157 output expansion manual DSE2548 annunciator expansion manual
2 INTRODUCTION
This document details the installation and operation requirements of the DSE7000 Series modules, part of the DSEControl® range of products. The manual forms part of the product and should be kept for the entire life of the product. If the product is passed or supplied to another party, ensure that this document is passed to them for reference purposes. This is not a controlled document. You will not be automatically informed of updates. Any future updates of this document will be included on the DSE website at www.deepseaplc.com
The DSE 7000 series is designed to provide differing levels of functionality across a common platform. This allows the generator OEM greater flexibility in the choice of controller to use for a specific application.
The DSE 7000 series module has been designed to allow the operator to start and stop the generator, and if required, transfer the load to the generator either manually (via fascia mounted push-buttons) or automatically. Additionally, the DSE7320 automatically starts and stops the generator set depending upon the status of the mains (utility) supply. The user also has the facility to view the system operating parameters via the LCD display.
The DSE 7000 module monitors the engine, indicating the operational status and fault conditions, automatically shutting down the engine and giving a true first up fault condition of an engine failure by a COMMON AUDIBLE ALARM. The LCD display indicates the fault.
The powerful ARM microprocessor contained within the module allows for incorporation of a range of complex features:
· Text based LCD display (supporting multiple languages). · True RMS Voltage, Current and Power monitoring. · Engine parameter monitoring. · Fully configurable inputs for use as alarms or a range of different functions. · Engine ECU interface to electronic engines.
Using a PC and the 7000 series configuration software allows alteration of selected operational sequences, timers and alarm trips.
Additionally, the module's integral fascia configuration editor allows adjustment of a subset of this information.
A robust plastic case designed for front panel mounting houses the module. Connections are via locking plug and sockets.
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3 SPECIFICATIONS
3.1 PART NUMBERING
Product type
DSE 7210 Autostart Module
7210
DSE 7220 Automatic Mains Failure Module
7220
DSE 7310 Autostart Module
7310
7210 - 001 - 00
Variant
Standard
00
product
Hardware revision
Revision 1
001
DSE 7320 Automatic Mains Failure Module
7320
At the time of this document production, there are no variants of this product and there have been no revisions of the module hardware.
3.1.1 MODEL NAMING
72
10
Series
DSE 7200 series
72
DSE 7300 series
73
3.1.2 SHORT NAMES
Short name DSE7000 DSE7x10 DSE7x20 DSE72x0 DSE73x0
Function
Autostart (remote start) and manual start
10
Autostart, manual start and start upon mains failure
20
(AMF)
Description All modules in the DSE7000 Series All Autostart modules in the DSE7000 Series All AMF modules in the DSE7000 Series All modules in the DSE7200 series All modules in the DSE7300 series
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3.1 POWER SUPPLY REQUIREMENTS
Minimum supply voltage Cranking dropouts Maximum supply voltage Reverse polarity protection Maximum operating current
Maximum standby current
8V continuous
Able to survive 0V for 50mS providing the supply was at least
10V before the dropout and recovers to 5V afterwards.
35V continuous (60V protection)
-35V continuous
DSE7200 / DSE7300
160mA at 24V 340mA at 12V
DSE7200 / DSE7300
80mA at 24V 160mA at 12V
Plant supply instrumentation display
Range
Resolution Accuracy
0V-70V DC (note Maximum continuous operating voltage of 35V DC) 0.1V 1% full scale
3.2 TERMINAL SPECIFICATION
Connection type Min cable size Max cable size
Screw terminal, rising clamp, no internal spring 0.5mm² (AWG 24) 2.5mm² (AWG 10)
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3.3 GENERATOR AND MAINS VOLTAGE / FREQUENCY SENSING
Measurement type Sample Rate Harmonics Input Impedance Phase to Neutral Phase to Phase Common mode offset from Earth Resolution
Accuracy
Minimum frequency Maximum frequency Frequency resolution Frequency accuracy
True RMS conversion 5KHz or better Up to 10th or better 300K ph-N 15V to 333V AC (max) 25V to 576V AC (max) 100V AC (max)
1V AC phase to neutral 2V AC phase to phase ±1% of full scale phase to neutral ±2% of full scale phase to phase 3.5Hz 75.0Hz 0.1Hz ±0.2Hz
3.4 GENERATOR CURRENT SENSING
Measurement type Sample Rate Harmonics Nominal CT secondary rating Maximum continuous current Overload Measurement Absolute maximum overload Burden
common mode offset Resolution Accuracy
True RMS conversion 5KHz or better Up to 10th or better 1A or 5A
5A
3 x Nominal Range setting 50A for 1 second
0.5VA (0.02 current shunts) ±2V peak plant ground to CT common terminal 0.5% of 5A ±1% of Nominal (1A or 5A) (excluding CT error)
3.5 INPUTS
3.5.1 DIGITAL INPUTS
Number
Arrangement Low level threshold High level threshold Maximum input voltage Minimum input voltage Contact wetting current Open circuit voltage
DSE72x0 6 DSE73x0 8 Contact between terminal and ground 2.1V minimum 6.6V maximum +50V DC with respect to plant supply negative -24V DC with respect to plant supply negative 7mA typical 12V typical
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3.5.2 ANALOGUE INPUTS
Oil Pressure Measurement type
Arrangement Measurement current Full scale Over range / fail Resolution Accuracy Max common mode voltage Display range
Resistance measurement by measuring voltage across sensor with a fixed current applied Differential resistance measurement input 15mA 240 270 1-2 PSI / 0.1 Bar +/-2% of full scale resistance excluding transducer error ±2V 0-200 PSI / 13.7 bar subject to limits of the sensor
Coolant Temperature Measurement type
Arrangement Measurement current Full scale Over range / fail Resolution Accuracy Max common mode voltage Display range
Resistance measurement by measuring voltage across sensor with a fixed current applied Differential resistance measurement input 10mA 480 540 1°C, 2°F +/-2% of full scale resistance excluding transducer error ±2V 0°C -140°C, 32°F - 284°F Depending on sensor
Fuel Level Measurement type
Arrangement Measurement current Full scale Over range / fail Resolution Accuracy Max common mode voltage Display range
Resistance measurement by measuring voltage across sensor with a fixed current applied Differential resistance measurement input 10mA 480 540 1% +/-2% of full scale resistance excluding transducer error ±2V 0-250%
Flexible Sensor
NOTE : Flexible sensor is not available on DSE7200 series controllers
Measurement type
Arrangement Measurement current Full scale Over range / fail Resolution Accuracy Max common mode voltage Display range
Resistance measurement by measuring voltage across sensor with a fixed current applied Differential resistance measurement input 10mA 480 540 1% +/-2% of full scale resistance excluding transducer error ±2V 0-250%
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3.5.3 CHARGE FAIL INPUT
Minimum voltage Maximum voltage Resolution Accuracy Excitation Output Power Current at 12V Current at 24V
0V 35V (plant supply) 0.2V ± 1% of max measured voltage Active circuit constant power output 2.5W Nominal @12V and 24V 210mA 10mA
3.5.4 MAGNETIC PICKUP
Type Minimum voltage Max common mode voltage Maximum voltage Maximum frequency Resolution Accuracy Flywheel teeth
Differential input 0.5V RMS ±2V
Clamped to ±70V by transient suppressers, dissipation not to exceed 1W. 10,000Hz 6.25 RPM ±25 RPM 10 to 500
3.6 OUTPUTS
3.6.1 OUTPUTS A & B
Type Rating
Normally used for Fuel / Start outputs. Fully configurable for other purposes if the module is configured to control an electronic engine. Supplied from Emergency Stop terminal 3. 15A @ 35V
3.6.2 OUTPUTS C & D
Type Rating
Voltage free relays, fully configurable, normally used for generator / mains load switch control. 8A @ 250 V AC
3.6.3 OUTPUTS E,F,G & H
Type Rating
Fully configurable, supplied from DC supply terminal 2. 3A @ 35V
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3.7 COMMUNICATION PORTS
USB Port Serial Communication (not available on DSE7200 series) RS232 Port (not available on DSE7200 series)
RS485 Serial (not available on DSE7200 series)
CAN Port
USB2.0 Device for connection to PC running DSE configuration suite only RS232 and RS485 are fitted but do NOT provide independent operation
Non Isolated port Max Baud rate 115K baud subject to S/W TX, RX, RTS, CTS, DSR, DTR, DCD Male 9 way D type connector Isolated Data connection 2 wire + common Half Duplex Data direction control for Transmit (by s/w protocol) Max Baud Rate 19200 External termination required (120R) Max common mode offset 70V (on board protection transorb) Engine CAN Port Standard implementation of `Slow mode', up to 250K bits/s Non Isolated. Internal Termination provided (120)
3.8 DSENET®
DSENet® is the interconnection cable between the host controller and the expansion module(s) and must not be connect to any device other than DSE equipment designed for connection to the DSENet®
NOTE : DSENet® is not available on DSE7200 series controllers.
Cable type Cable characteristic impedance Recommended cable
Maximum cable length
DSENet® topology DSENet® termination
Maximum expansion modules
Two core screened twisted pair
120 Belden 9841 Belden 9271 1000m (1km) when using Belden 9841 or direct equivalent. 500m (0.5km) when using Belden 9271 or direct equivalent. Bus with no stubs (spurs)
120. Fitted internally to host controller. Must be fitted externally to the `last' expansion module by the customer . Refer to host controller documentation
NOTE : As a termination resistor is internally fitted to the host controller, the host controller must be the `first' unit on the DSENet®. A termination resistor MUST be fitted to the `last' unit on the DSENet®. For connection details, you are referred to the section entitled `typical wiring diagram' elsewhere in this document.
3.9 ACCUMULATED INSTRUMENTATION
NOTE : When an accumulated instrumentation value exceeds the maximum number as listed below, it will reset and begin counting from zero again.
Engine hours run Number of starts
Maximum 99999 hrs 59 minutes (approximately 11yrs 4months) 1,000,000 (1 million)
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3.10 DIMENSIONS AND MOUNTING
DIMENSIONS 240.0mm x 181.1mm x 41.7mm (9.4" x 7.1" x 1.6") PANEL CUTOUT 220mm x 160mm (8.7" x 6.3") WEIGHT 0.7kg (1.4lb)
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3.10.1 FIXING CLIPS The module is held into the panel fascia using the supplied fixing clips.
· Withdraw the fixing clip screw (turn anticlockwise) until only the pointed end is protruding from the clip. · Insert the three `prongs' of the fixing clip into the slots in the side of the 7000 series module case. · Pull the fixing clip backwards (towards the back of the module) ensuring all three prongs of the clip are
inside their allotted slots. · Turn the fixing clip screws clockwise until they make contact with the panel fascia. · Turn the screws a little more to secure the module into the panel fascia. Care should be taken not to over
tighten the fixing clip screws. Fixing clip
Fixing clip fitted to module
NOTE:- In conditions of excessive vibration, mount the module on suitable anti-vibration mountings.
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3.10.2 CABLE TIE FIXING POINTS
Integral cable tie fixing points are included on the rear of the module's case to aid wiring. This additionally provides strain relief to the cable loom by removing the weight of the loom from the screw connectors, thus reducing the chance of future connection failures. Care should be taken not to overtighten the cable tie (for instance with cable tie tools) to prevent the risk of damage to the module case.
Cable tie fixing point
With cable and tie in place
3.10.3 SILICON SEALING GASKET
The supplied silicon gasket provides improved sealing between the 7000 series module and the panel fascia. The gasket is fitted to the module before installation into the panel fascia. Take care to ensure the gasket is correctly fitted to the module to maintain the integrity of the seal.
Sealing gasket
Gasket fitted to module
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3.11 APPLICABLE STANDARDS
BS 4884-1
BS 4884-2 BS 4884-3 BS EN 60068-2-1 (Minimum temperature) BS EN 60068-2-2 (Maximum temperature) BS EN 60950 BS EN 61000-6-2 BS EN 61000-6-4 BS EN 60529 (Degrees of protection provided by enclosures)
UL508 NEMA rating (Approximate)
IEEE C37.2 (Standard Electrical Power System Device Function Numbers and Contact Designations)
This document conforms to BS4884-1 1992 Specification for presentation of essential information. This document conforms to BS4884-2 1993 Guide to content This document conforms to BS4884-3 1993 Guide to presentation
-30°C (-22°F)
+70°C (158°F)
Safety of information technology equipment, including electrical business equipment EMC Generic Immunity Standard (Industrial) EMC Generic Emission Standard (Industrial) IP65 (front of module when installed into the control panel with the supplied sealing gasket) IP42 (front of module when installed into the control panel WITHOUT being sealed to the panel) 12 (Front of module when installed into the control panel with the supplied sealing gasket). 2 (Front of module when installed into the control panel WITHOUT being sealed to the panel) Under the scope of IEEE 37.2, function numbers can also be used to represent functions in microprocessor devices and software programs. The 7000 series controller is device number 11L-7000 (Multifunction device protecting Line (generator) 7000 series module).
As the module is configurable by the generator OEM, the functions covered by the module will vary. Under the module's factory configuration, the device numbers included within the module are :
2 Time delay starting or closing relay 6 Starting circuit breaker 27AC AC undervoltage relay 27DC DC undervoltage relay 30 annunciator relay 42 Running circuit breaker 50 instantaneous overcurrent relay 51 ac time overcurrent relay 52 ac circuit breaker 53DC exciter or dc generator relay 54 turning gear engaging device 59AC AC overvoltage relay 59DC DC overvoltage relay 62 time delay stopping or opening relay 63 pressure switch 74 alarm relay 81 frequency relay 86 lockout relay
In line with our policy of continual development, Deep Sea Electronics, reserve the right to change specification without notice.
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4 INSTALLATION
The DSE7000 Series module is designed to be mounted on the panel fascia. For dimension and mounting details, see the section entitled Specification, Dimension and mounting elsewhere in this document.
4.1 USER CONNECTIONS
To aid user connection, icons are used on the rear of the module to help identify terminal functions. An example of this is shown below.
NOTE : Availability of some terminals depends upon module version. Full details are given in the section entitled Terminal Description elsewhere in this manual.
Terminals 39-46
Terminals 47-50
Terminals 51-55
Terminals 60-67
RS485 connection RS232 connection
USB Connection
Terminals 1-11
Terminals 15-19
Terminals 22-30
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4.2 TERMINAL DESCRIPTION
4.2.1 DC SUPPLY, FUEL AND START OUTPUTS
PIN No
1
DESCRIPTION
DC Plant Supply Input (Negative)
2
DC Plant Supply Input (Positive)
3
Emergency Stop Input
4
Output relay A (FUEL)
5
Output relay B (START)
6
Charge fail / excite
7
Functional Earth
8
Output relay E
9
Output relay F
10
Output relay G
11
Output relay H
CABLE SIZE
2.5mm² AWG 13
2.5 mm² AWG 13
2.5mm² AWG 13 2.5mm² AWG 13 2.5mm² AWG 13 2.5mm² AWG 13 2.5mm² AWG 13 1.0mm² AWG 18 1.0mm² AWG 18 1.0mm² AWG 18 1.0mm² AWG 18
NOTES
(Recommended Maximum Fuse 15A anti-surge) Supplies the module (2A anti-surge requirement) and Output relays E,F,G & H Plant Supply Positive. Also supplies outputs 1 & 2. (Recommended Maximum Fuse 20A) Plant Supply Positive from terminal 3. 15 Amp rated. Fixed as FUEL relay if electronic engine is not configured. Plant Supply Positive from terminal 3. 15 Amp rated. Fixed as START relay if electronic engine is not configured. Do not connect to ground (battery negative). If charge alternator is not fitted, leave this terminal disconnected. Connect to a good clean earth point.
