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FINAL
OPERATIONS AND MAINTENANCE AP
Biosparge/Vapor Recovery Syster
For FTA-2/LF-2
MASSACHUSETTS MILITARY RESERVATION
CAPE COD, MASSACHUSETTS
Volume 2 of 2
Prepared for:
AFCEE/MMR
Installation Restoration Program
322 East Inner Road
Otis ANGB, Massachusetts 02542
Contract No. F41624-97-D-8009
Delivery Order: 0019
July 2002
Environmental Chemical Corporation
5 Kittridge Road
Otis ANGB, Massachusetts 02542
WECCIVA
CH IC
CORPORAI
July 5, 2002
Mr. Robert M. Gill
Remediation Program Manager
AFCEE/MMR
322 E. Inner Road, Box 41
Otis ANG Base, MA 02542-5028
Subject: Final Operations and Maintenance Manual Biosparge/Vapor Recovery
System for FTA-2/LF-2, Massachusetts Military Reservation Cape Cod,
Massachusetts
Contract No.: F41624-97-D-8009 (Ref: RSS02041.5422.019)
Dear Mr. Gill:
As directed by the Air Force Center for Environmental Excellence (AFCEE),
Environmental Chemical Corporation (ECC) is hereby distributing copies of the
aforementioned document. This submittal contains two volumes:
Volume I - Operations and Maintenance Manual Biosparge/Vapor Recovery System for
FTA-2/LF-2
Volume 2 - Vendor Operating Manual for the Biosparge/Vapor Recovery System
Enclosed are seventeen bound, one unbound, and one electronic copy. Copies are also
being sent to the appropriate agencies.
If you have any questions or comments, please contact Shouvik Gangopadhyay or
myself at (508) 563-9767 or Jon Davis at (508) 968-4952 extension 4952.
Sincerely,
RSS/cs
Attachments:
Document (17 bound, I unbound, 1 disk)
cc:
Paul Marchessault, USEPA (3 copies)
Leonard Pinaud, MADEP (2 copies) I-c t(L
Wells Hunt, RG (wo attachments)
SJUL - 2002
DEP
SOUTHEAST REGION
Table of Contents
Section 1 - Soil Vapor Extraction System
. Rotron EN858 Regenerative Blower Specifications and Performance Cure
. Rotron EN858 Regenerative Blower Installations and Wiring Diagram
. Solberg CSL-235P-300 Inlet Filter Specifications
. Solberg FS-19P-150 Dilution Filter Specifications
. Kunkle 215V Relief Valve Specifications
. Asahi Type 56 Butterfly Valve Specifications
Section 2 - Tanks
* Moisture Separator Dimensional Print
. Condensate Storage Tank Dimensional Print
Section 3 - Air Sparge System
. Curtis R S 25 LP Compressor Specifications and Performance Curve
. Curtis R'S 25 LP Compressor Parts and Instruction Manual
. Curtis R S 25 LP Compressor Control Panel Wiring Diagrams
. Compressed Air Filters Instruction Manual
* Hankison Condensate Drain Instruction Manual
. Dwyer ABV-105 Motor Operated Ball Valve Specifications
- Dwyer ABV-105 Motor Operated Ball Valve Installation, Operation and
Maintenance Manual
Section 4 - Heat Exchanger Modeling, Specifications and Installation Instructions
Section 5 - Carbon Adsorber Specifications
Section 6 - Transfer Pump
. Gould's NPE Transfer Pump Specifications and Performance Curve
- Gould's NPE Transfer Pump Installation, Operation & Maintenance
Instructions
Section 7 - Instrumentation
- Ashcroft Low Pressure Diaphragm Gauges
. Ashcroft Commercial Hydraulic Gauge
. Trend Instruments Industrial Thermometers Specifications
* Temperature Switch Specifications
. Dwyer Magnehelic Differential Pressure Gage
. Dwyer Series DS-300 Flow Sensor
. Dwyer Pressure Switches Specifications, Installation and Operating
Instructions
. Pneumatic In-Line Flowmeters Specifications
. Innovative Solutions Muliple Stage Switches
. Bisco Phase Separator3 Level Float Switch
. Bisco Level Switch 1 Float Product Tank
a GasTech Combustible Gas Diffusion Transmitter
- GasTech Data Sheet
Section 8 - Control Panel
. Control Panel Drawings
a EOS Series 2 Plus ProControl User Manual
. EOS Series 2 Plus ProView User's Guide
. Hoffman Cooling Fan Installation Instruction
. Hoffman Louver Kit Installation Instruction
. Hoffman Electric Heater Installation Instruction
. Hatachi J300 Series Inverter Instruction Manual
. Sabina Type 9592 SVC Instruction Manual
Section 9 - Container and Accessories
. Container Specifications
* Oatey Master Flash Instructions
Section 10 -Container HVAC
. Dayton Hazardous Location Exhaust Fan Instructions
- Dayton Intake Guard Instructions
* Dayton Wall Shutter Instructions
. Marley Hazardous Location Heater Instructions
. White-Rodgers Remote Bulb Thermostat Installation Instructions
Section 11 - Trailer Electrical
- Killark Type "SWB" Control Panel Installation Instructions
* Hubbell Hazardous Location Light Installation Instructions
. Hubbell Fitting Installation and Maintenance Data Sheet
Section 1
AMETEK R ,trof Industrial Poducts
EN 858 & CP 858
Sealed Regenerative Blower w/Explosion-Proof Motor
FEATURES
" Manufacturec in the USA - ISO 9001 compliant
- Maximum flow: 400 SCFM
e Maximum prEssure: 120 IWG
- Maximum vacuum: 98 IWG
- Standard motor: 10 HP, explosion-proof
- Cast aluminu n blower housing, cover, impeller &
manifold: cas: iron flanges (threaded); teflon lip seal
- UL & CSA approved motor with permanently
sealed ball bearings for explosive gas
atmospheres Class I Group D minimum
. Sealed blower assembly
- Quiet operation within OSHA standards
MOTOR OFTIONS
e International voltage & frequency (Hz)
- Chemical duty, high efficiency, inverter duty
or industry-specific designs
e Various horsepowers for application-specific needs
BLOWER OPTIONS
e Corrosion resistant surface treatments & sealing options
- Remote drive (motorless) models
- Slip-on or face flanges for application-specific needs
ACCESSORIES (See Catalog Accessory Section)
e Flowmeters reading in SCFM
- Filters & moisture separators
- Pressure gaLges, vacuum gauges & relief valves
- Switches - air flow, pressure, vacuum or temperature
- External mufflers for additional silencing
e Air knives (used on blow-off applications)
- Variable frequency drive package
BLOWER PERFORMANCE AT STANDARD CONDITIONS
AIR FLOW RATE (M/MIN) AIR FLOW RATE (M'/MIN)
2.0 4.0 5.0 8.0 10.0 12.0 14.0 2.0 4.0 610 8.0 10.0 12.0 14.0
50 140 -I 11 1405-0 - | PRESSURE 1 SUCTION
120 - A-MAX PRESSURE -300 -120 A-MAXION -3W
0- A A-10HP B-7.5HP 2
-B A- HP .75 HP
EN 25 -1 2
3080
2.0
1.0 -
o 6,
O0. '2,
3.
Rev 2/01
- ---~~
50 -.
- - 50Hz
I EEIE|E|\
100 200 300 400 500
AIR FLOW RATE (SCFM)
120 1 1 1 1
40
000
.000
200 A. -20
5 0 60Hz E
050H
2t 50 2 -20 N
0 100 200 300 400 500
AIR FLOW RATE (SCFM)
- 120
,am
;Se 80
w 0
,'12NG0
0= .000
10
0
C AMEETEK Rotron Industrial Products, Saugerties. NY 12477 * e mail. rotronindustrial@ametek com * internet www rotronindustrialcom
ZZI 1 1_I I I I T_
AMETSE Rotron" Industrial Products
EN 858 & CP 858
Sealed Regenerative Blower w/Explosion-Proof Motor
Scale CAD drawing .vallIabl Upon request.
DIA.
6.5_
ii44
DIMENSIONS: MM
TOLERANCES: XX * -
(UNLESS OTHERWISE NOTED) 0.75" NPT CONDUIT CONNECTION AT 12 O'CLOCK POSITION
SPECIFICATIONS
MODEL EN8588D72WL EN858BD86WL EN858BA72WL CP858FZ72WLR
Part No. 038744 038745 080070 038980
Motor Enclosure - Shaft Material Explosion-proof - CS Explosion-proof - CS Explosion-proof - CS Chem XP - SS
Horsepower 10.0 10.0 7.5
Phase - Frequency 1 Three - 60 Hz Three - 60 Hz Three - 60 Hz EN858BD72WL -Voltage 1 230 460 575 230 460 038744Motor Nameplate Amps 24 12 9.6 17 8.5 exceptaddMax. Blower Amps 3 29 14.5 11.6 26 13 Chemical ProcessinInrush Amps 162 81 93 126 63 I
Starter Size 2 1 1 1 1 featuresService Factor 1.0 1.0 1.0
Thermal Protection 2| Class B - Pilot Duty Class B - Pilot Duty Class B - Pilot Duty catalogXP Motor Class - Group i Il, ll-F&G I-D, l-F&G I-D, ll-F&G inside front cover
Shipping Weight | 332 lb (151 kg) | 332 lb (151 kg) 320 lb (145 kg) _ J
R otron motors are designed to handle a broad range of world voltages and power supply variations. Our dual voltage 3 phase motors are
factory tested and certified to operate on both: 208-230/415-460 VAC-3 ph-60 Hz and 190-208/380-415 VAC-3 ph-50 Hz. Our dual
voltage 1 phase motors are factory tested and certified to operate on both: 104-115/208-230 VAC-1 ph-60 Hz and 100-110/200-220
VAC-1 ph-50 Hz. All voltages above can handle a ±10% voltage fluctuation. Special wound motors can be ordered for voltages outside our
certified range.
2 Maximum operating temperature: Motor winding temperature (winding rise plus ambient) should not exceed 140*C for Class F rated motors
or 120"C for Class B rated motors. Blower outlet air temperature should not exceed 141" (air temperature rise plus inlet temperature).
Performance curve maximum pressure and suction points are based on a 40"C inlet and ambient temperature. Consult factory for inlet or
ambient temperatures above 40*C.
3 Maximum blower amps corresponds to the performance point at which the motor or blower temperature rise with a 40"C inlet and/or
ambient temperature reaches the maximum operating temperature.
Specifications subject to change without notice. Please consult your Local Field Sales Engineer for specification updates.
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Rev. 2/01
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AMETEK Rotron Industrial Products. Saugerties, NY 12477 * e mail: rotronindustrial@ametek.com * internet: www.rotronindustrial.com
GENERAL INSTALLATION INSTRUCTIONS
*WASSVA AMETEK
r. RON TECHNICAL MOTOR DIVISION
Industrial ProductsID5 North Street. Saugerties. NY 12477 U.S A
7eephone 914-24&-3401 Fax. 914-246-3802
Rotron Regenerative Blowers
Instaidtior, Instructions for SL, DR. EN, CP, and HiE Series Blowers
1 Bolt it Down - Any blower must be secured against movement prior to starting or testing to
prevent injury or damage. The blower does not vibrate much more than a standard electric
motor.
2 Filtration - All blowers should be filtered prior to starting. Care must be taken so that noI foreign material enters the blower. If foreign material does enter the blower, it could cause
internal damage or may exit at extremely high velocity.