Plant Supply Positive from terminal 2. 3 Amp rated.
Plant Supply Positive from terminal 2. 3 Amp rated.
Plant Supply Positive. from terminal 2. 3 Amp rated.
Plant Supply Positive from terminal 2. 3 Amp rated.
NOTE:- Terminals 12 to 14 are not fitted to the DSE7200/DSE7300 series controller.
NOTE:- When the module is configured for operation with an electronic engine, FUEL and START output requirements may be different. Refer to Electronic Engines and DSE Wiring for further information. Part No. 057-004.
4.2.2 ANALOGUE SENSOR
PIN No
15
DESCRIPTION
Sensor Common Return
16
Oil Pressure Input
17
Coolant Temperature Input
18
Fuel Level input
19
Flexible sensor (not available on 7200 series controller)
CABLE SIZE
0.5mm² AWG 20
0.5mm² AWG 20
0.5mm² AWG 20
0.5mm² AWG 20
0.5mm² AWG 20
NOTES
Return feed for sensors* Connect to Oil pressure sensor Connect to Coolant Temperature sensor Connect to Fuel Level sensor Connect to additional sensor (user configurable)
NOTE:- Terminals 20 and 21 are not fitted to the 7200/7300 series controller.
NOTE*:- If using single terminal sensors refer to the Appendix section entitled "Sensor wiring recommendations" elsewhere in this manual.
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4.2.3 MAGNETIC PICKUP, CAN AND EXPANSION
PIN No
22 23 24 25 26 27 28 29 30
DESCRIPTION
Magnetic pickup Positive Magnetic pickup Negative Magnetic pickup screen CAN port H CAN port L CAN port Common + SCR
CABLE SIZE
0.5mm² AWG 20 0.5mm² AWG 20
Shield
0.5mm² AWG 20 0.5mm² AWG 20 0.5mm² AWG 20 0.5mm² AWG 20 0.5mm² AWG 20 0.5mm² AWG 20
NOTES
Connect to Magnetic Pickup device Connect to Magnetic Pickup device Connect to ground at one end only Use only 120 CAN approved cable Use only 120 CAN approved cable Use only 120 CAN approved cable Use only 120 RS485 approved cable Use only 120 RS485 approved cable Use only 120 RS485 approved cable
NOTE:- Terminals 31 to 38 are not fitted to the 7200 / 7300 controller
NOTE:- Screened cable must be used for connecting the Magnetic Pickup, ensuring that the screen is earthed at one end ONLY.
NOTE:- Screened 120 impedance cable specified for use with CAN must be used for the CAN link and the Multiset comms link.
DSE stock and supply Belden cable 9841 which is a high quality 120 impedance cable suitable for CAN use (DSE part number 016-030)
NOTE:- When the module is configured for CAN operation, terminals 22, 23 & 24 should be left unconnected. Engine speed is transmitted to the 7000 series controller on the CAN link. Refer to Electronic Engines and DSE Wiring for further information. Part No. 057-004.
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4.2.4 LOAD SWITCHING AND GENERATOR VOLTAGE SENSING
PIN No
39
DESCRIPTION
Output relay C
40
Output relay C
41
Output relay D
42
Output relay D
43
Generator L1 (U) voltage monitoring
44
Generator L2 (V) voltage monitoring input
45
Generator L3 (W) voltage monitoring input
46
Generator Neutral (N) input
CABLE SIZE
1.0mm AWG 18 1.0mm AWG 18 1.0mm AWG 18 1.0mm AWG 18 1.0mm² AWG 18 1.0mm² AWG 18 1.0mm² AWG 18 1.0mm² AWG 18
NOTES
Normally configured to control mains contactor coil (Recommend 10A fuse)
Normally configured to control mains contactor coil
Normally configured to control generator contactor coil (Recommend 10A fuse)
Normally configured to control generator contactor coil
Connect to generator L1 (U) output (AC) (Recommend 2A fuse) Connect to generator L2 (V) output (AC) (Recommend 2A fuse) Connect to generator L3 (W) output (AC) (Recommend 2A fuse)
Connect to generator Neutral terminal (AC)
NOTE:- The above table describes connections to a three phase, four wire alternator. For alternative wiring topologies, please see the ALTERNATIVE AC TOPOLOGIES section of this manual.
4.2.5 MAINS VOLTAGE SENSING
PIN No
47
DESCRIPTION
Mains L1 (R) voltage monitoring
48
Mains L2 (S) voltage monitoring
49
Mains L3 (T) voltage monitoring
50
Mains Neutral (N) input
CABLE SIZE
1.0mm AWG 18 1.0mm AWG 18 1.0mm AWG 18 1.0mm AWG 18
NOTES
Connect to Mains L1 (R) incoming supply (AC) (Recommend 2A fuse) Connect to Mains L1 (S) incoming supply (AC) (Recommend 2A fuse) Connect to Mains L1 (T) incoming supply (AC) (Recommend 2A fuse) Connect to Mains N incoming supply (AC)
NOTE:- Terminals 47-50 are not fitted to the 7210 / 7310 controller.
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4.2.6 GENERATOR CURRENT TRANSFORMERS
WARNING!:- Do not disconnect this plug when the CTs are carrying current. Disconnection will open circuit the secondary of the C.T.'s and dangerous voltages may then develop. Always ensure the CTs are not carrying current and the CTs are short circuit connected before making or breaking connections to the module.
NOTE:- The 7000 series module has a burden of 0.5VA on the CT. Ensure the CT is rated for the burden of the 7000 series controller, the cable length being used and any other equipment sharing the CT. If in doubt, consult your CT supplier.
PIN No
51
DESCRIPTION
CT Secondary for Gen L1
52
CT Secondary for Gen L2
53
CT Secondary for Gen L3
Connection to terminals 54 & 55
CABLE SIZE
2.5mm² AWG 13 2.5mm² AWG 13 2.5mm² AWG 13
NOTES
Connect to s1 secondary of L1 monitoring CT Connect to s1 secondary of L2 monitoring CT Connect to s1 secondary of L3 monitoring CT
The function of terminals 54 and 55 change position depending upon wiring topology as follows :
Type
7200 series
All
Topology
Pin No
54
Description
DO NOT CONNECT
55
Common for CTs connected to L1,L2,L3
No earth fault measuring
54
DO NOT CONNECT
55
Common for CTs connected to L1,L2,L3
7300 series
Restricted earth fault measuring
54
Common for CTs connected to L1,L2,L3,N
55
Connect to CT on the neutral conductor
Un-restricted earth fault measuring
54
(Earth fault CT is fitted in the neutral to earth link) 55
DO NOT CONNECT Common for CTs connected to L1,L2,L3
CABLE SIZE
2.5mm² AWG 13
2.5mm² AWG 13 2.5mm² AWG 13 2.5mm² AWG 13
2.5mm² AWG 13
NOTE:- Terminals 56 to 59 are not fitted to the 7200 / 7300 series controller.
NOTE:- Take care to ensure correct polarity of the CT primary as shown below. If in doubt, check with the CT supplier.
CT labelled as
p1, k or K
To Load
To Supply
CT labelled as
p2, l or L
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4.2.7 CONFIGURABLE DIGITAL INPUTS
PIN No
60 61 62 63 64 65 66 67
DESCRIPTION
Configurable digital input A
Configurable digital input B
Configurable digital input C
Configurable digital input D
Configurable digital input E
Configurable digital input F Configurable digital input G (not available on 7200 series) Configurable digital input H (not available on 7200 series)
CABLE SIZE
0.5mm² AWG 20 0.5mm² AWG 20 0.5mm² AWG 20 0.5mm² AWG 20 0.5mm² AWG 20 0.5mm² AWG 20 0.5mm² AWG 20 0.5mm² AWG 20
Switch to negative Switch to negative Switch to negative Switch to negative Switch to negative Switch to negative Switch to negative Switch to negative
NOTES
NOTE:- Terminals 66 to 69 are not fitted to the 7200 series controller.
NOTE:- Terminals 68 and 69 are not fitted to the 7300 series controller.
4.2.8 PC CONFIGURATION INTERFACE CONNECTOR
This configuration cable is the same as normally used between a PC and a USB printer!
DESCRIPTION
Socket for connection to PC with 7xxx series PC software.
CABLE SIZE
0.5mm² AWG 20
NOTES
This is a standard USB type A to type B connector.
NOTE:- The USB connection cable between the PC and the 7000 series module must not be extended beyond 5m (5yds). For distances over 5m, it is possible to use a third party USB extender. Typically, they extend USB up to 50m (yds). The supply and support of this type of equipment is outside the scope of Deep Sea Electronics PLC.
CAUTION!: Care must be taken not to overload the PCs USB system by connecting more than the recommended number of USB devices to the PC. For further information, consult your PC supplier.
CAUTION!: This socket must not be used for any other purpose.
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4.2.9 RS485 CONNECTOR
NOTE:- RS485 connector is not fitted to the 7200 series controller.
PIN No A
B SCR
NOTES
Two core screened twisted pair cable. 120 impedance suitable for RS485 use. Recommended cable type - Belden 9841 Max distance 1000m (1km) when using Belden 9841 or direct equivalent.
Location of RS485 connector
4.2.10 RS232 CONNECTOR
Location of RS232 connector
NOTE:- RS232 connector is not fitted to the 7200 series controller.
PIN No 1 2 3 4 5 6 7 8 9
NOTES Received Line Signal Detector (Data Carrier Detect) Received Data Transmit Data Data Terminal Ready Signal Ground Data Set Ready Request To Send Clear To Send Ring Indicator
View looking into the male connector on the 7000 series module
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4.3 TYPICAL WIRING DIAGRAMS 4.3.1 7210 AUTOSTART CONTROLLER
3 phase, 4 wire
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4.3.2 7220 AMF CONTROLLER 3 phase, 4 wire
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4.3.3 7310 AUTOSTART CONTROLLER 3 phase, 4 wire with restricted earth fault protection
NOTE:- Earthing the neutral conductor `before' the neutral CT allows the module to read earth faults `after' the CT only (Restricted to load / downstream of the CT) Earthing the neutral conductor `after' the neutral CT allows the module to read earth faults `before' the CT only (Restricted to generator / upstream of the CT)
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4.3.4 7320 AMF CONTROLLER 3 phase, 4 wire with restricted earth fault protection
NOTE:- Earthing the neutral conductor `before' the neutral CT allows the module to read earth faults `after' the CT only (Restricted to load / downstream of the CT) Earthing the neutral conductor `after' the neutral CT allows the module to read earth faults `before' the CT only (Restricted to generator / upstream of the CT)
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4.4 ALTERNATIVE TOPOLOGIES
The 7000 controller is factory configured to connect to a 3 phase, 4 wire Star connected alternator. This section details connections for alternative AC topologies. Ensure to configure the 7000 series controller to suit the required topology.
NOTE:- Further details of module configuration are contained within the DSE7000 Series configuration software manual (DSE part number 057-077)
4.4.1 3 PHASE, 4 WIRE WITHOUT EARTH FAULT PROTECTION
NOTE:- Mains sensing (Terminals 47-50) is not fitted to DSE7210/ DSE7310 autostart controllers.
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4.4.2 SINGLE PHASE WITH RESTRICTED EARTH FAULT MEASURING
NOTE:- Earth fault measuring not available on 7200 series controllers.
NOTE:- Mains sensing (Terminals 47-50) is not fitted to DSE7210/ DSE7310 autostart controllers.
NOTE:- Earthing the neutral conductor `before' the neutral CT allows the module to read earth faults `after' the CT only (Restricted to load / downstream of the CT) Earthing the neutral conductor `after' the neutral CT allows the module to read earth faults `before' the CT only (Restricted to generator / upstream of the CT)
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4.4.3 SINGLE PHASE WITHOUT EARTH FAULT MEASURING
NOTE:- Mains sensing (Terminals 47-50) is not fitted to DSE7210/ DSE7310 autostart controllers.
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4.4.4 2 PHASE (L1 & L2) 3 WIRE WITH RESTRICTED EARTH FAULT MEASURING
NOTE:- Earth fault measuring not available on 7200 series controllers.
NOTE:- Mains sensing (Terminals 47-50) is not fitted to DSE7210/ DSE7310 autostart controllers.
NOTE:- Earthing the neutral conductor `before' the neutral CT allows the module to read earth faults `after' the CT only (Restricted to load / downstream of the CT) Earthing the neutral conductor `after' the neutral CT allows the module to read earth faults `before' the CT only (Restricted to generator / upstream of the CT)
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4.4.5 2 PHASE (L1 & L2) 3 WIRE WITHOUT EARTH FAULT MEASURING
NOTE:- Mains sensing (Terminals 47-50) is not fitted to DSE7210/ DSE7310 autostart controllers.
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4.4.6 2 PHASE (L1 & L3) 3 WIRE WITH RESTRICTED EARTH FAULT MEASURING
NOTE:- Earth fault measuring not available on 7200 series controllers.
NOTE:- Mains sensing (Terminals 47-50) is not fitted to DSE7210/ DSE7310 autostart controllers.
NOTE:- Earthing the neutral conductor `before' the neutral CT allows the module to read earth faults `after' the CT only (Restricted to load / downstream of the CT) Earthing the neutral conductor `after' the neutral CT allows the module to read earth faults `before' the CT only (Restricted to generator / upstream of the CT)
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4.4.7 2 PHASE (L1 & L3) 3 WIRE WITHOUT EARTH FAULT MEASURING
NOTE:- Mains sensing (Terminals 47-50) is not fitted to DSE7210/ DSE7310 autostart controllers.
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4.4.8 3 PHASE 4 WIRE WITH UNRESTRICTED EARTH FAULT MEASURING NOTE:- Earth fault measuring not available on 7200 series controllers.
NOTE:- Mains sensing (Terminals 47-50) is not fitted to DSE7210/ DSE7310 autostart controllers.
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4.5 CT LOCATION
NOTE:- CT Location is not applicable to the DSE7210 / DSE7310 autostart controllers. There are two possible locations for the current transformers in the system:
1) Generator : The CTs are used to measure and display generator current only. The typical wiring diagrams in the preceding section all show the CT measuring the generator load. For clarity, an example is shown below.
2) Load : The CTs are used to measure and display generator current when the generator is on load and mains current when the mains is on load. The module display automatically changes to display the current in the relevant instrumentation page. This example shows the CTs in the `load' for a three phase delta system but the same philosophy is applicable to the other topologies.
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5 DESCRIPTION OF CONTROLS
The following section details the function and meaning of the various controls on the module.
5.1 DSE7210 / DSE7310 AUTOSTART CONTROL MODULE
Menu navigation buttons
Main status and instrumentation display
Four configurable LEDs
Open generator (manual mode only)
Select Stop mode
Select Manual mode
Select Auto mode
Close generator (manual mode only)
Start engine (when in manual mode)
Mute alarm / Lamp test
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Close Generator LED. On When The Generator Is Required To Be On Load.
Generator Available LED. On when the generator is within limits and able to take load.
NOTE:- "Generator on load" LED has two modes of operation depending upon the configuration of the controllers digital inputs. 1) Digital input configured for "Generator closed auxiliary" The LED illuminates when the generator
closed auxiliary input is active The LED shows the state of the auxiliary contact. 2) There is NO input configured for "Generator closed auxiliary" (factory default setting) The LED
illuminates when the 7x20 gives the loading signal to the generator The LED shows the state of the 7x20's loading request.
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5.2 DSE7220 / DSE7320 AMF CONTROL MODULE
Menu navigation buttons
Main status and instrumentation display
Four configurable LEDs
Transfer to mains (manual mode only)
Select Stop mode
Continued overleaf....