Should excessive amounts of material pass through the blower, it is suggested that the
cover(s) and impeller(s) be removed periodically and cleaned to avoid impeller imbalance.
Impeller imbalance greatly speeds bearing wear, thus reducing blower life. Disassembling
the blower will void warranty, so contact the factory for cleaning authorization.
Support the Piping - The blower flanges and nozzles are designed as connection points
only and are not designed to be support members.
Caution: Plastic piping should not be used on blowers larger than 1 HP that are operating
near their maximum pressure or suction point. Blower housing and nearby piping
temperatures can exceed 2000F. Access by personnel to the blower or nearby
piping should be limited, guarded, or marked, to prevent danger of burns.
4 Wiring - Blowers must be wired and protected/fused in accordance with local and national
electrical codes. All blowers must be grounded to prevent electrical shock. Slo-Blo or time
delay fuses should be used to bypass the first second of start-up amperage.
5. Pressure/Suction Maximums - The maximum pressure and/or suction listed on the model
label should not be exceeded. This can be monitored by means of a pressure or suction
gage (available from Rotron), installed in the piping at the blower outlet or inlet. Also, if
problems do arise, the Rotron Field representative will need to know the operating
pressure/suction to properly diagnose the problem.
6. Excess Air - Bleed excess air off. DO NOT throttle to reduce flow. When bleeding off
excess air, the blower draws less power and runs cooler. Note: Remote Drive (Motorless) Blowers - Properly designed and installed guards should
be used on all belts, pulleys, couplings, etc. Observe maximum remote drive speed
allowable. Due to the range of uses, drive guards are the responsibility of the customer or
user. Belts should be tensioned using belt gauge.
-For further information regarding Rotron regenerative blowers (including service & parts
manuals), please contact your local field sales engineer.
MaIntenance Procedure
When properly piped, filtered, and applied, little or no routine m
filter Clean. Also, all st
that require no mainten
average. Replacement
andard
ance.
models in the DR, EN, CP and H
Bearing should be changed after
aintenance is required. Keep the
iE series have sealed bearings
15,000 to 20,000 hours, on
bearing information is specified on the chart below.
Seal Material
Polyacrytic
Grease
Nye Rheotemp 500
30% +/- 5% Fill
Heat Stabilized
Yes - 325 F
510449 203
51648 307 Buna N Shell Dolium "R" 25-40% Fill NO
516840 206 Shell Dolium -R'
516841 207
516842 1 208 Buna N 30%+/- 5% Fill NO
516843 210
516844 309
516845 310
516846 311
516847 313
Troubleshocotin
POSSiBLE CAUSE OuT OF WARRANTY REMEDY
One phase of power line not connected 1 Connect
- .2 'One phase of stator winding open 2. Rewind or buy new motor
3 Bearings defective 3. Change bearings
2 4 !mpeller jammed by foreign material 4. Clean and add filter
-. 5 .mpeller jammed against housing or cover 5. Adjust
6 " Capacitor open 6. Change capacitor
1. Two phases of power line not connected 1. Connect
2. Two phases of stator winding open 2. Rewind or buy new motor
nsufcient fuse capacity 1. Use time delay fuse of proper rating
0,D
2. Short circuit 2. Repair
1. High or low voltage - 1. Check input voltage
2. * Operating in single phase condition 2. Check connections
9 3. Bearings defective 3. Check bearings
4. Impeller rubbing against housing or cover 4. Adjust
5. Impeller or air passage clogged by foreign material 5. Clean and add filter
6 Unit operating beyond performance range - 6. Reduce system pressure/vacuum
7. Capacitor shorted 7. Change capacitor
8. * One phase of stator winding short circuited 8. Rewind or buy new motor
I i Impeller rubbing against housing or cover 1. Adjust
' ~ 2. Impeller or air passages clogged by foreign material 2. Clean and add filter
< 3. Bearings defective 3 Change bearings
1. Leak in piping 1. Tighten
2. Piping and air passages clogged 2. Clean
E 0 3. Impeller rotation reversed 3. Check wiring
2 4. Leak in blower 4. Tighten cover, flange
5. Low voltage 5. Check input voltage
3 phase units
*1 phase units
Disassembly and repair of new blowers or motors will void the Rotron warranty. Factory should be contacted prior to
any attempt to field repair an in-warranty unit. ,m-c - 1Bearing
Part Number
510218
510219
Size
205
206
207
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*AMETEK'
ROTRON TECHNICAL MOTOR DIVISION
'ZGENERATIVE BLOWER GROUP
North Street
Saugerties, New York 12477
Phone: (914) 246-3401
Fax: (914) 246-3802
A
SEXPLOSION-PROOF BLOWERS
IMPORTANT: Read before wiring this Explosion-proof Blower
This AMETEK Rotron Explosion-proof Regenerative Blower may be equipped with Pilot Duty
Thermal Overload (PDTO) or Automatic Thermal Overload (ATO) protection. When properly
wired to a motor starter, this protection limits the motor winding temperature rise per the
National Electric Code (NEC) article 500. Failure to properly wire this blower is an NEC
violation and could cause an explosion. AMETEK Rotron assumes no responsibilities for
damages incurred by negligent use of this product, and will not warranty a blower on which the
PDTO is not properly connected. Some blowers 1 HP and under do not require PDTO and
have built in ATO. Consult the factory if verification of wiring connections is required.
In all cases, follow the motor controller manufacturer's instructions. The following schematic isfor conceptual understanding only, and may not apply to all motor/controller combinations.
The manufacturer's wiring diagram found on the motor takes precedent over reference
diagrams supplied by AMETEK Rotron Technical Motor Division.
Schematic
Push Start The schematic is shown for a
three phase motor. For a
single phase motor disregard
Push stop L3 and M3. Pushing theA1C 0START button completes the
Magnetic Coil Jauxiliary control circuit,
PoAer allowing current to flow
L1C M1- Motor through the magnetic coil.
The contacts are
M2 magnetically closed, starting
the motor and latching the
L3C M3 auxiliary circuit. The motor
contacts Current will continue to run until the
Overloads STOP push button is
- depressed, the motorJ - Pilot Outy Thermal Overload Protection wires reaches the overloadL - Power leads from circuit breaker box
M - Motor leads (refer to wiring diagram inside rbox or on motor nameplate) temperature, or the current
sensing overloads trip out.
If you have any questions, contact AMETEK Rotron at 914-246-3401
area representative.
for the location of your
12/10/98 Rev. D
POLICY REGARDING INSTALLATION OF AMETEK ROTRON
REGENERATIVE BLOWERS IN HAZARDOUS LOCATIONS
AMETEK Rotron will not knowingly specify, design or build any regenerative blower for
installation in a hazardous, explosive location without the proper NEMA motor enclosure.
AMETEK Rotron does not recognize sealed blowers as a substitute for explosion-proof
motors. Sealed units with standard TEFC motors should never be utilized where local, state,
and/or federal codes specify the use of explosion-proof equipment.
AMETEK Rotron has a complete line of regenerative blowers with explosion-proof motors.
Division 1 & 2, Class I, Group D: Class 11, Groups F & G requirements are met with these
standard explosion-proof blowers.
AMETEK Rotron will not knowingly specify, design or build any regenerative blower for
installation in a hazardous, corrosive environment without the proper surface treatment and
sealing options,
AMETEK Rotron has a complete line of Chemical Processing and Nasty Gasm regenerative
blowers with Chem-Tought, stainless steel parts, and seals.
AMETEK Rotron offers general application guidance; however, suitability of the particular
blower selection is ultimately the responsibility of the purchaser, not the manufacturer of the
blower.
FS2 Rev. B 3/10/98
12/10/98 Rev. D
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Models 215V, 337 Model 337 is ASME Section Vill,
Air/Gas vacuum, -UV' National Board Certified, Safety Valves
Pressure and Temperature Limits
Model 337:
1 to 60 psig [0.07 to 4.1 barg]
-20" to 406'F [-29* to 208'C]
Vacuum Limits
Model 215V:
2-inch HG
to 29-inch HG
(67.7 to 982 mbarg]
-20* to 400*F [-29' to 205*C]
Applications
- Protection of low to medium pressure
high volume blowers, compressors and
pneumatic conveying systems.
- Bulk hauling trailers/equipment.
* Light gauge tanks.
- Protection of high volume vacuum
pumps and conveying systems.
Features and Benefits
- Large nozzle design provides high
capacity.
- Flat bronze valve seats are lapped
for optimum performance.
- Warn ring offers easy adjustability
for precise opening with minimum preopen or simmer and exact blowdown
control.
- Pivot between disc and spring corrects misalignment and compensates
for spring side thrust.
Model Descriptions
- Model 337 has 'pull-ring'lift device
for easy manual testing.
- Every valve is 100% tested/inspected
for pressure setting, blowdown and
leakage.
. All adjustments are factory sealed
to prevent tampering or disassembly.
Option
- SS trim. (nozzle and disc) (Variation 03)
IKunkle
ISafety and Relief Products
Models 215V, 337
a 7
6
5
4
3
2
Model 215V
2 7Y
Model 337
Pars and Materials - Models 2SV 337
Part Name
Nozzle'
Set Screw
Regulator Ring
Disc I
Spring Step
Spring
Body
Compression Screw
Stem 2
Lift Ringz
Regulator Ring Set Screw
215V
Bronze, 862
Steel A108-1018 Brass Plated
Bronze B584 Alloy 84400
Bronze B584 Alloy 84400
Steel A-109 Cadmium Plated
SS, A313 TY 302
Cast Iron, Zinc Plated, B633
Bronze, B-584 Alloy 84400
N/A
N/A
N/A
337
Bronze, 862
Steel A1OB-1018 Brass Plated
Bronze B584-084400
Bronze B584-084400
Steel A109, CAD Plated
SS A313-302
iron A-126, CL A or B
Bronze, 8584-C84400
Brass B16
SS A313-302
Brass 816
1. Disc and nozzle available in SSA-479 f
316.
2. Stem and lift ring available on Model 337
only.
_ - Dimensions, in Imm] A B C 21 5V
3V/4 [82.5]
33/4 [95.2]
41/4 [107 9]
3 [76.21
3/2 [88.9]
4 [101.6]
6/2 [165.1]
75/s [194.6]
811/ [215 9[
- Weight
C 337 lb [kgJ
7 (1778] 8 13.61
8 [203.2] 12 [5.4]
9 [228.6] 20 14.1]
10
Kunkle
Safety and Relief Products
No.
2
3
4
5
6
7
8
9
10
11
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Size Inlet
and Outlet
2" [50.8 mm]
21/2" [63.5 mm]
3" [176.2 mm]
Model 337
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[Specilicatilons
Type 56 Butterfly Valve
Standard Features (Sizes 1-1/2" - 16")
Standard model (1-1/2" - 14") has PVC Body
and PP Disc for better chemical resistance at
temperatures higher than can be achieved
with PVC. 16" has PP body and PP disc as
standard.
- Our 316/403 stainless steel shaft has full
engagement over the entire length of the disc
and is a non-wetted part, totally isolated from
the media.
- Only solid and abrasion-resistant plastic disc and
elastomeric liner are wetted parts.
- ISO bolt circle on top flange
- no body or stem modifications required for
accessories.
Options
Pneimatically and electrically actuated with
accessories
- Alte-nate discs:
(1) PVC : 1-1/2" - 14"
[ll) PVDF : 1-1/2" - 16"
- Gear operators for 1 -1/2"- 6"
- Lug style (Stainless Steel 304 or 316) as
blocking and end-of-line applications
- Sterns in 316 stainless steel, titanium,
Hastelloy C' etc.
- 2" square nut on stem
- 2" square nut on gear operator
- Stem extensions (single stem and two-piece
stem]
- Locking devices [Gear Type - Standard on Lever)
- Chan operators
Manual limit switch
- Tancem arrangements (Patented by A/A, Inc.)
6
Specifications
Sizes: Lever: 1-1/2" Gear: 8" - 16"
Models: Wafer Style
Operators: Lever and Gear
Bodies: PVC, PP and PV F
Discs: PVC, PP and PVDIF
Seats: EPDM or Vitan"? Also Nitrile, Butyl,
Hypalan't, and Neoprene"t
Seals: Same as seating material
Stems: 403 and 316 stainless steel,
titanium, Hastelloy C" I etc.
t Trademarks of E, 1. du Pont de Nemours and Company
$ Trademark of Cabot Corporation
Parts List (Lever: Sizes 1-1/2" - 8"1)
PARTS
NO.
2
3
4
5
6
7
8
16
16a
17
18
19
20
21
22
23
24
la DESCRIPTION
Body
Disc
Seat
0-fling (A)'
0- Ring (B)
O-Ring (C)
Stem
Stem Holder
Handle
Metal Insert in Handle
Handle Lever
Pin
Spring
Washer (A)
Bolt (B)
Locking Plate
Screw (B)
Cap (A)
Ring"*
PCs.
2
2
1
14
2
MATERIAL
PVC, PP, PVDF
PVC, PP. PVDF
EPDM, Viton* Others
EPDM, Viton* Others
EPDM. Viton* Others
EPDM, Viton Others
Stainless Steel 316
Stainless Steel 304
PP
Stainless Steel 316
PPG
PPG
Stainless Steel 304
Stainless Steel 304
Stainless Steel 304_
PPG
Stainless Steel 304
PP
Steel
- Used for sizes 2" through 8"
" *with Dowder coat finish and used for PP bnies 6" and R'
ASAHI/AMERICA
Rev. A01 02
I
Type 56 - Lever Operated Butterfly Valves
Aa Dimensions (Lever: Sizes 1-1/2" - 8")
NOMINAL
SIZE ANSI CLASS 150
dNES rm J C n h D 01 L H Hi H2 H3 A:
1 1/2 40 1.85 3.88 4 0.62 5.91 3.23 1.54 6.14 2.95 3.94 2.20 8.661
2 50 2.24 4.75 4 0.75 6.50 3.43 1.65 6.37 3.27 4.17 2.20 8.66
2 1/2 65 2.80 5.50 4 0.75 7.28 4.41 1.81 6.81 3.66 4.61 2.20 8.66
3 80 3.15 6.00 4 0.75 7.87 4.84 1.81 7.08 3.94 4.88 2.20 9.84
4 100 4.13 7.50 8 0.75 9.02 5.79 2.20 7.79 4.53 5.59 2.20 84
5 125 5.16 8.50 8 0.88 10.00 7.09 2.60 9.49 5.00 6.77 2.72 12.601
6 150 6.06 9.50 8 0.88 11.22 8.27 2.80 10.00 5.63 7.28 2.72 12.60
8 200 8.03 11.75 8 0.88 13.39 10.12 3.43 11.26 6.69 8.54 2.72 15.75
Pressure vs. Temperature (PSi, WATER NON-SHOCK)*
Cv Values
NOMINAL CV
SIZE (at vaus openiga ges
INCHES mm 300 600 900
1/2 40 2 9 43.3 71
2 50 3.9 56.1 92
2 1/2 65 5.9 85.4 140
3 80 9.3 1134.2 220
4 100 15.1 231 380
5 125 30.9 445 730
6 150 46.6 671 1100
8 200 106 1425 2500J
Wt. (LBS) /Vacuum Service
PVC
PP
30' F 121' F 141'
120' F 140' F 175'
150
150
150
150
150
150
150
150
70
70
70
70
45
45
45
40
30
30
30
30
30
30
30
20)
PP PVDF
PP PVDF
F -5' F 141' F -5' F 141' F 176' F211' F
F 140' F 175' F 140' F 175' F210' F250' Fl
150
150
150
150
150
150
150
150
100 150 100 85 75
100 150 100 85 75
100 150 100 1 85 75J
100 150 100 85 75
100 150 100 85 75
100 150 100 85 75
100 150 100 85 75
85 150 85 75 60
NOMINAL
SIZE
INCHES MM
11/2 40
2 50
2 1/2 65
3 80
4 100
5 125
6 150
8 200
NOMINAL VACUUM
L~v ~ SIZE SERVICE
c~iMED(INCHES OF!
I MERCURY)
270 11/2 40 -29.92
3.10 2 50 -29.92
3.50 ]2 1/2 65 -29.92
4.00 3 80 -29.92
5.50 4 100, -29.92
10.80 ' 5 125 -29.92
13.30 6 150 -27.56
19.90 8 200 27.56
- For lug style data consult factory
35 Green Street, P.O. Box 653, Maiden, MA 02148 e Tel: 800-343-3618 - 781-321-5409 * Fax: 800-426-7058 e E-mail: asahi@asahi-ameicacom
Register at our interactive web site for on line ordering, product availability, order tracking, and many useful features: www.asahi-america.com
BODY
DISC
NOMINAL
SIZE
INC.ES
1 1/2
2
2 1/2
3
4
5
6
8
mm 40
50
65
80
100
125
150
200
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T- 56 - Gear Operated Butterfly Valves
n-Ih
Dimensions (Sizes 1- 1/2" - 16") (NOTE: GEAR OPERATED VALVE IS STANDARD 8" - 16";
SIZES 1-1/2 "-6" ARE OPTIONS.)
NOMINAL
SIZE ANSI CLASS 150
cHs rrm d C n h D Di D2 D3 L H Hi H2 H3 / A Ai A2
1 1/2 40 1.85 3.88 4 0.62 5.91 3.23 3.94 6.30 1.54 4.88 2.95 3.74 2.36 8.03 6.57 3.15 1.85
2 50 2.24 4.75 4 0.75 6.50 3.43 3.94 6.30 1.65 5.12 3.27 3.98 2.36 8.27 6.57 3.15 1.85
2 1/2 65 2.80 5.50 4 0.75 7.28 4.41 3.94 6.30 1.81 5.55 3.66 4.41 2.36 8.70 6.57 3.15 1.85
3 80 3.15 6.00 4 0.75 7.87 4.84 3.94 6.30 1.81 5.83 3.94 4.69 2.36 8.98 6.57 3.15 1.85
4 100 4.13 7.50 8 0.75 9.02 5.79 3.94 6.30 2.20 6.54 4.53 5.39 2.36 9.69 6.57 3.15 1.85
5 125 5.16 8.50 8 0.88 10.00 7.09 6.50 6.30 2.60 7.60 5.00 6.46 2.36 10.75 6.57 3.15 1.85
6 150 6.06 9.50 8 0.88 11.22 8.27 6.50 6.30 2.80 8.11 5.63 6.97 2.36 11.26 6.57 3.15 1.85
8 200 8.03 11.75 8 0.88 13.39 10.1 7.87 7.87 3.4 9.37 669 8.2 3 12 57 3.15 1.85
10 250 10.08 14.25 12 1.00 15.98 12.44 7.87 7.87 4.33 10.63 7.99 9.49 2.36 14.57 7.83 3.74 2.36
12 300 12.60 17.00 12 1.00 19.02 14.57 9.25 9.84 5.08 12.87 9.53 11.73 2.72 17.80 8.35 3.74 2.99
14 350 14.37 18.75 12 1.12 20.47 16.54 9.25 9.84 5.08 13.19 10.24 12.05 2.72 18.11 8.35 3.74 2.99
16 400 15.98 21.25 16 1.12 23.62 18.50 9.25 9.84 6.65 14.69 11.81 13.54 2.72 19.61 8.35 3.74 2.99
28 ASAHI/AMERICA
Rev A01 02
Type 56 - Gear Operated Butterfly Valves
Parts List (Gear: Sizes 1-1/2" - 16")
PARTS
NO.
1
2
3
5
6
7
25
28
1a DESCRIPTION
Body
Disc
Seat
0-Ring (A)
C-Rin (B)
O-Ring (C)
Stem
Gear Box
Bolt(C)
Ring
PCs.
2
2
1
MATERIAL
PVC, PP, PVDF
PVC, PP, PVDF
EPODM, Viton? Others
EPOM, Viton Others
EPDM, Viton* Others
EPDM, Vitoni Others
1 Stainless Steel 316, 403
1
4
2
Diecast Aluminum AlloyStainless Steel 304
Steel
"with powder coatfinish
Troubleshooting
What if fluid still flows when valve is closed?
1. Make sure lever or gear is in a fully closed
position (gear type may require travel stop
adjustment].
2. Liner is damaged or worn. Replace liner
3. Disc is damaged or abraded. Change disc.
4. Foreign material is caught between seat and
disc. Remove the substance.
5. Mating flange bolts either over-tightened or
unevenly tightened. Retighten properly.
What if fluid leaks outside between seat and mating
flange?
1. Seat damage. Change seat.
2. Mating flange bolts not tightened with proper
torque or unevenly tightened. Retighten to the
appropriate torque.
What if valve does not operate smoothly?
1. Foreign material is caught between disc and
seat. Remove the material and clean.
2. Lever or gearbox is damaged. Replace.
3. Mating flange bolts over-tightened. Retighten.
Sample Specification
All solid thermoplastic butterfly valves sizes 1-1/2"
thru 16" shall be of the TYPE 56 lined body design
and bubble-tight seal (meeting or exceeding Class VI
as defined by American National Standard Institute)
with only the liner and disc as wetted parts. The
lever handle (sizes 1-1/2" thru 8") shall have a
molded provision for a padlock. Gear operators
shall be worm gear design, self locking with diecast
aluminum body and corrosion resistant powder
coat finish. The disc shall be of solid, abrasionresistant plastic, have double o-ring seals on top
and bottom trunnions of the same material as the
valve liner. Liner shall be molded and formed
around the body, functioning as gasket seals with
convex ring design on each side of the valve for
lower bolt tightening torque. Stem shall be of
316/403 stainless steel, non wetted and have
engagement over the full length of the disc. Valves
shall have a molded ISO bolt pattern conforming to
5211/I -5211/II on top flange for actuator mount.
PVC shall conform to ASTM D1784 Cell Classification 12454-A, PP conforming to ASTM D4101
Cell Classification PP0210867272, and PVDF
conforming to ASTM D 3222 Cell Classification Type
II. All PVC (1-1/2" thru 14" only), PP and PVDF body
valves shall be rated to 150 psi sizes 1-1/2" thru
10", 100 psi sizes 12" & 14" and 85 psi size 16" at
70 degrees F. Butterfly valves shall be wafer style,
as manufactured by Asahi/America.
Caution
- Never remove
valve from pipeline
under pressure.
* Always wear
protective gloves
and goggles.