Select Manual mode
Select Test on load mode
Select Auto mode
Transfer to generator (manual mode only)
Start engine (when in manual mode)
Mute alarm / Lamp test
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Mains Available LED. On when the mains is within limits and able to take load.
Close Mains LED. On When The Generator Is Required To Be On Load.
Close Generator LED. On When The Generator Is Required To Be On Load.
Generator Available LED. On when the generator is within limits and able to take load.
NOTE:- "Generator on load" LED has two modes of operation depending upon the configuration of the controllers digital inputs. 3) Digital input configured for "Generator closed auxiliary" The LED illuminates when the generator
closed auxiliary input is active The LED shows the state of the auxiliary contact. 4) There is NO input configured for "Generator closed auxiliary" (factory default setting) The LED
illuminates when the 7x20 gives the loading signal to the generator The LED shows the state of the 7x20's loading request.
NOTE:- "Mains on load" LED has two modes of operation depending upon the configuration of the controllers digital inputs. 5) Digital input configured for "Mains closed auxiliary" The LED illuminates when the mains closed
auxiliary input is active The LED shows the state of the auxiliary contact. 6) There is NO input configured for "Mains closed auxiliary" (factory default setting) The LED
illuminates when the 7x20 gives the loading signal to the mains The LED shows the state of the 7x20's loading request.
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5.3 QUICKSTART GUIDE
This section provides a quick start guide to the module's operation. 5.3.1 STARTING THE ENGINE
First, select manual mode...
...then press the Start button to crank the engine.
NOTE:- For further details, see the section entitled `OPERATION' elsewhere in this manual. 5.3.2 STOPPING THE ENGINE
Select Stop/Reset mode. The generator is stopped.
NOTE:- For further details, see the section entitled `OPERATION' elsewhere in this manual.
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5.4 VIEWING THE INSTRUMENTS
It is possible to scroll to display the different pages of information by repeatedly operating the next page button.
Once selected the page will remain on the LCD display until the user selects a different page or after an extended period of inactivity, the module will revert to the status display. If no buttons are pressed upon entering an instrumentation page, the instruments will be displayed automatically subject to the setting of the Scroll Delay.
Alternatively, to scroll manually through all instruments on the currently selected page, press the scroll
or
buttons. The `autoscroll' is disabled.
To re-enable `autoscroll' press the
or
Engine).
buttons to scroll to the `title' of the instrumentation page (ie
When scrolling manually, the display will automatically return to the Status page if no buttons are pressed for the duration of the configurable LCD Page Timer.
If an alarm becomes active while viewing the status page, the display shows the Alarms page to draw the operator's attention to the alarm condition.
Page order:-
Status, Engine, Generator, Mains, Alarms, ECU DTCs (electronic engines only), Event log, Scheduler (if enabled), About.
First page -
Press
to change to the next page -
Status Engine
If you want to view one of the instruments towards the end of the list, it may be quicker to scroll up through the instruments rather than down!
Press
to change to the next page -
Generator
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5.4.1 INSTRUMENT PAGE CONTENT
Engine
· Engine Speed · Oil Pressure · Coolant Temperature · Engine Battery Volts · Run Time · Oil Temperature* · Coolant Pressure* · Inlet Temperature* · Exhaust Temperature* · Fuel Temperature* · Turbo Pressure · Fuel Pressure* · Fuel Consumption* · Fuel Used* · Fuel Level* · Auxiliary Sensors (If fitted and configured) · Engine Maintenance Due (If configured) · Engine ECU Link*
*When connected to suitably configured and compatible engine ECU. For details of supported engines see `Electronic Engines and DSE wiring' (DSE Part number 057-004)
Generator
· Generator Voltage (ph-N) · Generator Voltage (ph-ph) · Generator Frequency · Generator Current · Generator Earth Current · Generator Load (kW) · Generator Load (kVA) · Generator Power Factor · Generator Load (kVAr) · Generator Load (kWh, kVAh, kVArh) · Generator Phase Sequence
Mains (DSE7220/DSE7320 only)
· Mains Voltage (ph-N) · Mains Voltage (ph-ph) · Mains Frequency
About · Module Type · Application Version · USB ID unique identifier for PC USB connection · Analogue Measurements Version · Firmware Update Bootloader Version
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5.4.2 CAN ERROR MESSAGES
When connected to a suitable CAN engine the 7000 series controller displays alarm status messages from the ECU.
Alarm ECU Warning
Type of alarm as reported by the ECU
Warning
Type of alarm that is triggered in the DSE module (ie Warning or Shutdown)
Press
to access the list of current active Engine DTCs (Diagnostic Trouble Codes).
Engine DTCs
Water Level Low Xxx,xxx,xxx
The code interpreted by the module shows on the display as a text message. Additionally, the manufactures code is shown.
NOTE:- For details on these code meanings, refer to the ECU instructions provided by the engine manufacturer, or contact the engine manufacturer for further assistance.
NOTE:- For further details on connection to electronic engines please refer to Electronic engines and DSE wiring. Part No. 057-004
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5.5 VIEWING THE EVENT LOG
Event log 1/50
Oil Pressure Low Shutdown 12 Sep 2007, 08:25:46
Number of present alarms. This is event 1 of a total of 50 logged events.
The 7000 series modules maintains a log of the last 50 shutdown alarms (7200 series logs 30 shutdown alarms) to enable the operator or engineer to view the past alarms history. The event log only includes shutdown and electrical trip alarms logged; The event log does not contain Warning alarms.
If All warnings are latched is configured, the event log will capture warning alarms. For more details consult the 7xxx series configuration software manual.
Once the log is full, any subsequent shutdown alarms will overwrite the oldest entry in the log. Hence, the log will always contain the most recent shutdown alarms. The module logs the alarm, along with the date and time of the event in the format shown in this example.
To view the event log, repeatedly press the next page button
until the LCD screen displays the Event log.
Press down
to view the next most recent shutdown alarm:
Continuing to press down
cycles through the past alarms after which the display shows the most recent
alarm and the cycle begins again.
To exit the event log and return to viewing the instruments, press the next page
button.
5.6 USER CONFIGURABLE INDICATORS
These LEDs can be configured by the user to indicate any one of 100+ different functions based around the following:· Indications - Monitoring of a digital input and indicating associated
functioning user's equipment - Such as Battery Charger On or Louver's Open, etc. · WARNINGS and SHUTDOWNS - Specific indication of a particular warning or shutdown condition, backed up by LCD indication - Such as Low Oil Pressure Shutdown, Low Coolant level, etc. · Status Indications - Indication of specific functions or sequences derived from the modules operating state - Such as Safety On, Preheating, Panel Locked, Generator Available, etc.
User configurable LEDs
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5.7 CONTROLS
Stop / Reset This button places the module into its Stop/Reset mode. This will clear any alarm conditions for which the triggering criteria have been removed. If the engine is running and the module is in Stop mode, the module will automatically instruct the changeover device to unload the generator (`Close Generator' becomes inactive (if used)). The fuel supply de-energises and the engine comes to a standstill. Should a remote start signal be present while operating in this mode, a remote start will not occur. Manual This mode allows manual control of the generator functions. Once in Manual mode the module will
respond to the start button, start the engine, and run off load. If the engine is running off-load in the Manual mode and a remote start signal becomes present, the module will automatically instruct the changeover device to place the generator on load (`Close Generator' becomes active (if used)). Upon removal of the remote start signal, the generator remains on load until either selection of the `STOP/RESET' or `AUTO' modes. For further details, please see the more detailed description of `Manual operation' elsewhere in this manual. Auto This button places the module into its `Automatic' mode. This mode allows the module to control the function of the generator automatically. The module will monitor the remote start input and mains supply status and once a start request is made, the set will be automatically started and placed on load. Upon removal of the starting signal, the module will automatically transfer the load from the generator and shut the set down observing the stop delay timer and cooling timer as necessary. The module will then await the next start event. For further details, please see the more detailed description of `Auto operation' elsewhere in this manual. Test (DSE7220/DSE7320 only) This button places the module into its `Test' mode. This allows an on load test of the generator.
Once in Test mode the module will respond to the start button, start the engine, and run on load. For further details, please see the more detailed description of `Test operation' elsewhere in this manual. Start
This button is only active in STOP/RESET or MANUAL mode. Pressing this button in manual or test mode will start the engine and run off load (manual) or on load (test). Pressing this button in STOP/RESET mode will turn on the CAN engine ECU (when correctly configured and fitted to a compatible engine ECU)
Mute / Lamp Test This button silences the audible alarm if it is sounding and illuminates all of the LEDs as a lamp test feature/ When correctly configured and fitted to a compatible engine ECU, pressing this button in
STOP/RESET mode after pressing the START "passive" alarms on the engine ECU.
button (to power the ECU) will cancel any
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Transfer to generator Allows the operator to transfer the load to the generator (when in Manual mode only)
Open generator (DSE7210/DSE7310 only) Allows the operator to open the generator (when in Manual mode only) Transfer to mains (DSE7220/DSE7320 only) Allows the operator to transfer the load to the mains (when in Manual mode only) Menu navigation Used for navigating the instrumentation, event log and configuration screens. For further details, please see the more detailed description of these items elsewhere in this manual.
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6 OPERATION
The following description details the sequences followed by a module containing the standard `factory configuration'.
Remember that if you have purchased a completed generator set or control panel from your supplier, the module's configuration will probably have been changed by them to suit their particular requirements.
Always refer to your configuration source for the exact sequences and timers observed by any particular module in the field.
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6.1 AUTOMATIC MODE OF OPERATION
NOTE:- If a digital input configured to panel lock is active, changing module modes will not be possible. Viewing the instruments and event logs is NOT affected by panel lock. Activate auto mode be pressing the pushbutton. An LED indicator beside the button confirms this action.
Auto mode will allow the generator to operate fully automatically, starting and stopping as required with no user intervention.
6.1.1 WAITING IN AUTO MODE
If a starting request is made, the starting sequence will begin. Starting requests can be from the following sources :
· Mains supply out of limits (DSE7220/7320 only) · Activation of an auxiliary input that has been configured to remote start · Activation of the inbuilt exercise scheduler.
6.1.2 STARTING SEQUENCE
To allow for `false' start requests such as mains brownouts, the start delay timer begins.
Should all start requests be removed during the start delay timer, the unit will return to a stand-by state.
If a start request is still present at the end of the start delay timer, the fuel relay is energised and the engine will be cranked.
NOTE:- If the unit has been configured for CAN, compatible ECU's will receive the start command via CAN.
If the engine fails to fire during this cranking attempt then the starter motor is disengaged for the crank rest duration after which the next start attempt is made. Should this sequence continue beyond the set number of attempts, the start sequence will be terminated and the display shows Fail to Start.
When the engine fires, the starter motor is disengaged. Speed detection is factory configured to be derived from the main alternator output frequency but can additionally be measured from a Magnetic Pickup mounted on the flywheel (Selected by PC using the 7000 series configuration software).
Additionally, rising oil pressure can be used to disconnect the starter motor (but cannot detect underspeed or overspeed).
NOTE:- If the unit has been configured for CAN, speed sensing is via CAN.
After the starter motor has disengaged, the Safety On timer activates, allowing Oil Pressure, High Engine Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to stabilise without triggering the fault.
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6.1.3 ENGINE RUNNING
Once the engine is running, the Warm Up timer, if selected, begins, allowing the engine to stabilise before accepting the load.
DSE7210/DSE7310 - The generator will be placed on load. DSE7220/DSE7320 - Load will be transferred from the mains supply to the generator
NOTE:-The load transfer signal remains inactive until the Oil Pressure has risen. This prevents excessive wear on the engine.
If all start requests are removed, the stopping sequence will begin.
6.1.4 STOPPING SEQUENCE
The return delay timer operates to ensure that the starting request has been permanently removed and isn't just a short term removal. Should another start request be made during the cooling down period, the set will return on load.
If there are no starting requests at the end of the return delay timer, the load is transferred back from the generator to the mains supply and the cooling timer is initiated.
The cooling timer allows the set to run off load and cool sufficiently before being stopped. This is particularly important where turbo chargers are fitted to the engine.
After the cooling timer has expired, the set is stopped.
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6.2 MANUAL OPERATION
NOTE:- If a digital input configured to panel lock is active, changing module modes will not be possible. Viewing the instruments and event logs is NOT affected by panel lock.
Activate Manual mode be pressing the pushbutton. An LED indicator beside the button confirms this action.
Manual mode allows the operator to start and stop the set manually, and if required change the state of the load switching devices.
6.2.1 WAITING IN MANUAL MODE
When in manual mode, the set will not start automatically.
To begin the starting sequence, press the
button.
6.2.2 STARTING SEQUENCE
NOTE:- There is no start delay in this mode of operation. The fuel relay is energised and the engine is cranked.
NOTE:- If the unit has been configured for CAN, compatible ECU's will receive the start command via CAN.
If the engine fails to fire during this cranking attempt then the starter motor is disengaged for the crank rest duration after which the next start attempt is made. Should this sequence continue beyond the set number of attempts, the start sequence will be terminated and the display shows Fail to Start.
When the engine fires, the starter motor is disengaged. Speed detection is factory configured to be derived from the main alternator output frequency but can additionally be measured from a Magnetic Pickup mounted on the flywheel (Selected by PC using the 7000 series configuration software).
Additionally, rising oil pressure can be used disconnect the starter motor (but cannot detect underspeed or overspeed).
NOTE:- If the unit has been configured for CAN, speed sensing is via CAN.
After the starter motor has disengaged, the Safety On timer activates, allowing Oil Pressure, High Engine Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to stabilise without triggering the fault.
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6.2.3 ENGINE RUNNING
In manual mode, the load is not transferred to the generator unless a `loading request' is made. A loading request can come from a number of sources.
· Pressing the transfer to generator button · Mains supply out of limits (DSE7220/DSE7320 only) · Activation of an auxiliary input that has been configured to remote start on load · Activation of the inbuilt exercise scheduler if configured for `on load' runs.
NOTE:-The load transfer signal remains inactive until the Oil Pressure has risen. This prevents excessive wear on the engine.
Once the load has been transferred to the generator, it will not be automatically transferred back to the mains supply. To manually transfer the load back to the mains either:
· Press the transfer to mains button (DSE7220/DSE7320 only) · Press the Open Generator button (DSE7210/DSE7310 only) · Press the auto mode button to return to automatic mode.
6.2.4 STOPPING SEQUENCE
In manual mode the set will continue to run until either :
· The stop button is pressed The set will immediately stop · The auto button is pressed. The set will observe all auto mode start requests and stopping timers
before beginning the Auto mode stopping sequence.
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6.3 TEST MODE OF OPERATION
NOTE:- Test Mode is only applicable to DSE7220/DSE7320 controllers.
NOTE:- If a digital input configured to panel lock is active, changing module modes will not be possible. Viewing the instruments and event logs is NOT affected by panel lock.
Activate test mode be pressing the pushbutton. An LED indicator beside the button confirms this action.
Test mode will start the set and transfer the load to the generator to provide a Test on load function.
6.3.1 WAITING IN TEST MODE
When in test mode, the set will not start automatically.
To begin the starting sequence, press the
button.
6.3.2 STARTING SEQUENCE
The set begins to crank.
NOTE:- If the unit has been configured for CAN, compatible ECU's will receive the start command via CAN.
If the engine fails to fire during this cranking attempt then the starter motor is disengaged for the crank rest duration after which the next start attempt is made. Should this sequence continue beyond the set number of attempts, the start sequence will be terminated and the display shows Fail to Start.
When the engine fires, the starter motor is disengaged. Speed detection is factory configured to be derived from the main alternator output frequency but can additionally be measured from a Magnetic Pickup mounted on the flywheel (Selected by PC using the 7000 series configuration software).