Cv Values
NOMINAL Cv
SIZE (at vao opening degrees
" S m 30- 600 90-
8 200 106 1425 2500
10 250 270 1476 3600
12 300 408 2140 5160
14 350 535 2770 6440
16 400 750 3760.8340,
Pressure vs. Temperature (PSI, WATER, NON-SHOCKY Wt. (LBS) / Vacuum Service
BODY PVC PP PVDF
DISC PP PP PVDF
NOMINAL 30' F 121' F 141' F -5' F 141' F -5' F 141* F 176 F211' Fl
s SIZE 120' F 140' F175' F 140' F 175' F 140' F 175' F 210' F 250' F
8 200 150 40 20 150 85 150 85 75 60
10 250 150 40 20 150 85 150 85 75 60
12 300 100 30 15 00 60 45730
14 350 100 30 7 100 45 100 45 30 15
16 400 NA NA NA 85 45 85 45 30 15
For lug style data consult factory
NOMINAL
SIE GEAR
OPIERATED
8 200 24.25
10 250 41.00
12 300 58.2
14 350 66.14
16 400 79.40
NOMINAL VACUUM
SIZE SERVICE
(INCHES OF
MERCURY)
8 200 -27.56
10 250 -27.56 l
12 300 -2362
14 350 -23.62
16 400 -23.62
35 Green Street, PO. Box 653, Malden, MA 02148 e Tel: 800-343-3618 e 781-321-5409 e Fax: 800-426-7058 e E-mail: asai@asahi-america.com
Register at our interactive web site for on line ordering, product availability, order tracking, and many useful features: www.asahi-america.com
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Section 2
THE BRUNNER DIFFERENCE. Leakproof. Vibration resistant. Accurately
Poswloned openings. Slotted and drilling to most intricate requirements.
Supenor design and precision fabrication of Brunner air receivers ensures
lfr/ performance and long life. Attention to details -the slotting and
*ig of tank attachments and accurately positioned vessel openings *c mode Brunner the favored choice. With a wide selection of standard
confgurition; from 6" to 12' diameters, we can quickly supply the tanks
va need. Brunner will also custom engineer. design and produce air
reoefvers for your specific needs and space requirements. Fast delivery ons::jii orders is a Brunner specialty.
-
VERTICAL
With Platform
C - -
- P
DESIGN PRESSURE 200 PSI
DESCRIP)TION DIMENSIONS OPENINGS
Gallons Diameter Lengt Height A B C D E F G H I J K L M N 0(TL) (TH]) _ _ _ _ _ _ _ __ _ _ _ _ _ _ _ _
30 16 38 4114 672 304 24% 1% 9 18 23 3/16 1/4 3/4 3/4 3/4 1/2 12 3/460 20 48 52 872 40 34 2/2 13 23 30 3/16 1/4 3/4 3/4 3/4 1/2 2 3/480 24 48 52/4 10 39/a 337/ 3% 13 26 30 1/4 1/4 14 174 14 1/2 2 174'120 30 46 55/2 10 41 35 8 15 26 39 1/4 1/4 2 2 2 1/2 2 2
ES RING usec on 120 gallon
\51A sloning standard
VERTICAL
VERTICAL Without Platform
DESIGN PRESSURE 200 PSI
P*ii-ORMS NOT AVAlABLE
ON4 THESE RECEIVERS
-o -,--
DESCRIPTION DIMENSIONS OPENINGS
Gallons Diameter Length Height A B C D F I J K L M N
10 10 30 32% 3 24/s - 23/a 132 1/4 3/4 - 3/4 1/4 N/A
15 12 33 35-Y 4 273a - 2% 15% 1/4 3/4 - 3/4 114 N/A
20 14 33 35% 5 274 - 2% 17% 1/4 3/4 - 3/4 1/4 1%
go---- It 3 39 2Q4- .4 391/' :?14' 14/ 18 1' 4 3 4 3' ?2 11,
60 20 48 5072 41&6 4 I 3~ 2A2 414 3/A 3/A 'VA 2 11)
211fln A2 AE54 -- 01/ C= A9 'L44 43 444 44'1d IO1/ 2P
80 24 48 514 10 39% 33/8 3% 26 1/4 1 1Y4 - 14 1/2 2
All Brunner air receivers are built to ASME code, National Board registered.
USCG, ABS. CSA and California UG 22 approvals also available. Standard
oesign temperature is 4500 F. All openings are NPT threaded. Standard
outside finish is red oxide primer. Other finishes available on request. In
addition to sizes listed in this catalog. Brunner can fabricate alternate sizes
up to 144" diameter, 15 tons maximum weight and 1500 psi.
VERTICAL Industrial
DESIGN PRESSURE 125 PSI to 600 PSI
DESCRIPTION DIMENSIONS (INCHES) OPENINGS
Jallons Diameter Len gth(H A B C D E F G H J K L M N
120 24 69 81 13 14 13 13 8 20 1% 1/4 1/2 2 1 1/2 2
120 30 46 58 7 7 7 12% 8 26 2 1/4 1/2 2 1 1/2 2
200 30 72 84 15 16 15 13 8 26 2 1/4 1/2 2 1 1/2 2
240 30 84 96 19 20 19 13 8 26 2 1/4 1/2 2 1 1/2 2
400 36 93 101 21 22 21 15 8 32 2/ 1/4 1/2 3 1 1/2 2
500 36 116 124 29 24 28 18 8 32 2%2 1/4 1/2 3 1 1/2 2
'C
C '
Section 3
cUKIb R/S SERIES ROTARY SCREWAIR CORMESSORS
The siinbol of Quality & Excellence Since 1854
.cuMSwr -MLf... .
4--4 -
................... 4-
"54" PROFILE ROTORS
INCREASED EFFICIENCY-All CURTIS Compressors
have the latest unique "54" Profile rotor design which
mean lower power cost and longer rotor life. The "54" is
designed for extra CFM output per horsepower even
with pressures as high as 175 PSIG. In most cases, our
rotors are larger by horsepower range than competitive
- ____units.
MANUFACTURED TO ISO-9CO1 STANDARDS
HIGH EFFICIENCY DESIGN- 454" Profile
ZERO ROTCR WEAR-CURTS&rotors run in an oil bath
and have no metal to metal contact.
Ail CURTIS Compressors are male rotcr-dnven.
LONG LIFE -LARGE
DIAMETER BEARINGS
LARGE CYUNDRICAL ROLLER BEARINGS designed
for years of continuous service. Precision ball bearings
with angular thrust contact provide twice the needed
hrust !cading. Bearings are a significant part of any air
end and detemine the time between overhauls. Curtis
put an emphasis on their long life bearings.
AIR OUTLET
OIL SEPARATORS
VERTICAL TWO-STAGE SEPARATION -First stage separation is achieved by offset air/oil inlet and special bafO L&IN ARfling which centrifugally separates 95% of oil
NTAKE from air.
6 OVERSIZE SEPARATOR ELEMENT will last loncer due
to the unique design separation system used by CURTIS. Second stage separator element is sized so
that even under maximum capacity flow, the velo[
through the filter is less than 1 ft.sec. for maximum effi
ciency. More efficient oil separation system provides virI tually oil-free air.
Ar aASME CODED, VERTICAL-TYPE SEPARATOR sa
ge st space and reduces turbulence to prevent oil carryo
Extra large oil sump capacity reduces possibility of
"foam over" and runs cooler.
Virtually oil free DESIGNED FOR EASY ACCESS to oil filter, oila fll
and oil separator element.
Air flow SIMPLIFIED
SIMPLE PIPING SYSTEM. Easy to traci and Ies
to repair. Designed with the fewest joints possib
joints are sealed to avoid leaks.
SIDE-BY-SIDE COOLER DESIGN offers very low r-k.4
approach temperatures and is accessible for clean ng
- -- '. ..- - --- -- ,.- - -' -.-..- .'. I
Packaged
Complete "package" features all comoonents. including
starters, pre-wired, pre-piped, tested and shipped "Ready
to Run." Ever unit is crated to avoid shipping damage.
100% Duty Cycle
The CUFTIS "54" Profile rotary screw compressors are
designec to run 24 hours per day at 100% load.
Vibration Free, Quiet Operation
Simple irstallation - no foundation recuired. Curtis Quiet
Line with oil resistant, acoustical caoinet operates at low
dBA levels.
Built-In Oil Galley Capacity
Assures lubrication tne instant the unit is started. When
the unit is shut off. oil fills the galley and pary floods the
rotor charmoer. On star-uo, the unit immediately receives
more oil via vacuum in the galley.
Distributor Network
CURTIS has a factory authonzed service network
throughout North Amenca. From its inception, CURTIS
has always placed a hign priority on oelvenng outstanding customer service. This guarantees you the nght size
and type of compressor to supply your compressed air
needs when you want it.
One Year "Total Warranty"
Two Year Warranty on the Air End
Every Curtis compressor is warranted a full year, including
all replacement parts and labor on any defective material,
your assurance of Curtis built-in quality. In addition, all air
ends are guaranteed a full two years.
Air Ends are "Built Like A Curtis"
All Curtis air ends are manufactured to ISO 9001 certification. Designed to deliver a maximum volume of air per
energy dollar
Parts Readily Available
The R/S Series is designed using standard parts, including off the shelf motors, electric controls, couplings, belts
and belt drives, most of which are universally available.
Dependable, Heavy Duty Components
We engineered our machines for trouble-free service.
Each model is designed with ease of maintenance in mind.
CURTIS Experience
Since 1854 the CURTIS name has been synonymous
with quality products and service. You'll receive knowledgeable, experienced assistance from our in-house
professional graduate engineering staff in design, manufacturing and production, as well as from our factory
sales representatives. Air compressors are our business.
You'll find a wide selection of styles and models from
which to choose.
Flexibility
CURTIS can meet special working environment conditions. A few of the many applications include automotive,
production lines, machine control, sand blasting and plan air
systems. We can customize a unit to fit your particular need.
COMPARE THE CURTIS FEATURES
e Competitive pricing
Ti-voltage, off the shelf motors (Dual Voltage 125-200 HP'
* High CFM output per HP
* Air End Manufactured to ISO 9001 Standards
* Liquid filled gauges
- Side-by-side coolers for better approach temperatures
e Vanety of configurations and options; base & tank
mounted, oil resistant, acoustical cabinets
- Complete line 5-200 HP rotary screws and /4-125 HP
reciprocating compressors
Heavy duty air ends (120mm-30 HP)
e Dual cbntrol with timed shutdown on 10-50 HP
(modulation on 50-200) HP
e Drain on oil cooler
e Curtis Quiet Line for low dBA levels
e Easy access to oil filter separator change, and oil fil
- Separate cooling fan
* All rotary screw units shipped in wooden crates
U. L. listed control panels with starters standard,
no micro chips to fail
R/-- S150-D-Air Coo DrtDrie Compressor
R/S SERIES ROTARY SCREW
4 cCM CEsscRs
~9* Kittjj
Cur-'s -5 ' with 5c csur
cuRl
Ib R1 |L 2u ft
&i Excellecizu 4inzx ;;
p. .t.
.C 4.-
V.
Form No RS197-F-P
r s vtwwcurtmstoledocom s oec ei905 .e , I . .oc MOUNT
ENGINEERING DATA
ROTARY SCREW COMPRESSOR
CURTIS-TOLEDO, INC
1905 Kienlen Avenue
St. Louis, MO 63133
LP-1
TESTED IN
ACCORDANCE
TO ISO 5167-1
MODEL RIS10ALP RISIOLP RISISLP R/S2( P R/S25LP R/S3 LP R/S40LP RJSSOLP
CFM 40 PSI 65 82 115 14 160 18) 260 310
CFM PSI
CFM PSI
CFM PSI -7.7
BHP 50 PSI 11 11 16.5 2 27 3: 43 54
I HP PSIl3
B3HP PSI
BHP PSI
OIL CAPACITY (GAL) 4 4 7 7 7 7 15 15
R CONNECTION (IN.) 1" 1" 1" 1%5 2'
DBA W/O ENCL. 85 83 83 8 85 8 85 86r BA W/ENCL 80 79 79 8( 80 8 82 83
EA W/ADDITIONAL ENCL ® 77 76 76 7~ 77 7 77 79
DIMENSIONAL W/O ENCL.
LENGTH®@ 60 60 60 6( 60 6$ 72 72
WIDTH @ 30 30 30 3( 30 3 42 42
HEIGHTO @35 44 44 4 44 60 60
WEIGHT 800 1150 1205 12: 0 1350 14 0 1950 2075
SHIPPING WEGHT 875 1225 1280 13 5 1425 14 5 2025 2150
DIMENSIONAL W/ ENC-.
LENGTHS 60 60 60 6( 60 6) 72 72
WIDTH @ 30 30 30 3( 30 3) 42 42
HEIGHT Z 42 42 46 4E 46 415 62 62
WEIGHT 950 1300 1355 13E 0 1500 15 i0 2155 2355
HIPPING WEIGHT 1025 1375 1430 14 5 1575 16 5 2230 2430
-NOTES OPTIONI DIMENSIONS SHOWN ARE FOR STANDARD MACHINES. FOR MACHINES WITH OFTiCNAL EQUIPMENT SUCH AS NEMA 4
CONTROLS, ADDITIONAL SOUND REDUCTION PANELS, TEFC MOTORS OR OTHER OPTIONS, DIMENSIONS COULD CHANGE.
CONSULT FACTORY FOR CORRECT DIMENSIONS WHEN ORDERING MACHINES WITH OPTIONAL EQUIPMENT.
SUBJECT TO CHANGE WITHOUT NOTICE
LP-2ENGINEERING DATA
ROTARY SCREW COMPRESSOR
CURTIS-TOLEDO, INC
1905 Kienlen Avenue
St. Louis, MO 63133AOUNT
TESTED IN
ACCORDANCE
TO ISO 5167-1
'I
MODEL R/S10TALP R/SIOTLP j R/SISTLP R/S20 LP R/S26TLP RIS3ZTLP R/S40TLP RISSOTLP
CFM40PSI 65 82 115 14) 160 1 0 260 310
CFM PSI
CFM PSI
CFM PSI
BHP 50 PSI 11 11 16.5 21 27 3 43 54
BHP PSI
B3H P P S I . .................. ...
BHP PSI
L CAPACITY (GAL) 4 4 7 7 7 15 15
P CONNETION (IN.) 1" 1" 1" 1'/ " 1%" 12" 2" 2"
DBA W/O ENCL. 85 83 83 8! 85 87 85 86
A W/ENCL. 80 79 79 8( 80 83 82 83
W/ADDITIONAL ENCL. ( 77 76 76 7 77 7 77 79
DIMENSIONAL W/O ENCL.
LENGTH © 67 67 1 75 74 75 75 75 75
WIDTH @ 30 30 30 3( 30 3) 42 42
HEIGHT®@ 60 60 64 6 64 6 80 80
WEIGHT 1020 1370 1525 15 0 1670 17 0 2370 2495
HIPPING WEIGHT 1095 1445 1600 16 5 1745 175 2445 2570
DIMENSIONAL W/ ENCL.
LENGTH__ 67 67 75 7 1 75 7 75 75
WIDTH @ 30 30 30 3 30 3 42 42
HEIGHT @ 67 67 71 7 71 71 82 82
WEIGHT 1170 1520 1675 18 0 1990 2 0 2575 2700
EHIPPING WEIGHT 1245 1595 1750 19 5 . 2065 2115 2645 2775
.OTES OPTION
JiMENSIONS SHOWN ARE FOR STANDARD MACHINES. FOR MACHINES WITH OPTIONAL EQUIPMENT SUCH AS NEMA 4
CONTROLS, ADDITONAL SOUND REDUCTION PANELS, TEFC MOTORS OR OTHER OPTIONS, DIMENSIONS COULD CHANGE.
CONSULT FACTORY FOR CORRECT DIMENSIONS WHEN ORDERING MACHINES WITH OPTIONAL EQUIPMENT.
SUBJECT TO CHANGE WITHOUT NOTICE
ENGINEERING DATA
ROTARY SCREW COMPRESSOR
CURTIS-TOLEDO, INC
1905 Kienlen Avenue
St. Louis, MO 63133
I
LP-3
MODEL RISIOTALP WSIOTLP WSISThP PJ2T PJ1251LP WSZ PRS40TLP RISSOTLP
R/S10ALP RISIOLP RJSISLP RISL LP RS2SLP WJSZ LP RJS40LP R/PSSOLP
AIR END MM 96 120 120 1' 0 120 123 155 155
RPM 50 PSI 3315 2150 2700 33 50 3800 44 0 3100 3850
RPM PSI
RPM PSI
RPM PSI
MOTOR RPM 3500 1750 1750 35)0 3500 3500 3500 3500
OIL GPM 11 16 16 13 16 1 23 23
STU/M OIL COOLER 350 350 525 70 890 10! 0 1400 1750
TU/M AFTERCOOLER 60 60 70 1 0 140 19) 240 270
ICZOLING FAN CFM 3000 3000 5000 50 D0 5000 50 0 7000 9000
FAN HP 1/2 1/2 1/2 1. 1/2 1/, 1% 2
)ACH TEMP (F) 15 1 15 15 15 15 15 15
SUBJECT TO CHANGE WITHOUT NOTICE
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CAP-2 16
JULY, 2000
REV. H
CURTIS - TOLEDO
Rotary Screw Compressor
Parts & Instruction Manual
Types R/S & RIS - T
)
WARNING: 7.-S MANUAL CONTAINS
.AL INFORMATION FOR THE SAFE USE
-;RFFICIENT OPERATION OF THIS AIR
20MPRESS'OF
'REFULLY READ THE OPERATOR'S
.1 NUAL BEFORE INSTALLING AND
STARTING THE UNIT
ILURE TO ADHERE TO THESE
.3TRUCTIONS COULD RESULT IN
SERIOUS BODILY INJURY OR
PROPERTY DAMAGE.
TABLE OF CONTENTS
Air and Oil Flow Diagram
Compressor Function and Control
Damaged Goods Policy
Drive Information
Drive Trouble Shooting
Electrical Schematics
Engineering Data
Initial Start-Up Procedure
Inlet Valve Diagram
Lubricant Specifications
Maintenance Record
Maintenance Schedule
Modulating Control
Oil Flow Diagram
Operating and Safety Instructions
Parts Ordering
Parts List
Parts Layout Diagram
Procedure for Long Term Storage of Compressor
Recommended Maintenance Schedule
Recommended Spare Parts
Safety and Warnings and Safety Precautions
Spare Parts Group
Standard Control
Trouble Shooting Guide
MODEL:
13,14
3,4
10,11
6
27
21,22,23,24
25
2,3
18,19,20
6
33
28
17
15
12
9
10
13,14
26
5
10
1
29,30,31,32
16
6,7,8,9
R/S 2S L P
SERIAL NO.: 7076 r-o/o1 /7 PSI: So SCFM: 100 VOLTS:
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SAFETY AND WARNINGS
Before you install this air compressor you should take the timeto carefully read all the instructions contained in this manual.
Electricity and compressed air have the potential to causesevere personal injury or property damage.
Before installing. wiring. starting, operating or making anyadjustments, identify the components of the air compressor
using this manual as a guide.
The operator should use common sense and good working
practices wnile operating and maintaining this unit. Follow allcodes, pipe adequately, understand the starting and stopping
sequence Check the safety devices following the procedures
contained in this manual.
Maintenance should be done by qualified personnel,
adequately equipped with proper tools. Follow the
maintenance schedules as outlined in the manual to insure
problem free ope-ation after start up.
BEFORE PRO
COM
WARNING
COMPRESSED AIR AND
ELECTRICITY ARE DANGEROUS.
BEFORE DOING ANY WORK ON THIS
UNIT, BE SURE THE ELECTRICAL
SUPPLY HAS BEEN CUT OFF,
LOCKED & TAGGED AND THE
ENTIRE COMPRESSOR SYSTEM HAS
BEEN VENTED OF ALL PRESSURE.
I Do not use plastic pipe, rubber hose, or
, ead-tin soldered joints in any part of the
ompressed air system.
2. Loose electrical connections can cause
damage to the machine and may cause
ersonal injury. Check and tighten
lectrical connections prior to first time
stan-up and after major maintenance
IDo not remove the covers, loosen or
move any fittings, connections or
evices when this unit is in operation. Hot
liquid and air under pressure that areIontained within this unit can cause
evere injury or death.
4 The compressor has high andingerous voltage in the motor starter and
ntrol box. All installations must be in
ccordance with recognized electrical
codes. Before working on the electrical
sstem, be sure to remove voltage from
e system by use of a manualsconnect-switch. A circuit breaker or
fuse safety switch must be provided in the
Safety instructions in this manual are bold-faced for emphasi-The signal words DANGER, WARNING and CAUTION areused to indicate hazard seriousness levels as follows
SWARNING
cuang.t i. used to Iil~ia. tha pesu~c. o.
h.z.rd which w0 Cu.a .n..ronal Injury,
d.th or substantial proplry damaga It th.
warning Is gnora.
Warning 1. uaed to indicate the presence of a
hazar which can a,.. piton jury
deast or .ustanti. 'propertyd.mag ifrha
wamrnigit 1.gn....d.
C.ution iuad to indicata I,. pr.stac. of a
hazard which wil or can c... minor p.,.ona
Injury or property daraga ir th. warning . ignora.
Noticeia u..a to notify p.opI.ooalialon,
operation, or ,aint.nance infonnation which
is niporlant bu not hazard.itd,
SAFETY PRECAUTIONS
CEEDING, READ CAREFULLY BEFORE INSTALLING THE
PRESSOR OR PERFORMING ANY MAINTENANCE
electrical suoply line leading to the
compressor.
Those responsible for installation of this
equipment must provide suitable grounds,
maintenance clearance and lightning
arrestors for all electrical components as
stipulated in 0 S.H A. 1910.308 through
1910 329.
5. Do not operate the compressor at
higher discharge pressure than those
specified on the Compressor Nameplate
or motor overload will occur. This
condition will result in motor compressor
shutdown.
6 Use only safety solvent for cleaning the
compressor and auxiliary equipment.
7 Install a manual shut off valve (isolation
type) in the discharge line. A safety valve,
with sufficient capacity to relieve full
compressor capacity, must be installed
between the compressor and the isolation
valve.
8. Whenever pressure is released
through the safety valve, it is due to
excessive pressure in the system. The
cause for the excessive pressure should
be investigated immediately.
9. Before doing any mechanical work on
the compressor:
A.) Shut the unit down.
B.) Electrically isolate the compressor by
use of the manual disconnect switch in the
power line to the unit. Lock and tag the
switch so that it cannot be operated.
C.) Blow down the compressor and
isolate the unit from any other source of
air.
10. There can be adverse effects if
compressor lubricants are allowed to enter
plant air systems.
Air line separators, properly selected and
installed, will minimize any liquid
carryover.
The use of plastic bowls on line filters
without metal guards can be hazardous.
Their safety can be affected by either
synthetic lubricants or the additives used
in mineral oils. From a safety standpoint,
metal bowls should be used on any
pressurized system. Review of your plant
air line system is recommended.