Additionally, rising oil pressure can be used disconnect the starter motor (but cannot detect underspeed or overspeed).
NOTE:- If the unit has been configured for CAN, speed sensing is via CAN.
After the starter motor has disengaged, the Safety On timer activates, allowing Oil Pressure, High Engine Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to stabilise without triggering the fault.
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6.3.3 ENGINE RUNNING Once the engine is running, the Warm Up timer, if selected, begins, allowing the engine to stabilise before accepting the load. Load will be automatically transferred from the mains supply to the generator.
NOTE:-The load transfer signal remains inactive until the Oil Pressure has risen. This prevents excessive wear on the engine.
In test mode, the set will continue to run on load until either:
· The stop button is pressed The set will immediately stop · The auto button is pressed. The set will observe all auto mode start requests and stopping timers
before beginning the Auto mode stopping sequence.
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7 PROTECTIONS
When an alarm is present, the Audible Alarm will sound and the Common alarm LED if configured will illuminate. The audible alarm can be silenced by pressing the Mute button
The LCD display will jump from the `Information page' to display the Alarm Page
Alarm 1/2
Warning Low oil pressure
Number of present alarms. This is alarm 1 of a total of 2 present alarms
The type of alarm. E.g. Shutdown or warning
The nature of alarm, eg Low oil pressure
The LCD will display multiple alarms E.g. "High Engine Temperature shutdown", "Emergency Stop" and "Low Coolant Warning". These will automatically scroll round in the order that they occurred;
In the event of a warning alarm, the LCD will display the appropriate text. If a shutdown then occurs, the module will again display the appropriate text. Example:-
Alarm 1/2 Warning Oil pressure Low
Alarm 2/2
Shutdown Coolant Temperature High
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7.1 WARNINGS
Warnings are non-critical alarm conditions and do not affect the operation of the generator system, they serve to draw the operators attention to an undesirable condition.
Example Alarm 1/1
Charge Failure Warning
In the event of an alarm the LCD will jump to the alarms page, and scroll through all active warnings and shutdowns.
By default, warning alarms are self-resetting when the fault condition is removed. However enabling `all warnings are latched' will cause warning alarms to latch until reset manually. This is enabled using the 7000 series configuration suite in conjunction with a compatible PC.
Display CHARGE FAILURE BATTERY UNDER VOLTAGE BATTERY OVER VOLTAGE
FAIL TO STOP
Reason The auxiliary charge alternator voltage is low as measured from the W/L terminal. The DC supply has fallen below the low volts setting level for the duration of the low battery volts timer
The DC supply has risen above the high volts setting level for the duration of the high battery volts timer The module has detected a condition that indicates that the engine is running when it has been instructed to stop.
AUXILIARY INPUTS
LOW FUEL LEVEL CAN ECU ERROR
NOTE:- `Fail to Stop' could indicate a faulty oil pressure sensor - If engine is at rest check oil sensor wiring and configuration.
Auxiliary inputs can be user configured and will display the message as written by the user. The level detected by the fuel level sensor is below the low fuel level setting. The engine ECU has detected a warning alarm and has informed the DSE module of this situation. The exact error is also indicated on the module's display.
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7.2 ANALOGUE PRE-ALARMS
The following alarms are termed `pre-alarms' as they pre-warn the operator of a potentially more serious alarm condition. For instance, if the engine temperature rises past the pre alarm level, a warning condition will occur to notify the operator. If the temperature falls below this level, then the alarm ceases, and the set will continue to run as normal. However if the temperature continues to rise until the coolant temperature trip point is reached, the warning is escalated and a high coolant temperature shutdown is initiated.
Example Alarm 1/1
Oil Pressure Low Warning
By default, analogue pre alarms are self-resetting when the fault condition is removed. However enabling `all warnings are latched' will cause warning alarms to latch until reset manually. This is enabled using the 7000 series configuration suite in conjunction with a compatible PC.
Display LOW OIL PRESSURE
ENGINE HIGH TEMPERATURE
ENGINE LOW TEMPERATURE
OVERSPEED UNDERSPEED GENERATOR OVER FREQUENCY GENERATOR UNDER FREQUENCY GENERATOR OVER VOLTAGE GENERATOR UNDER VOLTAGE ECU WARNING
Reason The module detects that the engine oil pressure has fallen below the low oil pressure pre-alarm setting level after the Safety On timer has expired. The module detects that the engine coolant temperature has exceeded the high engine temperature pre-alarm setting level after the Safety On timer has expired. The module detects that the engine coolant temperature has fallen below the high engine temperature pre-alarm setting level. The engine speed has risen above the overspeed pre alarm setting The engine speed has fallen below the underspeed pre alarm setting The generator output frequency has risen above the pre-set pre-alarm setting.
The generator output frequency has fallen below the pre-set pre-alarm setting after the Safety On timer has expired. The generator output voltage has risen above the pre-set pre-alarm setting.
The generator output voltage has fallen below the pre-set pre-alarm setting after the Safety On timer has expired. The engine ECU has detected a warning alarm and has informed the DSE module of this situation. The exact error is also indicated on the module's display.
If the module is configured for CAN and receives an "error" message from the engine control unit, `Can ECU Warning" is shown on the module's display and a warning alarm is generated.
7.3 HIGH CURRENT WARNING ALARM
GENERATOR HIGH CURRENT, if the module detects a generator output current in excess of the pre-set trip a warning alarm initiates. The module shows Alarm Warning High Current. If this high current condition continues for an excess period, then the alarm escalates to a shutdown condition. For further details of the high current alarm, please see High Current Shutdown Alarm.
By default, High Current Warning Alarm is self-resetting when the overcurrent condition is removed. However enabling `all warnings are latched' will cause the alarm to latch until reset manually. This is enabled using the 7000 series configuration suite in conjunction with a compatible PC.
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7.4 SHUTDOWNS
Shutdowns are latching alarms and stop the Generator. Clear the alarm and remove the fault then press Stop/Reset to reset the module. Example
Alarm 1/1 Oil Pressure Low Shutdown
NOTE:- The alarm condition must be rectified before a reset will take place. If the alarm condition remains, it will not be possible to reset the unit (The exception to this is the Low Oil Pressure alarm and similar `delayed alarms', as the oil pressure will be low with the engine at rest).
Display FAIL TO START EMERGENCY STOP
Reason The engine has not fired after the preset number of start attempts The emergency stop button has been depressed. This a failsafe (normally closed to battery positive) input and will immediately stop the set should the signal be removed. Removal of the battery positive supply from the emergency stop input will also remove DC supply from the Fuel and Start outputs of the controller.
NOTE:- The Emergency Stop Positive signal must be present otherwise the unit will shutdown.
LOW OIL PRESSURE ENGINE HIGH TEMPERATURE OVERSPEED
The engine oil pressure has fallen below the low oil pressure trip setting level after the Safety On timer has expired. The engine coolant temperature has exceeded the high engine temperature trip setting level after the Safety On timer has expired. The engine speed has exceeded the pre-set trip
NOTE:-During the start-up sequence, the overspeed trip logic can be configured to allow an extra trip level margin. This is used to prevent nuisance tripping on start-up - Refer to the 7000 series configuration software manual under heading `Overspeed Overshoot' for details.
UNDERSPEED
GENERATOR OVER FREQUENCY GENERATOR UNDER FREQUENCY GENERATOR OVER VOLTAGE GENERATOR UNDER VOLTAGE OIL PRESSURE SENSOR OPEN CIRCUIT AUXILIARY INPUTS
LOSS OF SPEED SIGNAL
ECU DATA FAIL
ECU SHUTDOWN
The engine speed has fallen below the pre-set trip after the Safety On timer has expired. The generator output frequency has risen above the preset level The generator output frequency has fallen below the preset level The generator output voltage has risen above the preset level The generator output voltage has fallen below the preset level The oil pressure sensor is detected as not being present (open circuit)
An active auxiliary input configured as a shutdown will cause the engine to shut down. The display shows the text as configured by the user. The speed signal from the magnetic pickup is not being received by the DSE controller. The module is configured for CAN operation and does not detect data on the engine Can datalink, the engine shuts down. The engine ECU has detected a shutdown alarm and has informed the DSE module of this situation. The exact error is also indicated on the module's display.
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7.5 HIGH CURRENT SHUTDOWN ALARM
GENERATOR HIGH CURRENT, if the module detects a generator output current in excess of the adjustable trip a warning alarm occurs. This warning will continue for a period depending upon the level of overload placed on the generator, and the configuration setting for Generator High Current in the 7000 series configuration software.
For instance, the factory default settings for Generator High Current allow for a loading of the generator to 110% for one hour. That is to say if the generator load level exceeds the trip point by 10%, a warning alarm will occur while the overload condition exists. If the load level does not drop to normal levels within one hour, the set stops, with the 7000 series module displaying either a shutdown or electrical trip alarm depending upon module configuration.
High current shutdown is a latching alarm and stops the Generator. Remove the fault then press Stop/Reset to reset the module.
NOTE:- Higher overload levels will result in a faster acting shutdown condition. For instance with the factory default configuration, an overload level twice that of the trip level (typically 200%) will result in a Generator High Current shutdown condition after 36 seconds. For details of the relationship between the overload and the shutdown time, please see the Appendix section of this manual.
7.6 ELECTRICAL TRIPS
Electrical trips are latching and stop the Generator but in a controlled manner. On initiation of the electrical trip condition the module will de-energise the `Close Generator' Output to remove the load from the generator. Once this has occurred the module will start the Cooling timer and allow the engine to cool off-load before shutting down the engine. The alarm must be accepted and cleared, and the fault removed to reset the module.
Example Alarm 1/1
Generator Current High Electrical Trip
Electrical trips are latching alarms and stop the Generator. Remove the fault then press Stop/Reset the module.
to reset
Display GENERATOR OVER CURRENT
AUXILIARY INPUTS
Reason If a generator output in excess of the high current alarm point, a warning alarm occurs. If this high current condition continues for an excess period, then the alarm escalates to either a shutdown or electrical trip condition (depending upon module configuration). For further details of the high current alarm, please see High Current Shutdown Alarm. If an auxiliary input configured as an electrical trip is active, the appropriate message will be displayed as configured by the user.
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8 FRONT PANEL CONFIGURATION
This configuration mode allows the operator limited customising of the way the module operates. Use the module's navigation buttons to traverse the menu and make value changes to the parameters:
Previous page
Increase value / next item
Next page
Decrease value / next item
Accept
8.1 ACCESSING THE MAIN FRONT PANEL CONFIGURATION EDITOR
Ensure the engine is at rest and the module is in STOP mode by pressing the Stop/Reset
Press the Stop/Reset and Info buttons simultaneously. If a module security PIN has been set, the PIN number request is then shown :
button.
Press , the first `#' changes to `0'. Press
(up) or
(down) to adjust it to the correct value.
Press
(right) when the first digit is correctly entered. The digit you have just entered will now show
`#' for security.
Repeat this process for the other digits of the PIN number. You can press move back to adjust one of the previous digits.
(left) if you need to
When is pressed after editing the final PIN digit, the PIN is checked for validity. If the number is not correct, you must re-enter the PIN.
If the PIN has been successfully entered (or the module PIN has not been enabled), the editor is displayed :
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8.1.1 EDITING A PARAMETER Enter the editor as described above.
Press the
(left) or
(right) buttons to cycle to the section you wish to view/change.
Press the
(up) or
(down) buttons to select the parameter you wish to view/change within
the currently selected section.
To edit the parameter, press to enter edit mode. The parameter begins to flash to indicate that you are editing the value.
Press the
(up) or
(down) buttons to change the parameter to the required value.
Press to save the value. The parameter ceases flashing to indicate that it has been saved.
To exit the editor at any time, press and hold the button.
NOTE: - When the editor is visible, it is automatically exited after 5 minutes of inactivity to ensure security.
NOTE: - The PIN number is automatically reset when the editor is exited (manually or automatically) to ensure security.
NOTE: - More comprehensive module configuration is possible using the 7xxx series PC configuration software. Please contact us for further details.
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8.1.2 ADJUSTABLE PARAMETERS
Front Panel Configuration Editor
Section
DISPLAY ENGINE
GENERATOR
MAINS Mains settings only applicable to DSE7220 and DSE7320 controllers. TIMERS
DSE7220 / DSE7320 only DSE7220 / DSE7320 only
Parameter as shown on display
Contrast Language LCD Page Timer Auto Scroll Delay Current Date and time Oil Pressure Low Shutdown Oil Pressure Low Pre Alarm Coolant Temperature Low Warning Coolant Temperature High Pre Alarm Coolant Temperature High Shutdown Start Delay Timer Pre Heat Timer Crank Duration Timer Crank Rest Timer Safety On Delay Smoke Limiting Smoke Limiting Off Warm Up Timer Cool Down Timer Engine Under Speed Shutdown Engine Under Speed Shutdown Engine Under Speed Warning Engine Under Speed Warning Engine Over Speed Warning Engine Over Speed Warning Engine Over Speed Shutdown Engine Speed Overshoot Delay Engine Speed Overshoot Fail To Stop Delay Battery Under Voltage Warning Battery Under voltage Warning Delay Battery Under Voltage Charge Alternator Failure Warning Battery Over Voltage Warning Delay Battery Over Voltage Warning Charge Alternator Failure Warning Charge Alternator Failure Warning Droop control Droop control
Generator Under Voltage Shutdown Generator Under Voltage Pre Alarm Generator Over Voltage Pre Alarm Generator Over Voltage Shutdown Generator Under Frequency Shutdown Generator Under Frequency Pre Alarm Generator Over Frequency Pre Alarm Generator Over Frequency Shutdown Full Load Rating
Delayed Over Current Delayed Over Current AC System CT Primary CT Secondary Generator Transient Delay
Mains Under Voltage Trip Mains Over Voltage Trip Mains Under Frequency Trip Mains Over Frequency Trip Mains Transient Delay Return Delay Mains Transfer Time Auto Scroll Delay LCD Page Timer Start Delay Timer Pre Heat Timer Crank Duration Timer Crank Rest Timer Safety On Delay Smoke Limiting Smoke Limiting Off Warm Up Timer Cool Down Timer Speed Overshoot Delay Fail To Stop Delay Battery voltage Low Warning Delay Battery Voltage High Warning Delay
Generator Transient Delay Mains Transient Delay Return Delay Mains Transfer Time
Factory Settings
53% English 5m 2s hh:mm 1.03bar 1.17bar 70ºC 90ºC 95ºC 5s 0s 10s 10s 10s 0s 0s 0s 1m Inactive 1260RPM Inactive 1350RPM Inactive 1650RPM 1710RPM 2s 0s 30s Active 1m 10V Active 1m 30V Active 6V Disable (Compatible engine ECUs only) 4% (Compatible engine ECUs only) 184V 196V 265V 276V 40Hz 42Hz 55Hz 57Hz 500A Active 100% 3 Phase, 4 Wire
600A 5A 0s 184V 276V 45Hz 55Hz 2s 30s 0.7s 2s 5m 5s 0s 10s 10s 10s 0s 0s 0s 1m 2s 30s 1m 1m 0s 2s 30s 0.7s
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8.2 ACCESSING THE `RUNNING' CONFIGURATION EDITOR
The `running' editor can be entered while the engine is running. All protections remain active if the engine is running while the running editor is entered. Press and hold the button to enter the running editor. 8.2.1 EDITING A PARAMETER
Enter the editor as described above.
Press the
(left) or
view/change.
(right) buttons to cycle to the section you wish to
Press the
(up) or
(down) buttons to select the parameter you wish to
view/change within the currently selected section.