11. When a receiver is installed, it is
recommended that occupational safety
and health standards as covered in the
Federal Register, Volume 36, number 105,
part 11, paragraph 1910.169 be adhered
to in the installation and maintenance of
this receiver.
12. Before starting the compressor, its
maintenance instructions should be
thoroughly read and understood.
13. After maintenance functions are
completed, covers and guards must be
replaced.
NOTE
OPERATING SAFETY WARNINGS ARE
INTERSPERSED THROUGHOUT THIS MANUAL IT IS
-HE RESPONSIBILITY OF THE OWNER, LESSOR
AND/ OR OPERATOR TO READ AND FOLLOW
THESE INSTRUCTIONS
UNIT MUST BE INSTALLED BY A LICENSED
ELECTRICIAN, IN COMPLIANCE WITH ALL
APPROPRIATE CODES
COMPRESSOR MUST BE GROUNDED, ACCORDING
TO CODE USING A MINIMUM SIZE #8 WIRE OR
LARGER
COMPRESSOR MUST BE INSTALLED IN AN AREA
THAT IS PROTECTED FROM THE WEATHER
INITIAL START-UP PROCEDURE FOR ROTARY
SCREW COMPRESSORS
Every Curtis Toledo Rotary Screw Compressor has been
operated and thoroughly tested at the factory prior to
shipment. Before putting the compressor into operation,
preparation for initial start-up should be as follows:
1. VISUAL INSPECTION CHECK-
Inspect the compressor for any visible damage which may
have occurred in shipment. If visible damage is found at
the time of delivery, be sure notation is made on the
freight bill by the delivering carrier and request a damage
report. However, if the shipment is accepted and later
'find that the compressor unit has been damaged, this
assified as "concealed damage". If concealed
damage is found, report it within fifteen (15) days from
date of delivery to the delivering carrier who then must
prepare a damage report. Itemized supporting papers
are essential for filing a freight claim. (See Damaged
Goods Policy).
2. LOCATION CHECK -
Locate compressor on leveled surface. No special
foundation is required. Allow at least three (3) feet
clearance on all sides of the compressor to facilitate
maintenance as well as free circulation of air. Unit should
be located in a clean, well lighted area that will not have
an ambient air temperature exceeding 1050 F. If located
in an enclosed room, Provisions must be made for proper
ventilation so that the temperature of the room will not
exceed 1050 F.
OUTDOOR OPERATION
Unsheltered operations should be avoided. The unit must
be protected against elements such as rain, snow and
freezing temperatures. Failure to do so will void all
warranties.
Any unsheltered installation must have at least:
- NEMA 4 controls
- Weather resistant cabinet
- TEFC motors
- Freeze protection (if applicable)
COLD WEATHER OPERATION
The unit should be installed inside a shelter heated to
temperatures above freezing (32* F).
If installation must be in unheated area all control lines
and drain lines must be heated to avoid freezing. The oil
sump must be heated to maintain proper oil viscosity
during shut downs.
R/S 8000 (synthetic) oil must be used.
Low temperature kits are available.
ELECTRIC CONNECTION CHECK -
Make sure that power supply and wiring is performed by a
licensed electrician in accordance with the wiring
diagram, National Electric Code, State Code and any
other applicable codes. A wiring diagram is enclosed with
each compressor. A magnetic starter of the proper size
and type must be used.
4. GROUNDING CHECK -
The compressor should be grounded in accordance with
the National Electric Code and any other applicable
codes.
5. ELECTRIC QUALITY CHECK -
Test the quality and consistency of the electric Power
supply. Low voltage and/or voltage spikes can destroy
the motor or other electrical components.
6. OIL LEVEL CHECK -
The receiver is filled at the factory with the correct amount
of compressor oil. Check oil level gauge. For
recommended lubrication, see Oil Specifications in the
Recommended Maintenance Schedule. Oil level point is
at mark on sight gauge when unit is off, and sitting for 10
minutes.
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7 WATER PIPING CONNECTIONS CHECK -
(Water Cooled Models Only) - Make sure that the supply
is connected arid open. Piping supplied by the customer
should be at least equal to the connections provided with
the compressor.
8 AIR INTAKE PIPING: A Clean cool air supply isrequired for the satisfactory operation of your
compressor. Where alternate sources of intake air are
available, select the source supplying the cleanest air.IThe standard ai, filter with which the compressor is
equipped is of sufficient size and design to meet all
normal operating conditions.
When an outside air intake source is used, a flexible
sleeve should be provided to connect the filter inlet to the
inlet piping. The machine should be located as close as
possible to the intake source because a restriction at the
inlet will result in a capacity loss for the machine. Do not
:emove the filter except for maintenance. With an outside
*arr installation, the following principles must be applied:
Keeo the piping as short and direct as possible.
' ) Piping size must be at least as large as the inlet
opening.
3) MAKE ABSOLUTELY SURE THAT INLET PIPING
IS CLEANED AFTER FABRICATION.
' I C Air inlet must be protected from the ingestion of rainwater.
WARNING
INLET AIR CONTAINING REACTIVE GASES WILL
CAUSE FAILURE OF THE LUBRICANT AND
COMPRESSOR. INSURE AN AIR SUPPLY THAT IS
WELL CLEAR OF ANY REACTIVE GAS SOURCE.
9 COMPRESSOR ROTATION CHECK -
WURN POWER ON. CHECK FOR PROPER ROTATION
Y MOMENTARILY STARTING AND STOPPING THE
OTOR. DIRECTION ARROW IS SHOWN ON
OMPRESSOR DRIVE END.
CAUTION
'REVERSE ROTATION OF THE COMPRESSOR WILL
AUSE AIR END DAMAGE. AFTER ANY CHANGE OR
RE-CONNECTION OF WIRING, CHECK FOR
CORRECT ROTATION OF COMPRESSOR AND FAN,
NEVER ALLOW THE COMPRESSOR TO RUN IN
REVERSE ROTATION AS INJURY OR PROPERTY
DAMAGE MAY RESULT.
. A RECEIVER TANK - should always be used with
se mounted units. The minimum amount of storage
recommended is one gallon per CFM of capacity. This
ould be increased to three gallons per CEM of capacity
Er svstems with sl-ar chances in demand.
INITIAL START UP
After completing the initial start-up checks, the machine
ready to start. When starting the unit, turn the unl/load
switch to unload. When unit is a full speed, turn to load
position. The minimum pressure valve will allow 60-65
PSI to build in the separator before releasing down
stream.
When the compressor is running, the following
measurements should be watched carefully at the
instrument panel:
1 Compressor Discharge Temperature Should be in the range of 1600 F to 1800 F when running
at full load. (2000 F is maximum allowable)
2. Tank Pressure Gauge For standard operating pressure 100 - 125 PSIG
3. Receiver Pressure Should not be less than 100 PSIG when running full load.
,
WARNING
ELECTRIC MOTORS IN THE SIZE USED IN THE R/S
AND R/S-T COMPRESSORS MAY NOT BE STARTED
MORE THAN 5 TIMES PER HOUR WITHOUT
DAMAGE TO THE STARTER WINDINGS. RUN
UNDER THE OPTIONAL MODULATING CONTROL
RATHER THAN RISK DAMAGE DUE TO FREQUENT
STARTS WHICH VOIDS THE WARRANTY.
SHUTTING DOWN THE COMPRESSOR
When shutting down the compressor, turn the switch to
unload and allow the separator tank time to blow down,
i.e. 45-60 seconds. When separator tank reads zero
pressure, turn off the compressor.
WARNING
FAILURE TO FOLLOW THIS PROCEDURE WILL LEAD
TO OIL CARRY OVER.
COMPRESSOR FUNCTION & CONTROL
Standard R/S models are base mounted compressors.
Standard R/S-T models are tank mounted. Both models
have the motor starters furnished.
All controls are 120V/60HZ.
Auto Dual control with constant run or start / stop is the
standard control system. In the constant run position the
motor runs continuously and the compressor loads and
unloads as necessary to meet system air demand. When
air demand is met the compressor blows down so that
after a brief delay, energy consumption is reduced.
This control method is accomplished with a pressure
switch, a two position selector switch, a three way
normally open solenoid valve and a two way air operated
blow down valve.
~ne compressors are provided with a 25 PSI differential
switcn as standard equipment.
nressure regulator is included in the control system
t :o the unloader solenoid. This functions to quiet the
::.moressor in the unload mode and prolong the inlet
* l've component life. This regulator is factory set at 60
=S1 for 125 PSI units and 80 PSI for 175 PSI units
OPTIONAL MODULATING CONTROL
:cnstant run modulating control valve with low demand
t-eIgy saving mode is an OPTIONAL control available.
,:s allows the compressor to unload and then load
c-acually to meet system air demand.
Ktooulating with Auto Dual control is standard on 50 H.P.
As demand decreases and air system pressure increases
Soove the modulating valve low setting, the valve passes
:essure to the inlet piston and the inlet piston closes
enough to match the air system demand. As demand
rcreases, and air system pressure decreases toward the
modulating valve low setting, less pressure is passed to
ine inlet piston and the inlet piston opens to match the air
system demand.
mn system air demand falls below 20% the low
:emand pressure switch de-energizes the 3 way solenoid
aive This activates the blow down valve and closes the
t valve. At this time the separator blows down.
"Vhen the system pressure falls the pressure switch
:ioses, energizing the 3 way solenoid, closing the blow
:own and opening the inlet valve thereby pumping up to
system pressure again.
Optional modulating control with automatic start-timed
stop has the same features as constant run modulating,
but is best used in applications where air demand varies
widely, or there are periods of no demand. A timer is
added to the system which then stops the unit during long
unloaded periods and then restarts the unit when the
system requires more air.
~he modulating valve ( RN42612 ) is adjusted by turning
the screw in the valve dome, clockwise raises the
Dressure and counter-clockwise lowers the pressure.
This adjustment should be made slowly. The low
oemand pressure switch adjustment must be coordinated
with (set slightly LOWER than) the modulating valve. The
unit should begin blow down before the inlet valve is
closed tight.
NOTE
USE A LIGHT TOUCH WHEN ADJUSTING THE
MODULATING VALVE, AS THE METAL DIAPHRAGM
THE VALVE CAN BE DAMAGED IF TOO MUCH
rESSURE IS APPLIED TO THE ADJUSTING STEM,
STANDARD AUTOMATIC DUAL CONTROL
This is a timed stop, automatic start up system that also
will respond to the compressor air demand control
With the switch in constant position the compressor will
operate in its normal state (Modulating or Load/Unload).
With the switch in the auto position, when the compressor
unloads completely and the separator tank blows down, a
timer is activated which will shut off the unit after a timed
period. (Minimum setting should be 10 minutes). When
the system calls for air, the unit will restart automatically
COMPONENTS USED:
1.) 2 Position Switch
2.) Timer
3.) Power "ON" Light
4.) Compressor "Stand-by" light.
5.) 2 Pole Relay (Units with stop-start push button
control)
NOTE
FOR ALL R/S OR R/S-T UNITS HAVING MODULATING
CONTROL, THE PRESSURE SWITCH MUST ALWAYS
BE SET 2-3 PSI LOWER THAN THE MODULATING
VALVE MINIMUM TIMER SETTING WITH DUAL
CONTROL MUST BE 10 MINUTES.
EFFECT OF VARIOUS TEMPERATURE CONDITION
A thermostatic mixing valve is Standard Equipment.
ALWAYS SUPPLY CLEAN/ COOL AIR TO THE
COMPRESSOR
ROTARY SCREW COMPRESSORS OF THE RIS or
RJS-T SIZE PRODUCE A GREAT DEAL OF HEAT. The
ambient temperature in a compressor room must not
exceed 1050 F. Provide a constant supply of fresh air to
prevent overheating.
In addition, when operating In ambient temperatures
under 32* F/0* C an oil sump heater must be used with
the Thermostatic mixing valve, which Is standard
equipment. When operating in ambients over
105* F/410 C consistently, water cooled heat exchangers
or synthetic oil should be used. When operating in
extreme dusty dirty ambients, water cooled units should
be used along with extra heavy duty double inlet filtering.
Provision should also be made by the user to keep any
moisture condensate traps from freezing.
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INSTRUCTIONS: WATER COOLED COMPRESSORS
COMPRESSOR OIL COOLER
Adjust the Manual Valve on the Water Outlet from the Oil
Cooler to maintain a discharge temperature of air/oil from
the compressor at 170/2000 F.
f an Automatic Water Flow Valve is used, adjust the Flow
Control to maintain the same temperatures as above.
The Valves' Sensing Bulb is located in the Oil Outlet from
the Cooler.
The Oil Inlet Injection Temperature to the compressorIshould be a minmum 1 300 F.
COMPRESSOR AFTERCOOLER
Adjust the Manual Valve on the Water Outlet from the
Aftercooler, so the shell of the Cooler is cool to the touch
on the Air Outlet End and warm on the Air Inlet End. Too
much water flow can cause damage to the Cooler where
hot air meets extremely cold water.
An Electric Water Shut Off Solenoid may be installed at
the Inlet of water to the unit. This valve must be open at
all times when the compressor is operating
Do not use water lines smaller than the In and Out
Connectons at the unit.
I RECOMMENDED MAINTENANCE SCHEDULE
AIR FILTER
Frequency of servicing will depend on the environmental
onditions under which the compressor is operating.
ervice the air filter element under any of the following
conditions, whichever comes first:
) Check air filter element weekly and change if outside
surface of the element appears to be evenly coated
with dust.I) Change every two thousand (2000) hours of
operation every six (6) months.
3) Under unusually dirty ambient conditions, change
afilter as required (See 1 above).
The standard air filter with which the compressor isEquipped is of sufficient size and design to meet all
ormal operating, conditions.
'hen an outside air intake source is used, a flexible
eeve should be provided to connect the filter inlet to the
*let piping. The machine should be located as close as
possible to the intake source because a restriction at the
let will result in a capacity loss for the machine. It is not
tended that the filter be removed except for
maintenance.
DANGER
DISCHARGE AIR IS NOT INTENDED FOR
BREATHING. USING DISCHARGE AIR FOR
BREATHING CAN LEAD TO SERIOUS INJURY OR
DEATH!
AIR/OIL SEPARATOR
Change the separator element under any of the following
conditions, whichever comes first:
1.) Whenever pressure drop between system and
separator exceeds 10 PSI. This pressure drop
should be checked daily under full load conditions.
2.) Once a year.
3.) Every four thousand hours (4000).
4.) When excessive oil appears in the service line as a
result of a faulty separator (due to pin hole leak),
ruptured, or collapsed separator element.
Wrong lubricants will cause oil carryover
The Air/Oil Separator element never "wears out" but it
does lose its effectiveness due to being plugged with dirt.
To obtain long separator element life, it is important to
change the air inlet filter and the lubricant filter on a
regular schedule.
Moisture in the oil will cause oil carryover.
LUBRICANT FILTER
Change the lubricant filter element(s) under any of the
following conditions, whichever comes first:
1) After first 100 hours then
2) Every three (3) months OR.
3) Every one thousand (1000) hours OR
4) Every lubricant change, WHICH EVER IS SOONER.
WARNING
Under very dirty operating conditions lubricants may
become contaminated before the one thousand (1000)
hour interval. It may be necessary to change the lubricant
filter more often in dirty environments such as foundries.
THE USE OF SYNTHETIC LUBRICANTS DOES NOT
CHANGE THE FILTER REPLACEMENT INTERVAL.
FAILURE TO KEEP SYNTHETIC LUBRICANTS CLEAN
WILL DESTROY THE AIR END!!!!!
LUBRICANT CHANGE
Change the lubricant after the first two thousand (2000)
hours of operation to make sure that any initial
contaminants in the system are removed.
-J
DANGER
HOT OIL UNDER PRESSURE CAN CAUSE SEVERE
:NJURY, DEATH OR PROPERTY DAMAGE. BE SURE
tOMPRESSOR IS SHUT DOWN AND RELIEVED OF
_L PRESSURE BEFORE ATTEMPTING TO CHANGE
DIL. OIL FILTER OR AIR/OIL SEPARATOR ELEMENT.
fter that, the lubricant should be changed every two
:,ousand (2000) hours, when using petroleum based
Luoricating Coolant. Change every eight-thousand (8000)
nours when using a recommended Synthetic Lubricant.
SYNTHETIC LUBRICANTS MUST BE TESTED EVERY
1000 HOURS. SYNTHETIC LUBRICANTS CAN FAIL IF
CONTAMINATED AND BREAK DOWN WITHOUT
WARNINGI FAILURE TO TEST CAN LEAD TO
DESTRUCTION OF COMPRESSOR.
CLEAN SCAVENGER LINE ORIFICE:
When no lubricant flow is visible in the sight glass.
LUBRICANT SPECIFICATIONS
Your unit has been filled and tested with high quality
Rotary Screw Lubricant which can be used for year round
coeration to 1050 F ambients. Proper maintenance and
a-tention is a MUST to provide continuous trouble free
:zeration. Follow the maintenance schedule provided for
tFiter, Lubricant Filter and Separator Element
,nges.
All models furnished with Petroleum Oil
PRODUCT NUMBER
CURTIS PART NUMBER:
BASIC DESCRIPTION:
RECOMMENDED OIL CHANGE:
AVAILABLE IN:
When ordering specify part number:
R/S 2000
V0413
Petroleum ISO 46
2000 hours
5 gallon container
V0413
For extended life
Available for all models
PRODUCT NUMBER
CURTIS PART NUMBER:
BASIC DESCRIPTION:
RECOMMENDED OIL CHANGE:
AVAILABLE IN:
When ordering specify part number:
R/S 8000
V0414
Synthetic ISO 46
8000 hours
5 gallon container
V0414
WARNING
DO NOT MIX LUBRICANTS. PROPERTY DAMAGE OR
PERSONAL INJURY COULD OCCUR.
A/wavs chanoe Filter Element when chanQinp lubricants.
WARNING
STOP UNIT, RELIEVE AIR PRESSURE AND
DISCONNECT POWER BEFORE CHECKING ADDI
OR CHANGING LUBRICANTS
NG
FAILURE TO FOLLOW THESE PRECAUTIONS CAN
LEAD TO PERSONAL INJURY AND/OR PROPERTY
DAMAGE.
All components supplied by Curtis - Toledo are
compatible with the above lubricants. Check with your
supplier to insure compatibility of components in your air
supply system.
V-BELT DRIVE
Check motor / compressor v-belt alignment every six (6)
months, or at any sign of slippage. See page 26 for v-belt
maintenance suggestions.
Check belts weekly for condition and tightness. It should
have the slack taken up after the initial 100 hours of
operation. Use motor base adjusting bolts and a straight
edge to adjust and align belts, properly.
NOTE
TO AVOID POTENTIAL, DAMAGE TO BELTS, NEVER
FORCE BELTS OVER SHEAVES, MOVE DRIVE
INSTEAD.
WARNING
NEVER LUBRICATE BELTS OR ALLOW LUBRICANTS
TO COME IN CONTACT WITH BELTS OR SHEAVES.
SERIOUS DAMAGE OR PERSONAL INJURY MAY
OCCUR.
OIL COOLER MAINTENANCE
AIR COOLED MODELS
Oil cooler FIN surfaces MUST be cleaned periodically
Frequency of cleaning depends on surrounding
environmental conditions. Dirt and dust buildup on the
cooling fins will cause a decrease in thermal efficiency
and cooling capacity. This will ultimately lead to
compressor overheating and potential compressor
failure.
GENERAL TROUBLE SHOOTING GUIDE
FAILURE TO START
Cause: Power not turned on
Correction: Turn power ON" by connecting main
disconnect switch or circuit breaker.
Cause: Blown main circuit fuse
Correction: Replace fuse
6
Cause. Blown control circuit fuse
Correction Replace fuse
Cause: Safety circuit shutdown - high discharge
temperature
Correction Correct situation as per solutions described
uncer "HIGH DISCHARGE AIR
TEMPERATURE, of this trouble shooting
guide, then press manual reset button at high
discharge temperature switch. Restart
compressor.
Cause: Overloaded motor relay tripped.
Correction: Press motor reset button.
Cause: Low Voltage.
Correction: Test voltage and correct.
ICause
Correction:
Cause:
Correction
Cause:r orrection:
ause
orrection
t ause:
orrection:
I
Cause:
orrection:
ause:
Correction:
Bause:
Correction:
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Cause:
N rrection:
Faulty start switch or connection.
Che'k and correct
Power failure.
Check power supply.
UNSCHEDULED SHUTDOWN
High discharge temperature.
Correct situation as per solutions
desc-ibed in "HIGH DISCHARGE
TEMPERATURE" , section in this trouble
snoong guide, then press manual reset
buttoi at high discharge temperature
switcn. Restart the compressor.
Overloaded motor - Thermal overload
relay tripping.
Press reset button at motor starter.
Power failure.
Check power supply.
LOW RECEIVER PRESSURE
Excessive air demand.
Reevaluate air demand.
Excessive leaks in service lines.
Repair service lines.
Inlet valve not fully open.
Correct situation as per solutions described
under 'MALFUNCTIONS IN THE CAPACITY
CONTROL SYSTEM" - "(A) Inlet Valve Not
Opening or Closing in Relation to Air
Demand", section of this trouble shooting
guide.
Plugged air cleaner.
Clean air filter element or replace with new
element.
Air pressure switch not set correctly
Correction: Readjust air pressure switch to desired cut-in
and cut out pressures.
Cause: Faulty receiver pressure gauge.
Correction: Check and if found faulty, replace it.
HIGH DISCHARGE AIR TEMPERATURE
Cause: Not enough cooling water flowing through
cooler (water cooled models).
Correction: Check water system for possible restriction,
including water regulating valve.
Cause: Inadequate circulation of cooling air at cooler
(air-cooled models).
Correction: Check location of cooler to make sure that
there is no restriction to free circulation of
cooling air.( SEE PAGE 4 ) Also check fins
at the cooler and if found dust laden, clean
them with air while the machine is not
running. If greasy dirt the unit may have to
be power washed as above.
Cause: Low oil level in the reservoir.
Correction: Add oil and bring oil level to recommended
level, Also check oil system for possible
leaks.
Cause: Clogged oil filter.
Correction: Replace oil filter element(s).
LOW AIR DELIVERY
Cause: Plugged air filter.
Correction: Clean air filter element(s) or replace with
new element(s).
Cause: Excessive leaks in service lines.
Correction: Repair service lines.
Cause: Inlet valve not opening fully.
Correction: Correct situation as per solutions described
under "MALFUNCTIONS IN THE CAPACITY
CONTROL SYSTEM" - "(A) Inlet Valve Not
Opening or Closing in Relation to Air
Demand". section of this trouble shooting
guide.