To edit the parameter, press to enter edit mode. The parameter begins to flash to indicate that you are editing the value.
Press the
(up) or
required value.
(down) buttons to change the parameter to the
Press to save the value. The parameter ceases flashing to indicate that it has been saved.
To exit the editor at any time, press and hold the button.
8.2.2 ADJUSTABLE PARAMETERS (RUNNING EDITOR)
Running Editor (Factory default settings are shown in bold italicised text)
Sectio Parameter as shown on display
Factory Setting
nDISPLAY
Contrast
50%
Language
English
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9 COMMISSIONING
9.1.1 PRE-COMMISSIONING Before the system is started, it is recommended that the following checks are made:-
10.1. The unit is adequately cooled and all the wiring to the module is of a standard and rating compatible with the system. Check all mechanical parts are fitted correctly and that all electrical connections (including earths) are sound.
10.2. The unit DC supply is fused and connected to the battery and that it is of the correct polarity.
10.3. The Emergency Stop input is wired to an external normally closed switch connected to DC positive.
NOTE:- If Emergency Stop feature is not required, link this input to the DC Positive. The module will not operate unless either the Emergency Stop is fitted correctly OR terminal 3 is connected to DC positive.
10.4. To check the start cycle operation, take appropriate measures to prevent the engine from starting (disable the operation of the fuel solenoid). After a visual inspection to ensure it is safe to proceed, connect the battery supply. Select "MANUAL" and then press "START" the unit start sequence will commence.
10.5. The starter will engage and operate for the pre-set crank period. After the starter motor has attempted to start the engine for the pre-set number of attempts, the LCD will display `Failed to start. Select the STOP/RESET position to reset the unit.
10.6. Restore the engine to operational status (reconnect the fuel solenoid). Select "MANUAL" and then press "START". This time the engine should start and the starter motor should disengage automatically. If not then check that the engine is fully operational (fuel available, etc.) and that the fuel solenoid is operating. The engine should now run up to operating speed. If not, and an alarm is present, check the alarm condition for validity, then check input wiring. The engine should continue to run for an indefinite period. It will be possible at this time to view the engine and alternator parameters - refer to the `Description of Controls' section of this manual.
10.7. Select "AUTO" on the front panel, the engine will run for the pre-set cooling down period, then stop. The generator should stay in the standby mode. If not check that there is not a signal present on the Remote start input.
10.8. Initiate an automatic start by supplying the remote start signal (if configured). The start sequence will commence and the engine will run up to operational speed. Once the generator is available a load transfer will take place (if configured), the Generator will accept the load. If not, check the wiring to the Generator Contactor Coil (if used). Check the Warming timer has timed out.
10.9. Remove the remote start signal. The return sequence will begin. After the pre-set time, the generator is unloaded. The generator will then run for the pre-set cooling down period, then shutdown into its standby mode.
10.10.Set the modules internal clock/calendar to ensure correct operation of the scheduler and event logging functions. For details of this procedure see section entitled Front Panel Configuration Editing the date and time.
10.11.If, despite repeated checking of the connections between the 7000 series controller and the customer's system, satisfactory operation cannot be achieved, then the customer is requested to contact the factory for further advice on:-
INTERNATIONAL TEL: +44 (0) 1723 890099 INTERNATIONAL FAX: +44 (0) 1723 893303
E-mail: Support@Deepseaplc.com Website : www.deepseaplc.com
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10 FAULT FINDING
SYMPTOM
Unit is inoperative Read/Write configuration does not operate Unit shuts down Unit locks out on Emergency Stop
Intermittent Magnetic Pick-up sensor fault
Low oil Pressure fault operates after engine has fired
High engine temperature fault operates after engine has fired. Shutdown fault operates Warning fault operates Fail to Start is activated after preset number of attempts to start
Continuous starting of generator when in AUTO
Generator fails to start on receipt of Remote Start signal.
POSSIBLE REMEDY
Check the battery and wiring to the unit. Check the DC supply. Check the DC fuse.
Check DC supply voltage is not above 35 Volts or below 9 Volts Check the operating temperature is not above 70°C. Check the DC fuse. If no Emergency Stop Switch is fitted, ensure that a DC positive signal is connected to the Emergency Stop input. Check emergency stop switch is functioning correctly. Check Wiring is not open circuit. Ensure that Magnetic pick-up screen only connects to earth at one end, if connected at both ends, this enables the screen to act as an aerial and will pick up random voltages. Check pickup is correct distance from the flywheel teeth. Check engine oil pressure. Check oil pressure switch/sensor and wiring. Check configured polarity (if applicable) is correct (i.e. Normally Open or Normally Closed) or that sensor is compatible with the 73x0 Module and is correctly configured. Check engine temperature. Check switch/sensor and wiring. Check configured polarity (if applicable) is correct (i.e. Normally Open or Normally Closed) or that sensor is compatible with the 7000 series module. Check relevant switch and wiring of fault indicated on LCD display. Check configuration of input. Check relevant switch and wiring of fault indicated on LCD display. Check configuration of input. Check wiring of fuel solenoid. Check fuel. Check battery supply. Check battery supply is present on the Fuel output of the module. Check the speedsensing signal is present on the 7000 series module's inputs. Refer to engine manual. Check that there is no signal present on the "Remote Start" input. Check configured polarity is correct. Check the mains supply is available and within configured limits (DSE7220/DSE7320 only) Check Start Delay timer has timed out.
Check signal is on "Remote Start" input. Confirm correct configuration of input is configured to be used as "Remote Start".
Pre-heat inoperative Starter motor inoperative
Engine runs but generator will not take load
Check that the oil pressure switch or sensor is indicating low oil pressure to the controller. Depending upon configuration, then set will not start if oil pressure is not low. Check wiring to engine heater plugs. Check battery supply. Check battery supply is present on the Pre-heat output of module. Check pre-heat configuration is correct. Check wiring to starter solenoid. Check battery supply. Check battery supply is present on the Starter output of module. Ensure that the Emergency Stop input is at Positive. Ensure oil pressure switch or sensor is indicating the "low oil pressure" state to the 7300 series controller. Check Warm up timer has timed out. Ensure generator load inhibit signal is not present on the module inputs. Check connections to the switching device. Note that the set will not take load in manual mode unless there is an active remote start on load signal.
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SYMPTOM
Incorrect reading on Engine gauges
Fail to stop alarm when engine is at rest Module appears to `revert' to an earlier configuration
POSSIBLE REMEDY
Check engine is operating correctly. Check sensor and wiring paying particular attention to the wiring to terminal 47 (refer to appendix). Check that sensor is compatible with the 7000 series module and that the module configuration is suited to the sensor.
When editing a configuration using the PC software it is vital that the configuration is first `read' from the controller before editing it. This edited configuration must then be "written" back to the controller for the changes to take effect.
When editing a configuration using the fascia editor, be sure to press the
Accept button to save the change before moving to another item or exiting the fascia editor
Set will not take load
Ensure the generator available LED is lit
Check that the output configuration is correct to drive the load switch device and that all connections are correct.
Inaccurate generator measurements on controller display
Remember that the set will not take load in manual mode unless a remote start on load input is present or the close generator button is pressed. Check that the CT primary, CT secondary and VT ratio settings are correct for the application.
Check that the CTs are wired correctly with regards to the direction of current flow (p1,p2 and s1,s2) and additionally ensure that CTs are connected to the correct phase (errors will occur if CT1 is connected to phase 2).
Remember to consider the power factor. Ie (kW = kVA x powerfactor)
The 7000 series controller is true RMS measuring so gives more accurate display when compared with an `average' meter such as an analogue panel meter or some lower specified digital multimeters.
Accuracy of the controller is better than 1% of full scale. Ie Gen volts full scale is 333V ph-n so accuracy is ±3.33V (1% of 333V).
NOTE:- The above fault finding is provided as a guide check-list only. As the module can be configured to provide a wide range of different features, always refer to the source of your module configuration if in doubt.
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11 FACTORY DEFAULT CONFIGURATION
NOTE:- Flexible sensor not available on DSE7200 series controllers.
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NOTE:- The following timers are not available on DSE7210 / DSE7310 controllers: - Mains Transient Delay - Transfer time
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NOTE:- Mains settings are not available on DSE7210 / DSE7310 controllers.
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NOTE:- Communications settings are not available on DSE7200 series controllers.
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12 MAINTENANCE, SPARES, REPAIR AND SERVICING
The DSE7000 Series controller is designed to be Fit and Forget. As such, there are no user serviceable parts within the controller. In the case of malfunction, you should contact your original equipment supplier (OEM).
12.1 PURCHASING ADDITIONAL CONNECTOR PLUGS FROM DSE
12.1.1 DSE7200 SERIES
If you require additional plugs from DSE, please contact our Sales department using the part numbers below.
7000 series terminal designation 1-11 15-18 22-30 39-46 47-50 51-56 60-65 60-67
Plug description 11 way 5.08mm
4 way 5.08mm (DSE7200 series only) 9 way 5.08mm 8 way 7.62mm
4 way 7.62mm (Not fitted to DSE7210)
6 way 5.08mm 6 way 5.08mm (DSE7200 series only) 8 way 5.08mm (DSE7300 series only) PC Configuration interface lead (USB type A type B)
Part No. 007-451 007-100 007-167 007-454 007-171 007-446 007-379 007-164 016-125
NOTE:- Terminal 19 is not fitted to DSE72000 series controllers.
NOTE:- Mains sensing (Terminals 47-50) is not fitted on DSE7210 autostart controller.
NOTE:- RS485 connector is not fitted to the 7200 series controller.
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12.1.2 DSE7300 SERIES
If you require additional plugs from DSE, please contact our Sales department using the part numbers below.
7000 series terminal designation 1-11 15-19 22-30 39-46 47-50 51-56 60-67 RS485
Plug description 11 way 5.08mm
5 way 5.08mm 9 way 5.08mm 8 way 7.62mm
4 way 7.62mm (Not fitted to DSE7310)
6 way 5.08mm 8 way 5.08mm (DSE7300 series only) 3 way 5.08mm PC Configuration interface lead (USB type A type B)
Part No. 007-451 007-445 007-167 007-454 007-171 007-446 007-164 007-174 016-125
NOTE:- Mains sensing (Terminals 47-50) is not fitted on DSE7310 autostart controller.
12.2 PURCHASING ADDITIONAL FIXING CLIPS FROM DSE
Item
Description
7000 series fixing clips (packet of 4)
Part No. 020-294
12.3 PURCHASING ADDITIONAL SEALING GASKET FROM DSE
Item
Description
7000 series silicon sealing gasket
Part No. 020-507
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12.4 EXPANSION MODULES
NOTE:- Expansion modules are not compatible with the DSE7200 series controllers.
NOTE:- A maximum of twenty (20) expansion modules can be connected to the DSENet.
Item
Description
DSE Part numbers Sales literature Operator manual
Model DSE2130 expansion input module provides additional analogue and digital inputs for use with the 7320 controller.
055-060
057-082
Up to 4 DSE2130s can be fitted to the 73x0 module at one time. Model DSE2157 expansion relay module provides eight additional voltage free relays for use with the 73x0 controller
055-061
057-083
Up to 10 DSE2157s can be fitted to the 73x0 module at one time.
Model DSE2548 expansion LED module provides additional LED indications for use with the 73x0 controller.
Up to 10 DSE2548s can be fitted to the 73x0 module at one time.
055-062
057-084
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13 WARRANTY
DSE provides limited warranty to the equipment purchaser at the point of sale. For full details of any applicable warranty, you are referred to your original equipment supplier (OEM).
14 DISPOSAL
14.1 WEEE (WASTE ELECTRICAL AND ELECTRONIC EQUIPMENT)
Directive 2002/96/EC If you use electrical and electronic equipment you must store, collect, treat, recycle and dispose of WEEE separately from your other waste.
14.2 ROHS (RESTRICTION OF HAZARDOUS SUBSTANCES)
Directive 2002/95/EC:2006 To remove specified hazardous substances (Lead, Mercury, Hexavalent Chromium, Cadmium, PBB & PBDE´s) Exemption Note: Category 9. (Monitoring & Control Instruments) as defined in Annex 1B of the WEEE directive will be exempt from the RoHS legislation. This was confirmed in the August 2005 UK´s Department of Trade and Industry RoHS REGULATIONS Guide (Para 11). Despite this exemption DSE has been carefully removing all non RoHS compliant components from our supply chain and products. When this is completed a Lead Free & RoHS compatible manufacturing process will be phased into DSE production. This is a process that is almost complete and is being phased through different product groups.
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15 APPENDIX
15.1 IDMT TRIPPING CURVES (TYPICAL)
NOTE:- The factory default settings of tripping curve 36 and trip level of 100% of full load allows for the set to run at 110% of full load for one hour.
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15.2 SENSOR WIRING RECOMMENDATIONS 15.2.1 EARTH RETURN SENSORS
Connection Name
Terminal Number
Sensor common Oil pressure Sensor
15
NOTE:- . It is important that terminal 15 (sensor
common) is soundly connected to an earth point on the
ENGINE BLOCK, not within the control panel, and must
16
be a sound electrical connection to the sensor bodies.
Coolant temperature sensor
Fuel level sensor
17
NOTE:- . If you use PTFE insulating tape on the sensor thread when using earth return sensors, ensure
you do not insulate the entire thread, as this will prevent
the sensor body from being earthed via the engine block. 18
Flexible Sensor (Not fitted to 7200 series)
19
15.2.2 INSULATED RETURN SENSORS
Connection Name
Terminal Number
Sensor common Oil pressure Sensor
15
NOTE:- . It is important that terminal 15 (sensor
common) is soundly connected to an earth point on the
ENGINE BLOCK, not within the control panel.
16
Coolant temperature sensor
17
Fuel level sensor
18
Flexible Sensor (Not fitted to 7200 series)
19
15.3 CAN INTERFACE
Modules are fitted with the CAN interface as standard and are capable of receiving engine data from engine CAN controllers compliant with the CAN standard. CAN enabled engine controllers monitor the engines operating parameters such as engine speed, oil pressure, engine temperature (among others) in order to closely monitor and control the engine. The industry standard communications interface (CAN) transports data gathered by the engine controller interface (CAN). This allows generator controllers such as the DSE 73x0 range to access these engine parameters with no physical connection to the sensor device.
NOTE:- For further details for connections to CAN enabled engines and the functions available with each engine type, refer to the manual Electronic Engines and DSE Wiring. Part No. 057-004
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15.4 COMMUNICATIONS OPTION CONNECTIONS 15.4.1 DESCRIPTION
The 7000 series configuration software allows the controller to communicate with a PC. The computer connects to the module as shown below. The operator is then able to control the module, starting or stopping the generator, selecting operating modes, etc. The various operating parameters (such as output volts, oil pressure, etc.) of the remote generator can be viewed. 15.4.2 PC TO CONTROLLER (DIRECT) CONNECTION To connect a 7000 series module to a PC the following items are required: -
· 7000 series module
· 7000 series configuration software (Supplied on configuration suite software CD).
· USB cable Type A to Type B.
NOTE:- The DC supply must be connected to the module for configuration by PC. NOTE:- Refer to 7xxx software Manual for further details on configuring, monitoring and control.
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15.5 ENCLOSURE CLASSIFICATIONS
IP CLASSIFICATIONS
7000 series specification under BS EN 60529 Degrees of protection provided by enclosures
IP65 (Front of module when module is installed into the control panel with the optional sealing gasket). IP42 (front of module when module is installed into the control panel WITHOUT being sealed to the panel)
First Digit
Second Digit
Protection against contact and ingress of solid objects
Protection against ingress of water
0 No protection
0 No protection
1 Protected against ingress solid objects with a diameter 1 Protection against dripping water falling vertically. No
of more than 50 mm. No protection against deliberate
harmful effect must be produced (vertically falling drops).
access, e.g. with a hand, but large surfaces of the
body are prevented from approach.
2 Protected against penetration by solid objects with a diameter of more than 12 mm. Fingers or similar objects prevented from approach.
2 Protection against dripping water falling vertically. There must be no harmful effect when the equipment (enclosure) is tilted at an angle up to 15°from it s normal position (drops falling at an angle).
3 Protected against ingress of solid objects with a
3 Protection against water falling at any angle up to 60°
diameter of more than 2.5 mm. Tools, wires etc. with a
from the vertical. There must be no harmful effect (spray
thickness of more than 2.5 mm are prevented from
water).
approach.
4 Protected against ingress of solid objects with a diameter of more than 1 mm. Tools, wires etc. with a thickness of more than 1 mm are prevented from approach.
4 Protection against water splashed against the equipment (enclosure) from any direction. There must be no harmful effect (splashing water).
5 Protected against harmful dust deposits. Ingress of
5 Protection against water projected from a nozzle against
dust is not totally prevented but the dust must not
the equipment (enclosure) from any direction. There must
enter in sufficient quantity to interface with satisfactory
be no harmful effect (water jet).
operation of the equipment. Complete protection
against contact.
6 Protection against ingress of dust (dust tight). Complete protection against contact.
6 Protection against heavy seas or powerful water jets. Water must not enter the equipment (enclosure) in harmful quantities (splashing over).
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DSE Model 7000 Series Control & Instrumentation System Operators Manual
NEMA CLASSIFICATIONS
7000 series NEMA Rating (Approximate) 12 (Front of module when module is installed into the control panel with the optional sealing gasket). 2 (front of module when module is installed into the control panel WITHOUT being sealed to the panel)
NOTE: - There is no direct equivalence between IP / NEMA ratings. IP figures shown are approximate only.
1
Provides a degree of protection against contact with the enclosure equipment and against a limited amount of falling dirt.
IP30
2
Provides a degree of protection against limited amounts of falling water and dirt.
IP31
3
Provides a degree of protection against windblown dust, rain and sleet; undamaged by the formation of ice on the enclosure.
IP64
3R
Provides a degree of protection against rain and sleet:; undamaged by the formation of ice on the enclosure.
IP32
4 (X) IP66
Provides a degree of protection against splashing water, windblown dust and rain, hose directed water; undamaged by the formation of ice on the enclosure. (Resist corrosion).
12/12K Provides a degree of protection against dust, falling dirt and dripping non corrosive liquids.
IP65
13
Provides a degree of protection against dust and spraying of water, oil and non corrosive coolants.
IP65
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SPARE PARTS & SERVICE
Service & Maintenance History
Serial No.:
Page No.:
Date Eng. Hr.
Scope of Work Completed
Serviced by
PLEASE DIRECT ALL SPARE PARTS, SERVICE AND MAINTENANCE ENQUIRIES TO
ENERAQUE
1937 IPSWICH ROAD, ROCKLEA, QLD 4106 PO BOX 3306, TINGALPA BC. QLD 4173 T 1800 636 744 / F +61 7 3434 3593
FOR EMERGENCY SERVICE CALL 1800 636 744
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SPARE PARTS & SERVICE
Service & Maintenance History
Serial No.:
Page No.:
Date Eng. Hr.
Scope of Work Completed
Serviced by
PLEASE DIRECT ALL SPARE PARTS, SERVICE AND MAINTENANCE ENQUIRIES TO
ENERAQUE
1937 IPSWICH ROAD, ROCKLEA, QLD 4106 PO BOX 3306, TINGALPA BC. QLD 4173 T 1800 636 744 / F +61 7 3434 3593
FOR EMERGENCY SERVICE CALL 1800 636 744
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SPARE PARTS & SERVICE
Service & Maintenance History
Serial No.:
Page No.:
Date Eng. Hr.
Scope of Work Completed
Serviced by
PLEASE DIRECT ALL SPARE PARTS, SERVICE AND MAINTENANCE ENQUIRIES TO
ENERAQUE
1937 IPSWICH ROAD, ROCKLEA, QLD 4106 PO BOX 3306, TINGALPA BC. QLD 4173 T 1800 636 744 / F +61 7 3434 3593
FOR EMERGENCY SERVICE CALL 1800 636 744
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SPARE PARTS & SERVICE
Service & Maintenance History
Serial No.:
Page No.:
Date Eng. Hr.
Scope of Work Completed
Serviced by
PLEASE DIRECT ALL SPARE PARTS, SERVICE AND MAINTENANCE ENQUIRIES TO
ENERAQUE
1937 IPSWICH ROAD, ROCKLEA, QLD 4106 PO BOX 3306, TINGALPA BC. QLD 4173 T 1800 636 744 / F +61 7 3434 3593
FOR EMERGENCY SERVICE CALL 1800 636 744
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SPARE PARTS & SERVICE
Service & Maintenance History
Serial No.:
Page No.:
Date Eng. Hr.
Scope of Work Completed
Serviced by
PLEASE DIRECT ALL SPARE PARTS, SERVICE AND MAINTENANCE ENQUIRIES TO
ENERAQUE
1937 IPSWICH ROAD, ROCKLEA, QLD 4106 PO BOX 3306, TINGALPA BC. QLD 4173 T 1800 636 744 / F +61 7 3434 3593
FOR EMERGENCY SERVICE CALL 1800 636 744
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SPARE PARTS & SERVICE
Service & Maintenance History
Serial No.:
Page No.:
Date Eng. Hr.
Scope of Work Completed
Serviced by
PLEASE DIRECT ALL SPARE PARTS, SERVICE AND MAINTENANCE ENQUIRIES TO
ENERAQUE
1937 IPSWICH ROAD, ROCKLEA, QLD 4106 PO BOX 3306, TINGALPA BC. QLD 4173 T 1800 636 744 / F +61 7 3434 3593
FOR EMERGENCY SERVICE CALL 1800 636 744
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SPARE PARTS & SERVICE
Service & Maintenance History
Serial No.:
Page No.:
Date Eng. Hr.
Scope of Work Completed
Serviced by
PLEASE DIRECT ALL SPARE PARTS, SERVICE AND MAINTENANCE ENQUIRIES TO
ENERAQUE
1937 IPSWICH ROAD, ROCKLEA, QLD 4106 PO BOX 3306, TINGALPA BC. QLD 4173 T 1800 636 744 / F +61 7 3434 3593
FOR EMERGENCY SERVICE CALL 1800 636 744
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SPARE PARTS & SERVICE
Service & Maintenance History
Serial No.:
Page No.:
Date Eng. Hr.
Scope of Work Completed
Serviced by
PLEASE DIRECT ALL SPARE PARTS, SERVICE AND MAINTENANCE ENQUIRIES TO
ENERAQUE
1937 IPSWICH ROAD, ROCKLEA, QLD 4106 PO BOX 3306, TINGALPA BC. QLD 4173 T 1800 636 744 / F +61 7 3434 3593
FOR EMERGENCY SERVICE CALL 1800 636 744
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6 Test Results
C63100-WB065_Manual_DRAFT.doc Revision 0
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Compliance Certificate for building Design or Specification
15
NOTE
This is to be used for the purposes of section 10 of the Building Act 1975 and/or section 46 of the Building Regulation 2006.
RESTRICTION: A building certifier (class B) can only give a compliance certificate about whether building work complies with the BCA or a provision of the QDC. A building certifier (Class B) can not give a certificate regarding QDC boundary clearance and site cover provisions.
1. Property description This section need only be completed if details of street address and property description are applicable. EG. In the case of (standard/generic) pool design/shell manufacture and/or patio and carport systems this section may not be applicable.
The description must identify all land the subject of the application.
The lot & plan details (eg. SP / RP) are shown on title documents or a rates notice.
If the plan is not registered by title, provide previous lot and plan details.
2. Description of component/s certified
Clearly describe the extent of work covered by this certificate, e.g. all structural aspects of the steel roof beams.
Street address (include no., street, suburb / locality & postcode) Sieb Street KILCOY
Lot & plan details (attach list if necessary) In which local government area is the land situated?
Pump well and valve pit plus aluminium cover to pump well
Postcode
3. Basis of certification
Detail the basis for giving the certificate and the extent to which tests, specifications, rules, standards, codes of practice and other publications, were relied upon.
AS3996 : 2006 - Australian Standard Load Classifications - Class B AS1170.2 - 2002 Loading Code AS/NZS1664.1 - 1997 Aluminium Structures AS3600 - 2001 Concrete Structures Principles of structural mechanics
LOCAL GOVERNMENT USE ONLY
Date received
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Form 15 continued
4. Reference documentation
Clearly identify any relevant documentation, e.g. numbered structural engineering plans.
Hughes, Beal and Wright Pty Ltd drawings 2013-067-1C, 2C, 3A, 4A, 5A, 6A, 7A, Drawings 1 and 12 dated the latter five dated 18/08/13
5. Building certifier reference number Building certifier reference number
6. Competent person details
A competent person for building work, means a person who is assessed by the building certifier for the work as competent to practise in an aspect of the building and specification design, of the building work because of the individual's skill, experience and qualifications in the aspect. The competent person must also be registered or licensed under a law applying in the State to practice the aspect.
If no relevant law requires the individual to be licensed or registered to be able to give the help, the certifier must assess the individual as having appropriate experience, qualifications or skills to be able to give the help.
If the chief executive issues any guidelines for assessing a competent person, the building certifier must use the guidelines when assessing the person.
Name (in full) Peter Geoffrey Wright
Company name (if applicable) Hughes, Beal and Wright Pty Ltd
Phone no. business hours 07 3814 4993
Mobile no. 0418 745 342
Email address peterwright01@optusnet.com.au
Postal address 11 Wilkie Avenue
REDBANK PLAINS
Licence or registration number (if applicable) RPEQ 1193
7. Signature of competent person
This certificate must be signed by the individual assessed by the building certifier as competent.
Signature
Contact person Peter Wright Fax no.
Postcode 4301
Date 13 December 2013
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Version 4 March 2013
Form 16--Inspection Certificate / Aspect Certificate / QBSA Licensee Aspect Certificate
NOTE 1. Indicate the type of certificate
This form is to be used for the purposes of section 10(c) and 239 of the Building Act 1975 and/or sections 32, 35B, 43, 44 and 47 of the Building Regulation 2006.
Inspection Certificate for
The stages of assessable building work are listed in section 24 of the Building Regulation 2006 or as conditioned by the building certifier.
An aspect of building work is part of a stage (e.g. waterproofing).
Stage of building work (for single detached class 1a or class 10 building or structure)
(indicate the stage)
________________________________________
Aspect of building work (indicate the aspect)
Pump and valve pit
QBSA Licensee Aspect Certificate Scope of the work Scope of the work covered by the licence class under the Queensland Building Services Authority Regulation 2003 for the aspect being certified, e.g. scope of work for a waterproofing licence is "installing waterproofing materials or systems for preventing moisture penetration". An aspect being certified may include "wet area sealing to showers".
2. Property description
The description must identify all land the subject of the application.
The lot & plan details (eg. SP / RP) are shown on title documents or a rates notice. If the plan is not registered by title, provide previous lot and plan details.
Street address (Include no., street, suburb / locality & postcode)
Sieb Street KILCOY
Lot & plan details (Attach list if necessary)
In which local government area is the land situated?
3. Building/structure description
Building/structure description
Postcode Class of building / structure
LOCAL GOVERNMENT USE ONLY
DATE RECEIVED
REFERENCE NUMBER/S
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4. Description of component/s certified Clearly describe the extent of work covered by this certificate, e.g. all structural aspects of the steel roof beams.
5. Basis of certification Detail the basis for giving the certificate and the extent to which tests, specifications, rules, standards, codes of practice and other publications, were relied upon.
Prefabricated Concrete Pump Pit floor and wall reinforcing gages prior to placement in excavations. Prefabricated Concrete Pump Pit roof reinforcement in place prior to placement of concrete. Prefabricated Concrete Valve Pump Pit floor and wall reinforcing gages prior to placement of concrete.
The floor and wall reinforcement was of the specified size and spacing. The reinforcement in the pump pit lit was of the required size, spacing and in the correct location prior to casting concrete.
6. Reference documentation Clearly identify any relevant documentation, e.g. numbered structural engineering plans.
Hughes, Beal and Wright Pty Ltd drawings 2013-067-1C, 2C, 3A, 4A, 5A, 6A, 7A, dated 18/08/13
7. Building certifier reference number and development approval number
Building certifier reference number
Development approval number
8. Building Certifier, competent person or QBSA licensee details
A competent person must be assessed as competent before carrying out the inspection.
The builder for the work cannot give a stage certificate of inspection.
A competent person is assessed by the building certifier for the work as competent to practice in an aspect of the building and specification design, because of the individual's skill, experience and qualifications. The competent person must be registered or licensed under a law applying in the State to practice the aspect.
If no relevant law requires the individual to be licensed or registered, the certifier must assess the individual as having appropriate experience, qualifications or skills to be able to give the help.
If the chief executive issues any guidelines for assessing a competent person, the building certifier must use the guidelines when assessing the person.
Name (in full) Peter Wright
Company name if applicable Hughes, Beal & Wright Pty Ltd
Contact person Peter Wright
Phone no. business hours 07 3814 4993
Mobile no.
Fax no.
Email address peterwright01@optusnet.com.au
Postal address 11 Wilkie Avenue REDBANK PLAINS
Postcode 4301
Licence class
Licence number RPEQ 1193
Date approval to inspect received from building certifier
9. Signature of building certifier, competent person or QBSA licensee
Note: A building certifier must sign this form for temporary swimming pool fencing under section 4 of Schedule 1 of QDC MP 3.4.
Signature
Date 13 December 2013
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual J & P Richardson Industries Pty Ltd
7 "AS INSTALLED" Drawings
C63100-WB065_Manual_DRAFT.doc Revision 0
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13
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A
A
B
B
C
C
D
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E
F
F
AS CONSTRUCTED DETAILS
I CERTIFY THAT THE "AS CONSTRUCTED" DETAILS
G
SHOWN ON THIS PLAN ARE A TRUE AND ACCURATE
G
RECORD OF THE WORKS.
SIGNED:
DATE:
NAME of SIGNATORY:
WB196
RPEQ No. or LICENCE: COMPANY NAME: START DATE:
FINISH DATE:
H
SEIB STREET, KILCOY
H
WATER BOOSTER
I
I
SITE COVER SHEET
NAME
SIGNATURE
DATE
QUEENSLAND URBAN UTILITIES DELEGATE (AUTHORISED FOR 12 MONTHS FROM DATE SHOWN)
J
C 12.13 AMEND PUMP ID
B 10.13 AS CONSTRUCTED
D 12.13 AS INSTALLED
DATE
AMENDMENT
1
2
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3
FUNDING
DESIGN W.O. No.
QUUXXX
SOA XXXXX-XXX
FUNDED BY Q.U.U. (9) EXTERNAL ( )
DRAFTED
LIEN LE
DRAFTING CHECK LUCAS WEDLEY
CAD FILE
Q.U.U. FILE No.
4
5
6
LUCAS WEDLEY DESIGN ORIGINAL SIGNED BY DESIGN CHECK
7
24/01/13
R.P.E.Q. No. DATE
APPROVED BY
SIGNATURE DATE
R.P.E.Q. No. DATE 8
CONSTRUCTION MANAGER 9
SIGNATURE DATE 10
WB196 ASSET/PROJECT SEIB STREET - KILCOY WATER BOOSTER
11
12
DRAWING TITLE
ELECTRICAL DRAWING INDEX
13
14
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QUEENSLAND URBAN UTILITIES DRAWING No.
AMEND.
D
15
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A
A
B
B
C
C
D
D
E
E
F
F
AS CONSTRUCTED DETAILS
I CERTIFY THAT THE "AS CONSTRUCTED" DETAILS
G
SHOWN ON THIS PLAN ARE A TRUE AND ACCURATE
G
RECORD OF THE WORKS.
SIGNED:
DATE:
NAME of SIGNATORY:
RPEQ No. or LICENCE:
COMPANY NAME:
START DATE:
FINISH DATE:
H
H
I
I
NAME
SIGNATURE
DATE
QUEENSLAND URBAN UTILITIES DELEGATE (AUTHORISED FOR 12 MONTHS FROM DATE SHOWN)
J
C 12.13 AMEND PUMP ID
B 10.13 AS CONSTRUCTED
D 12.13 AS INSTALLED
DATE
AMENDMENT
1
2
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3
FUNDING
DESIGN W.O. No.
QUUXXX
SOA XXXXX-XXX
FUNDED BY Q.U.U. (9) EXTERNAL ( )
DRAFTED
LIEN LE
DRAFTING CHECK LUCAS WEDLEY
CAD FILE
Q.U.U. FILE No.
4
5
6
LUCAS WEDLEY DESIGN ORIGINAL SIGNED BY DESIGN CHECK
7
24/01/13
R.P.E.Q. No. DATE
APPROVED BY
SIGNATURE DATE
R.P.E.Q. No. DATE 8
CONSTRUCTION MANAGER 9
SIGNATURE DATE 10
WB196 ASSET/PROJECT SEIB STREET - KILCOY WATER BOOSTER
11
12
DRAWING TITLE
BLOCK DIAGRAM
13
14
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AMEND.
D
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A
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B
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F
AS CONSTRUCTED DETAILS
I CERTIFY THAT THE "AS CONSTRUCTED" DETAILS
G
SHOWN ON THIS PLAN ARE A TRUE AND ACCURATE
G
RECORD OF THE WORKS.
SIGNED:
DATE:
NAME of SIGNATORY:
RPEQ No. or LICENCE:
COMPANY NAME:
START DATE:
FINISH DATE:
H
H
I
I
NAME
SIGNATURE
DATE
QUEENSLAND URBAN UTILITIES DELEGATE (AUTHORISED FOR 12 MONTHS FROM DATE SHOWN)
J
C 12.13 AMEND PUMP ID
B 10.13 AS CONSTRUCTED
D 12.13 AS INSTALLED
DATE
AMENDMENT
1
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Q-Pulse Id: TMS1594
P.C. P.C. L.L. M.F. L.L. M.F.
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FUNDING
DESIGN W.O. No.
QUUXXX
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APPROVED BY
SIGNATURE DATE
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CONSTRUCTION MANAGER 9
SIGNATURE DATE 10
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SHOWN ON THIS PLAN ARE A TRUE AND ACCURATE
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RECORD OF THE WORKS.
SIGNED:
DATE:
NAME of SIGNATORY:
RPEQ No. or LICENCE:
COMPANY NAME:
START DATE:
FINISH DATE:
H
H
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SIGNATURE
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QUEENSLAND URBAN UTILITIES DELEGATE (AUTHORISED FOR 12 MONTHS FROM DATE SHOWN)
J
C 12.13 AMEND PUMP ID
B 10.13 AS CONSTRUCTED
D 12.13 AS INSTALLED
DATE
AMENDMENT
1
2
Q-Pulse Id: TMS1594
P.C. P.C. L.L. M.F. L.L. M.F.
3
FUNDING
DESIGN W.O. No.
QUUXXX
SOA XXXXX-XXX
FUNDED BY Q.U.U. (9) EXTERNAL ( )
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Q.U.U. FILE No.
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APPROVED BY
SIGNATURE DATE
R.P.E.Q. No. DATE 8
CONSTRUCTION MANAGER 9
SIGNATURE DATE 10
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SHOWN ON THIS PLAN ARE A TRUE AND ACCURATE
G
RECORD OF THE WORKS.
SIGNED:
DATE:
NAME of SIGNATORY:
RPEQ No. or LICENCE:
COMPANY NAME:
START DATE:
FINISH DATE:
H
H
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NAME
SIGNATURE
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QUEENSLAND URBAN UTILITIES DELEGATE (AUTHORISED FOR 12 MONTHS FROM DATE SHOWN)
J
C 12.13 AMEND PUMP ID
B 10.13 AS CONSTRUCTED
D 12.13 AS INSTALLED
DATE
AMENDMENT
1
2
Q-Pulse Id: TMS1594
P.C. P.C. L.L. M.F. L.L. M.F.
3
FUNDING
DESIGN W.O. No.
QUUXXX
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FUNDED BY Q.U.U. (9) EXTERNAL ( )
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Q.U.U. FILE No.
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24/01/13
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APPROVED BY
SIGNATURE DATE
R.P.E.Q. No. DATE 8
CONSTRUCTION MANAGER 9
SIGNATURE DATE 10
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I CERTIFY THAT THE "AS CONSTRUCTED" DETAILS
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SHOWN ON THIS PLAN ARE A TRUE AND ACCURATE
G
RECORD OF THE WORKS.
SIGNED:
DATE:
NAME of SIGNATORY:
RPEQ No. or LICENCE:
COMPANY NAME:
START DATE:
FINISH DATE:
H
H
I
I
NAME
SIGNATURE
DATE
QUEENSLAND URBAN UTILITIES DELEGATE (AUTHORISED FOR 12 MONTHS FROM DATE SHOWN)
J
C 12.13 AMEND PUMP ID
B 10.13 AS CONSTRUCTED
D 12.13 AS INSTALLED
DATE
AMENDMENT
1
2
Q-Pulse Id: TMS1594
P.C. P.C. L.L. M.F. L.L. M.F.
3
FUNDING
DESIGN W.O. No.
QUUXXX
SOA XXXXX-XXX
FUNDED BY Q.U.U. (9) EXTERNAL ( )
DRAFTED
LIEN LE
DRAFTING CHECK LUCAS WEDLEY
CAD FILE
Q.U.U. FILE No.
4
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7
24/01/13
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APPROVED BY
SIGNATURE DATE
R.P.E.Q. No. DATE 8
CONSTRUCTION MANAGER 9
SIGNATURE DATE 10
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SHOWN ON THIS PLAN ARE A TRUE AND ACCURATE
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RECORD OF THE WORKS.
SIGNED:
DATE:
NAME of SIGNATORY:
RPEQ No. or LICENCE:
COMPANY NAME:
START DATE:
FINISH DATE:
H
H
I
I
NAME
SIGNATURE
DATE
QUEENSLAND URBAN UTILITIES DELEGATE (AUTHORISED FOR 12 MONTHS FROM DATE SHOWN)
J
C 12.13 AMEND PUMP ID
B 10.13 AS CONSTRUCTED
D 12.13 AS INSTALLED
DATE
AMENDMENT
1
2
Q-Pulse Id: TMS1594
P.C. P.C. L.L. M.F. L.L. M.F.
3
FUNDING
DESIGN W.O. No.
QUUXXX
SOA XXXXX-XXX
FUNDED BY Q.U.U. (9) EXTERNAL ( )
DRAFTED
LIEN LE
DRAFTING CHECK LUCAS WEDLEY
CAD FILE
Q.U.U. FILE No.
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7
24/01/13
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APPROVED BY
SIGNATURE DATE
R.P.E.Q. No. DATE
CONSTRUCTION MANAGER
8
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I CERTIFY THAT THE "AS CONSTRUCTED" DETAILS
G
SHOWN ON THIS PLAN ARE A TRUE AND ACCURATE
G
RECORD OF THE WORKS.
SIGNED:
DATE:
NAME of SIGNATORY:
RPEQ No. or LICENCE:
COMPANY NAME:
START DATE:
FINISH DATE:
H
H
I
I
NAME
SIGNATURE
DATE
QUEENSLAND URBAN UTILITIES DELEGATE (AUTHORISED FOR 12 MONTHS FROM DATE SHOWN)
J
C 12.13 AMEND PUMP ID
B 10.13 AS CONSTRUCTED
D 12.13 AS INSTALLED
DATE
AMENDMENT
1
2
Q-Pulse Id: TMS1594
P.C. P.C. L.L. M.F. L.L. M.F.
3
FUNDING
DESIGN W.O. No.
QUUXXX
SOA XXXXX-XXX
FUNDED BY Q.U.U. (9) EXTERNAL ( )
DRAFTED
LIEN LE
DRAFTING CHECK LUCAS WEDLEY
CAD FILE
Q.U.U. FILE No.
4
5
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LUCAS WEDLEY DESIGN ORIGINAL SIGNED BY DESIGN CHECK
7
24/01/13
R.P.E.Q. No. DATE
APPROVED BY
SIGNATURE DATE
R.P.E.Q. No. DATE 8
CONSTRUCTION MANAGER 9
SIGNATURE DATE 10
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I CERTIFY THAT THE "AS CONSTRUCTED" DETAILS
G
SHOWN ON THIS PLAN ARE A TRUE AND ACCURATE
G
RECORD OF THE WORKS.
SIGNED:
DATE:
NAME of SIGNATORY:
RPEQ No. or LICENCE:
COMPANY NAME:
START DATE:
FINISH DATE:
H
H
I
I
NAME
SIGNATURE
DATE
QUEENSLAND URBAN UTILITIES DELEGATE (AUTHORISED FOR 12 MONTHS FROM DATE SHOWN)
J
C 12.13 AMEND PUMP ID
B 10.13 AS CONSTRUCTED
D 12.13 AS INSTALLED
DATE
AMENDMENT
1
2
Q-Pulse Id: TMS1594
P.C. P.C. L.L. M.F. L.L. M.F.
3
FUNDING
DESIGN W.O. No.
QUUXXX
SOA XXXXX-XXX
FUNDED BY Q.U.U. (9) EXTERNAL ( )
DRAFTED
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DRAFTING CHECK LUCAS WEDLEY
CAD FILE
Q.U.U. FILE No.
4
5
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7
24/01/13
R.P.E.Q. No. DATE
APPROVED BY
SIGNATURE DATE
R.P.E.Q. No. DATE 8
CONSTRUCTION MANAGER 9
SIGNATURE DATE 10
WB196 ASSET/PROJECT SEIB STREET - KILCOY WATER BOOSTER
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PUMPS CONTROL
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TERMINATION DIAGRAM
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I CERTIFY THAT THE "AS CONSTRUCTED" DETAILS
G
SHOWN ON THIS PLAN ARE A TRUE AND ACCURATE
G
RECORD OF THE WORKS.
SIGNED:
DATE:
NAME of SIGNATORY:
RPEQ No. or LICENCE:
COMPANY NAME:
START DATE:
FINISH DATE:
H
H
I
I
NAME
SIGNATURE
DATE
QUEENSLAND URBAN UTILITIES DELEGATE (AUTHORISED FOR 12 MONTHS FROM DATE SHOWN)
J
C 12.13 AMEND PUMP ID
B 10.13 AS CONSTRUCTED
D 12.13 AS INSTALLED
DATE
AMENDMENT
1
2
Q-Pulse Id: TMS1594
P.C. P.C. L.L. M.F. L.L. M.F.
3
FUNDING
DESIGN W.O. No.
QUUXXX
SOA XXXXX-XXX
FUNDED BY Q.U.U. (9) EXTERNAL ( )
DRAFTED
LIEN LE
DRAFTING CHECK LUCAS WEDLEY
CAD FILE
Q.U.U. FILE No.
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24/01/13
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APPROVED BY
SIGNATURE DATE
R.P.E.Q. No. DATE 8
CONSTRUCTION MANAGER 9
SIGNATURE DATE 10
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I CERTIFY THAT THE "AS CONSTRUCTED" DETAILS
G
SHOWN ON THIS PLAN ARE A TRUE AND ACCURATE
G
RECORD OF THE WORKS.
SIGNED:
DATE:
NAME of SIGNATORY:
RPEQ No. or LICENCE:
COMPANY NAME:
START DATE:
FINISH DATE:
H
H
I
I
NAME
SIGNATURE
DATE
QUEENSLAND URBAN UTILITIES DELEGATE (AUTHORISED FOR 12 MONTHS FROM DATE SHOWN)
J
C 12.13 AMEND PUMP ID
B 10.13 AS CONSTRUCTED
D 12.13 AS INSTALLED
DATE
AMENDMENT
1
2
Q-Pulse Id: TMS1594
P.C. P.C. L.L. M.F. L.L. M.F.
3
FUNDING
DESIGN W.O. No.
QUUXXX
SOA XXXXX-XXX
FUNDED BY Q.U.U. (9) EXTERNAL ( )
DRAFTED
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CAD FILE
Q.U.U. FILE No.
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7
24/01/13
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APPROVED BY
SIGNATURE DATE
R.P.E.Q. No. DATE
CONSTRUCTION MANAGER
8
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SIGNATURE DATE 10
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I CERTIFY THAT THE "AS CONSTRUCTED" DETAILS
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SHOWN ON THIS PLAN ARE A TRUE AND ACCURATE
G
RECORD OF THE WORKS.
SIGNED:
DATE:
NAME of SIGNATORY:
RPEQ No. or LICENCE:
COMPANY NAME:
START DATE:
FINISH DATE:
H
H
I
I
NAME
SIGNATURE
DATE
QUEENSLAND URBAN UTILITIES DELEGATE (AUTHORISED FOR 12 MONTHS FROM DATE SHOWN)
J
C 12.13 AMEND PUMP ID
B 10.13 AS CONSTRUCTED
D 12.13 AS INSTALLED
DATE
AMENDMENT
1
2
Q-Pulse Id: TMS1594
P.C. P.C. L.L. M.F. L.L. M.F.
3
FUNDING
DESIGN W.O. No.
QUUXXX
SOA XXXXX-XXX
FUNDED BY Q.U.U. (9) EXTERNAL ( )
DRAFTED
LIEN LE
DRAFTING CHECK LUCAS WEDLEY
CAD FILE
Q.U.U. FILE No.
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5
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7
24/01/13
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APPROVED BY
SIGNATURE DATE
R.P.E.Q. No. DATE 8
CONSTRUCTION MANAGER 9
SIGNATURE DATE 10
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I CERTIFY THAT THE "AS CONSTRUCTED" DETAILS
G
SHOWN ON THIS PLAN ARE A TRUE AND ACCURATE
G
RECORD OF THE WORKS.
SIGNED:
DATE:
NAME of SIGNATORY:
RPEQ No. or LICENCE:
COMPANY NAME:
START DATE:
FINISH DATE:
H
H
I
I
NAME
SIGNATURE
DATE
QUEENSLAND URBAN UTILITIES DELEGATE (AUTHORISED FOR 12 MONTHS FROM DATE SHOWN)
J
C 12.13 AMEND PUMP ID
B 10.13 AS CONSTRUCTED
D 12.13 AS INSTALLED
DATE
AMENDMENT
1
2
Q-Pulse Id: TMS1594
P.C. P.C. L.L. M.F. L.L. M.F.
3
FUNDING
DESIGN W.O. No.
QUUXXX
SOA XXXXX-XXX
FUNDED BY Q.U.U. (9) EXTERNAL ( )
DRAFTED
LIEN LE
DRAFTING CHECK LUCAS WEDLEY
CAD FILE
Q.U.U. FILE No.
4
5
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7
24/01/13
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APPROVED BY
SIGNATURE DATE
R.P.E.Q. No. DATE 8
CONSTRUCTION MANAGER 9
SIGNATURE DATE 10
WB196 ASSET/PROJECT SEIB STREET - KILCOY WATER BOOSTER
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AS CONSTRUCTED DETAILS
I CERTIFY THAT THE "AS CONSTRUCTED" DETAILS
G
SHOWN ON THIS PLAN ARE A TRUE AND ACCURATE
G
RECORD OF THE WORKS.
SIGNED:
DATE:
NAME of SIGNATORY:
RPEQ No. or LICENCE:
COMPANY NAME:
START DATE:
FINISH DATE:
H
H
I
I
NAME
SIGNATURE
DATE
QUEENSLAND URBAN UTILITIES DELEGATE (AUTHORISED FOR 12 MONTHS FROM DATE SHOWN)
J
C 12.13 AMEND PUMP ID
B 10.13 AS CONSTRUCTED
D 12.13 AS INSTALLED
DATE
AMENDMENT
1
2
Q-Pulse Id: TMS1594
P.C. P.C. L.L. M.F. L.L. M.F.
3
FUNDING
DESIGN W.O. No.
QUUXXX
SOA XXXXX-XXX
FUNDED BY Q.U.U. (9) EXTERNAL ( )
DRAFTED
LIEN LE
DRAFTING CHECK LUCAS WEDLEY
CAD FILE
Q.U.U. FILE No.
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24/01/13
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APPROVED BY
SIGNATURE DATE
R.P.E.Q. No. DATE 8
CONSTRUCTION MANAGER 9
SIGNATURE DATE 10
WB196 ASSET/PROJECT SEIB STREET - KILCOY WATER BOOSTER
11
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GENERAL ARRANGEMENT
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AS CONSTRUCTED DETAILS
I CERTIFY THAT THE "AS CONSTRUCTED" DETAILS
G
SHOWN ON THIS PLAN ARE A TRUE AND ACCURATE
G
RECORD OF THE WORKS.
SIGNED:
DATE:
NAME of SIGNATORY:
RPEQ No. or LICENCE:
COMPANY NAME:
START DATE:
FINISH DATE:
H
H
I
I
NAME
SIGNATURE
DATE
QUEENSLAND URBAN UTILITIES DELEGATE (AUTHORISED FOR 12 MONTHS FROM DATE SHOWN)
J
C 12.13 AMEND PUMP ID
B 10.13 AS CONSTRUCTED
D 12.13 AS INSTALLED
DATE
AMENDMENT
1
2
Q-Pulse Id: TMS1594
P.C. P.C. L.L. M.F. L.L. M.F.
3
FUNDING
DESIGN W.O. No.
QUUXXX
SOA XXXXX-XXX
FUNDED BY Q.U.U. (9) EXTERNAL ( )
DRAFTED
LIEN LE
DRAFTING CHECK LUCAS WEDLEY
CAD FILE
Q.U.U. FILE No.
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24/01/13
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APPROVED BY
SIGNATURE DATE
R.P.E.Q. No. DATE 8
CONSTRUCTION MANAGER 9
SIGNATURE DATE 10
WB196 ASSET/PROJECT SEIB STREET - KILCOY WATER BOOSTER
11
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J SHEET No. 15 OF 16
SWITCHBOARD
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SHOWN ON THIS PLAN ARE A TRUE AND ACCURATE
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RECORD OF THE WORKS.
SIGNED:
DATE:
NAME of SIGNATORY:
RPEQ No. or LICENCE:
COMPANY NAME:
START DATE:
FINISH DATE:
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NAME
SIGNATURE
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QUEENSLAND URBAN UTILITIES DELEGATE (AUTHORISED FOR 12 MONTHS FROM DATE SHOWN)
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C 12.13 AMEND PUMP ID
B 10.13 AS CONSTRUCTED
D 12.13 AS INSTALLED
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AMENDMENT
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Q-Pulse Id: TMS1594
P.C. P.C. L.L. M.F. L.L. M.F.
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FUNDING
DESIGN W.O. No.
QUUXXX
SOA XXXXX-XXX
FUNDED BY Q.U.U. (9) EXTERNAL ( )
DRAFTED
LIEN LE
DRAFTING CHECK LUCAS WEDLEY
CAD FILE
Q.U.U. FILE No.
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LUCAS WEDLEY DESIGN ORIGINAL SIGNED BY DESIGN CHECK
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24/01/13
R.P.E.Q. No. DATE
APPROVED BY
SIGNATURE DATE
R.P.E.Q. No. DATE
CONSTRUCTION MANAGER
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SIGNATURE DATE 10
WB196 ASSET/PROJECT SEIB STREET - KILCOY WATER BOOSTER
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QUEENSLAND URBAN UTILITIES DRAWING No. AMEND.
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AS CONSTRUCTED DETAILS
I CERTIFY THAT THE "AS CONSTRUCTED" DETAILS
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SHOWN ON THIS PLAN ARE A TRUE AND ACCURATE
G
RECORD OF THE WORKS.
SIGNED:
DATE:
NAME of SIGNATORY:
RPEQ No. or LICENCE:
COMPANY NAME:
START DATE:
FINISH DATE:
H
H
I
I
NAME
SIGNATURE
DATE
QUEENSLAND URBAN UTILITIES DELEGATE (AUTHORISED FOR 12 MONTHS FROM DATE SHOWN)
J
C 12.13 AMEND PUMP ID
B 10.13 AS CONSTRUCTED
D 12.13 AS INSTALLED
DATE
AMENDMENT
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Q-Pulse Id: TMS1594
P.C. P.C. L.L. M.F. L.L. M.F.
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FUNDING
DESIGN W.O. No.
QUUXXX
SOA XXXXX-XXX
FUNDED BY Q.U.U. (9) EXTERNAL ( )
DRAFTED
LIEN LE
DRAFTING CHECK LUCAS WEDLEY
CAD FILE
Q.U.U. FILE No.
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LUCAS WEDLEY DESIGN ORIGINAL SIGNED BY DESIGN CHECK
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24/01/13
R.P.E.Q. No. DATE
APPROVED BY
SIGNATURE DATE
R.P.E.Q. No. DATE 8
CONSTRUCTION MANAGER 9
SIGNATURE DATE 10
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AS CONSTRUCTED DETAILS
I CERTIFY THAT THE "AS CONSTRUCTED" DETAILS
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SHOWN ON THIS PLAN ARE A TRUE AND ACCURATE
G
RECORD OF THE WORKS.
SIGNED:
DATE:
NAME of SIGNATORY:
RPEQ No. or LICENCE:
COMPANY NAME:
START DATE:
FINISH DATE:
H
H
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NAME
SIGNATURE
DATE
QUEENSLAND URBAN UTILITIES DELEGATE (AUTHORISED FOR 12 MONTHS FROM DATE SHOWN)
J
4 9-13 AS CONSTRUCTED
P.C. P.C.
3 8-13 ADD THRUST BLOCK & NOTE
P.C. P.C.
2 5-13 VENT INDUCT & EDUCT PIPE MODIFIED P.C. P.C.
DATE
AMENDMENT
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Q-Pulse Id: TMS1594
FUNDING
DESIGN W.O. No.
QUU065
SOA C1011-045
FUNDED BY Q.U.U. (9) EXTERNAL ( )
DRAFTED
P. CRISTEA
DRAFTING CHECK P. HOUSTON
CAD FILE
486-4-9-1194-030-2
Q.U.U. FILE No.
B. CLARKE DESIGN ORIGINAL SIGNED BY DESIGN CHECK
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20-2-13
R.P.E.Q. No. DATE
APPROVED BY
SIGNATURE DATE
R.P.E.Q. No. DATE 8
CONSTRUCTION MANAGER 9
SIGNATURE DATE 10
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AS CONSTRUCTED DETAILS
I CERTIFY THAT THE "AS CONSTRUCTED" DETAILS
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SHOWN ON THIS PLAN ARE A TRUE AND ACCURATE
G
RECORD OF THE WORKS.
SIGNED:
DATE:
NAME of SIGNATORY:
RPEQ No. or LICENCE:
COMPANY NAME:
START DATE:
FINISH DATE:
H
H
I
I
NAME
SIGNATURE
DATE
QUEENSLAND URBAN UTILITIES DELEGATE (AUTHORISED FOR 12 MONTHS FROM DATE SHOWN)
J
4 9-13 AS CONSTRUCTED
P.C. P.C.
3 8-13 ADD THRUST BLOCK & NOTE
P.C. P.C.
2 5-13 VENT INDUCT & EDUCT PIPE MODIFIED
P.C. P.C.
DATE
AMENDMENT
1
2
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Q-Pulse Id: TMS1594
FUNDING
DESIGN W.O. No.
QUU065
SOA C1011-045
FUNDED BY Q.U.U. ( 9) EXTERNAL ( )
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DRAFTED DRAFTING CHECK CAD FILE Q.U.U. FILE No.
P. CRISTEA P. HOUSTON 486-4-9-1194-031-2
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20-2-13
R.P.E.Q. No. DATE
APPROVED BY
R.P.E.Q. No. DATE 8
CONSTRUCTION MANAGER 9
SIGNATURE DATE SIGNATURE DATE
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AS CONSTRUCTED DETAILS
I CERTIFY THAT THE "AS CONSTRUCTED" DETAILS
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SHOWN ON THIS PLAN ARE A TRUE AND ACCURATE
G
RECORD OF THE WORKS.
SIGNED:
DATE:
NAME of SIGNATORY:
RPEQ No. or LICENCE:
COMPANY NAME:
START DATE:
FINISH DATE:
H
H
I
I
NAME
SIGNATURE
DATE
QUEENSLAND URBAN UTILITIES DELEGATE (AUTHORISED FOR 12 MONTHS FROM DATE SHOWN)
J
4 8-13 AS CONSTRUCTED
P.C. P.C.
3 9-13 ADDED THRUST BLOCK & NOTE
P.C. P.C.
2 5-13 VENT INDUCT & EDUCT PIPE MODIFIED P.H. P.H.
DATE
AMENDMENT
1
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Q-Pulse Id: TMS1594
FUNDING
DESIGN W.O. No.
QUU065
SOA C1011-045
FUNDED BY Q.U.U. (9) EXTERNAL ( )
DRAFTED
P. CRISTEA
DRAFTING CHECK P. HOUSTON
CAD FILE
486-4-9-1194-032-2
Q.U.U. FILE No.
B. CLARKE DESIGN ORIGINAL SIGNED BY DESIGN CHECK
4
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20-2-13
R.P.E.Q. No. DATE
APPROVED BY
SIGNATURE DATE
R.P.E.Q. No. DATE
CONSTRUCTION MANAGER
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SIGNATURE DATE 10
WB065 ASSET/PROJECT SEIB STREET - KILCOY WATER BOOSTER
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DRAWING TITLE
PIPEWORK LAYOUT
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AS CONSTRUCTED DETAILS
I CERTIFY THAT THE "AS CONSTRUCTED" DETAILS
G
SHOWN ON THIS PLAN ARE A TRUE AND ACCURATE
G
RECORD OF THE WORKS.
SIGNED:
DATE:
NAME of SIGNATORY:
RPEQ No. or LICENCE:
COMPANY NAME:
START DATE:
FINISH DATE:
H
H
I
I
NAME
SIGNATURE
DATE
QUEENSLAND URBAN UTILITIES DELEGATE (AUTHORISED FOR 12 MONTHS FROM DATE SHOWN)
J
4 9-13 AS CONSTRUCTED
P.C. P.C.
3 8-13 ADDED THRUST BLOCK & NOTE
P.C. P.C.
2 5-13 VENT INDUCT & EDUCT PIPE MODIFIED P.C. P.C.
DATE
AMENDMENT
1
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Q-Pulse Id: TMS1594
FUNDING
DESIGN W.O. No.
QUU065
SOA C1011-045
FUNDED BY Q.U.U. (9) EXTERNAL ( )
DRAFTED
P. CRISTEA
DRAFTING CHECK P. HOUSTON
CAD FILE
486-4-9-1194-033-2
Q.U.U. FILE No.
B. CLARKE DESIGN ORIGINAL SIGNED BY DESIGN CHECK
4
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20-2-13
R.P.E.Q. No. DATE
APPROVED BY
SIGNATURE DATE
R.P.E.Q. No. DATE 8
CONSTRUCTION MANAGER 9
SIGNATURE DATE 10
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& MATERIAL LIST
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EDGE OF DRIVEWAY
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QUU
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POWER POLE No.P101048
AS CONSTRUCTED DETAILS
I CERTIFY THAT THE "AS CONSTRUCTED" DETAILS
G
SHOWN ON THIS PLAN ARE A TRUE AND ACCURATE
G
RECORD OF THE WORKS.
SIGNED:
DATE:
NAME of SIGNATORY:
RPEQ No. or LICENCE: COMPANY NAME:
START DATE:
FINISH DATE:
H
H
I
I
NAME
SIGNATURE
DATE
QUEENSLAND URBAN UTILITIES DELEGATE (AUTHORISED FOR 12 MONTHS FROM DATE SHOWN)
J
4 9-13 AS CONSTRUCTED
P.C. P.C.
3 8-13 ADDED THRUST BLOCK & NOTE
P.C. P.C.
2 5-13 VENT INDUCT & EDUCT PIPE MODIFIED P.C. P.C.
DATE
AMENDMENT
1
2
3
Q-Pulse Id: TMS1594
FUNDING
DESIGN W.O. No.
QUU065
SOA C1011-045
FUNDED BY Q.U.U. (9) EXTERNAL ( )
DRAFTED
P. CRISTEA
DRAFTING CHECK P. HOUSTON
CAD FILE
486-4-9-1194-034-2
Q.U.U. FILE No.
B. CLARKE DESIGN ORIGINAL SIGNED BY DESIGN CHECK
4
5
6
7
20-2-13
R.P.E.Q. No. DATE
APPROVED BY
SIGNATURE DATE
R.P.E.Q. No. DATE 8
CONSTRUCTION MANAGER 9
SIGNATURE DATE 10
WB065 ASSET/PROJECT SEIB STREET - KILCOY WATER BOOSTER
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DRAWING TITLE
SITE LAYOUT & LAND CONTOURS
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WB196 Seib Street Water Booster - JPR - Operation and Maintenance Manual J & P Richardson Industries Pty Ltd
8 Service and Maintenance
This product is designed to operate under specific environmental, supply and load conditions. Should these conditions change, consult a licenced electrician or electrical engineer before operating this product.
These procedures are to be performed only by a licenced electrician as they may expose live equipment.
The Switchgear and Controlgear Assembly is essentially maintenance free, however the following safety measures and routine maintenance is recommended.
Where fitted, ensure cabinet vents and filters are clear and clean. During operation, ensure all doors and covers are secure and closed. All faults are to be investigated and repaired by an appropriately licenced electrician. All components to be operated in accordance with manufacturers data. The protective devices within switchboards are designed to operate in the event of a
short circuit or overload condition. In the event of these devices operating under such conditions the device or devices must be inspected and tested by a suitably trained person to ascertain its condition prior to reconnecting the protective device to the supply.
Periodic checks should ensure
The switchboard is clean and free of any contaminants, which could reduce the insulation properties of the switchboard.
All entries are sealed to ensure no vermin can enter. There is no evidence of overheating, arcing or moisture. The earthing system is maintained and is adequate to allow correct operation of
protective devices. Insulation resistance is maintained to appropriate levels. Check terminations for correct tension. Test operation of protective devices. Re-calibrate instrument loops as required.
Refer to AS-INSTALLED electrical drawings for details of protection equipment settings.
No special tools or equipment are required to perform routine maintenance.
C63100-WB065_Manual_DRAFT.doc Revision 0
Q-Pulse Id: TMS1594
Active: 18/04/2016
Date: February 18, 2014
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