SAFETY VALVE BLOWS
Cause: Air pressure switch not set correctly
Correction: Readjust air pressure switch so that the
compressor unloads at desired pressure,
Cause: Inlet valve not closing properly in relation
to air demand.
Correction: Correct situation as per solutions described
under "MALFUNCTIONS IN THE CAPACITY
CONTROL SYSTEM" -"(A) Inlet Valve Not
Opening or Closing in Relation to Air
Demand", section of this trouble shooting
guide.
I
Cause: Plugged separator.
Correction: Replace with new air/oil separator.
Cause: Faulty receiver pressure gauge.
rrection: Check gauge for accuracy.
Cause: Faulty safety valve.
Correction: Check safety valve for correct pressure
setting. If valve is leaking, replace it.
EXCESSIVE OIL CONSUMPTION
Cause: Too high oil level in the separator tank.
Correction: Bring oil down to recommended level by
draining the separator. Use oil level gauge
as a guide.
Cause Plugged scavenger line.
Correction: Clean scavenger line.
Cause:
Correction:
Cause:
Correction:
Faulty oil filter(s).
Replace oil filter element(s).
Oil break down.
Correct situation as per solutions described
under "OIL BREAK DOWN" section of this
trouble shooting guide.
Cause Wrong kind of oil being used.
Correction: Refer to page 6 for type of oil.
use: Rapid start/stop or load/unload (short cycle)
.,rrection: Set controls to correct short cycling. (C.
page 9)
Cause Excessive oil foaming.
Correction: Set controls to correct short cycling. (C.
page 9)
Cause. Scavenger line not reaching the bottom of
the separator.
Correction: Check scavenger line connections in
separator
Cause: Operating pressure too low.
Correction: Receiver pressure should not fall below 100
PSIG when running loaded. Leak in system
or air consumption too great.
Cause: Faulty or damaged separator. (e.g. - loose
separator assembly, defective primary
element.).
Correction: Change air/oil separator
Cause: Leak in oil line.
Correction: Check for leaks and correct.
"quse: Shaft seal failure.
rection: Replace necessary component of the seal or
the complete seal as deemed necessary.
Cause: Rapid pressure loss in system.
Correction: Look for applications that use large amount
of air very quickly. An air receiver should be
installed in the system.
Cause: Starting the unit before the separator has
been blown down.
Correction: Change procedure and instruct operators
on use.
FREQUENT AIR/OIL SEPARATOR CLOGGING
Cause: Faulty air cleaner or inadequate cleaner
for the environment.
Correction: If faulty air filter element(s), replace them
air filter is inadequate for environment,
replace it with a heavy duty cleaner.
If Cause: Wrong kind of oil being used.
Correction: Refer to page 6 for type of oil.
OIL BREAK DOWN
Cause: Extreme operating conditions such as high
oil injection and compressor discharge
temperatures, high ambient temperature with
high humidity and high receiver pressure.
Correction: Operate compressor at recommended
receiver pressure and oil injection
temperature.
Cause: Contaminated oil.
Correction: Service air filter element and oil filter
element promptly in accordance with
recommended maintenance schedules.
Cause: Negligence in draining condensate from the
separator.
Correction: Drain condensate from the separator
periodically. More frequent draining might
be necessary when operating at high
ambient temperature and high humidity
environment.
Cause: Mixing of different brands of oil
Correction: DO NOT MIX DIFFERENT BRANDS OF
OIL.
Cause: Wrong kind of oil being used.
Correction: Refer to page 6 for type of oil.
WARNING
PERSONAL DAMAGE MAY RESULT FROM MIXING
OILS.
Cause: Use of wrong oil.
Correction: Follow compressor oil specifications as
described in the INSTRUCTION MANUAL
(see page 6)
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I8
MALFUNCTIONS IN THE CAPACITY CONTROL
SYSTEM
(A) Inlet Valve Not Opening or Closing in Relation to
Air Demand
Cause: Improper setting of air pressure switch or
faulty switch.
Correction: Readjust air pressure switch to proper
sett ngs If faulty, replace switch.
Cause:
Correction:
Cause
ICorrection
Cause.
Correction
Faulty unloader solenoid valve.
Replace unloader solenoid valve.
Jammed inlet valve.
Check inlet valve assembly
Pressure regulator set to low.
Adjust pressure regulator to 60 PSI
minirmium.
(B) Comressor Does not Unload When There Is No
I Air Demand
Cause:
orrection:
Cause
orrection
ause:
Correction:
lause:
Correction:
Air p-essure switch not set correctly
Readjust air pressure switch setting.
Faulty solenoid valve.
Check wiring and solenoid valve.
Fault/ air pressure switch.
Replace air pressure switch.
Leaks in service lines.
Repair leaks.
C) Too Rapid Cycling Between Load and Unload
Cause: Too small volume of air in service line.
orrection: Provide sufficient volume, by adding air
receiver.
ause:
orrection:
Iause:
Correction:
Cut-in and cut out pressures too close at air
pressure switch.
Re-adjust cut-in and cut out pressure
settings.
Using too much air.
Add larger compressor, check system for air
leaks.
Oil Coming Out Through Air Cleaner At Shutdown
ause: Faulty Inlet Valve.
orrection: Inspect check valve. If necessary, replace.
il Comino Out Throuah Blow Down Valve
Too high oil level in the separator.
on: Bring cil level to recommended oil level by
draining the separator. Use the oil level
gauge as a guide
Cause: Cycling too often between load and unload.
Correction: Correct situation as per solutions described
under "MALFUNCTIONS IN THE CAPACITY
CONTROL SYSTEM" - "(C) Too Rapid
Cycling Between Load and Unload", section
of this trouble shooting guide.
Too Frequent Air Cleaner Clogging
Cause: Compressor operating in highly
contaminated area.
Correction: Use remote air intake mounting.
Cause: Air cleaner not adequate for the operating
conditions.
Correction: Use heavy duty air cleaner.
INSTRUCTIONS FOR ORDERING PARTS
When ordering parts:
1) List the compressor model an serial number.
2) List the compressor motor horsepower.
3) List the part description.
A BILL OF MATERIALS WITH PART NUMBERS AND
DESCRIPTION FOR YOUR SPECIFIC COMPRESSOR
IS PROVIDED WITH EACH UNIT.
EXAMPLE:
When ordering an inlet filter element for a 25 HP base
mounted unit, please provide:
1) Model Number, Serial Number, and Horsepower i e.
R/S - 25, S/N 1234 & 25 HP
2) Part Number and Description i.e. RN24020-1, inlet
filter element.
EqO
Cause:
Iorrecti
PART NAME LISTED BY GROUP, REFER TO BILL OF
MATERIAL FOR PART NUMBER.
CABINET GROUP
-binet
2ssure Gauge
7enperature Gauge
AIR GROUP
Ai nd
Motor
Compressor Sheave with Bushing
Motor Sheave with Bushing
V-Belts (set)
oteel Base
Safety Valve
Theck Valve, Discharge Valve, & Outlet Valve
tressure, Temperature and Oil Level Gauge
Scavenger Line Sight Glass
Secarator Tank and Separator Element
nliet Valve, Inlet Filter Assembly and Inlet Filer Element
Sevice Valve
Fiex Coupling
OIL GROUP
DOi Cooler
-an Blade, Fan Motor and Fan Guard
Di' FLter Assembly
:i: Drain Valve and Oil Stop Valve (when used)
mNTROL AND ELECTRIC GROUP
ssure Switch
Control Box and Control Transformer
jnioader/Blow down Solenoid Valve
Pneumatic Blow Down Valve
Control Relay
Hign Temperature Shutdown Switch & Well
Fjse Block-Control & Fuse-Control
Main Motor Magnetic Starter & Fan Motor Starter
Start Push Button & Stop Push Button
2 position switch
Stop delay relay timer
MISCELLANEOUS GROUP
Thermal Mixing Valve (Standard)
Aftercooler (Standard)
Moisture Separator (Standard on base mounted)
4uto Drain (optional)
Modulating valve (Standard 50 H.P.)
Modulating valve (Optional 10-40 H.P.)
SPARE PARTS GROUP
4 000 HOUR KIT (SEE Pg. 29)
2 Air filter elements
4 Oil filter elements
' Air/Oil separator element
uo 00 HOUR KIT (SEE Pg. 30)
4 Air filter elements
8 Oil filter elements
2 Air/Oil separator elements
12,000 HOUR KIT
6 Air filter elements
12 Oil filter elements
1 Inlet Valve Kit
3 Air/Oil separator elemE
1 Thermo mixing valve
1 Set, V-belts
1 Minimum pressure val
RECOMMENDED FOR
EXPORT COMPRESSORS
(SEE Pg. 30,31,32)
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LOST or DAMAGED GOODS POLICY
All goods are shipped "F.O.B." factory (Freight on Board).
In essence, this means that the customer owns the goods
once they leave our dock and any lost or damaged goods
are his responsibility. The F.O.B. policy is consistently
used by every manufacturer in the compressed air
industry. Freight allowed or freight prepaid shipments are
still under the F.O.B. terms.
This F.O.B. policy is used by all manufacturers for one
reason - it is the only workable policy, for only the
"receiving point' cap inspect the arriving shipment and
properly file a claim. It would be impossible for the
"shipper" to inspect equipment hundreds, or sometimes
even thousands of miles away from his location.
10
PROCEDURE FOR HANDLING DAMAGED
SHIPMENTS
PROCEDURE #1
The "Lost/Damaged Goods Policy". is designed to be a
ear. fair and effective aid in helping the customer file hisI:aim.
1) The customer at the receiving point MUST inspect
each shipment for damage.
2) If the shipmeit is damaged, the customer should so
note it on the freight bill.
I3) The customer should request an inspector from the
freight company to inspect the equipment immediately. It is best to send a confirming letter
with the following information:
a. Freight bill number.
b Date delivered - shipper's name & address.I c Description of item(s) damaged,
d. Description of damage (a polaroid picture if
possible.)
e A copy of your invoice for the equipment.
After inspecticn. (before the inspector leaves):
a Get a copy of the inspection report.
b Request the unit be shipped back "free astray".
c, Request a credit for the original freight bill.
Call the factory and:
a. Get a Return Material Tag (RMT number).
b. Give a purchase order for repair. The purchase
order should refer to the item and trucker claim.
We will accept the shipment back and repair (under
normal conditions) and return it within (7) seven
working days.
i) We will invoice the customer for the repair which will
then become "part" of your claim. The invoice must
be presented to the trucking claim department along
with their claim form.
)We suggest if the trucker does not pay within 30 days
that you call ard / or write the ICC making a formal
complaint of poor service. Also advise Curtis Toledo
in writing for fo low-up.
ROCEDURE #2
Edama e can be repaired at the receiving point, follow
Wocedure 1, steps 1 through 4a. Repair the unit and
make out a detailed invoice to the trucker showing laborI urs, labor rate, materials used, and cost of materials,
A$ COMPRESSOR OPERATING AND SAFETY j 16. Do not operate compressor in areas where there is a
PRECAUTIONS: Because an air compressor is a highs:eed. rotating piece of machinery, the same common
sense safety precautions should be observed as with any
sece of machinery of this type where carelessness in
-- eration or maintenance can be hazardous to personnel.
m addition to the many obvious safety rules that
should be followed with this type of machinery, the
following specific precautions and prohibitions may_
orevent personal injury or property damage.
1. Pull main disconnect switch and disconnect any
separate control lines, if used, before attempting
to work onlor perform maintenance on the unit, Use
std. lockout procedure.
Do not attempt to remove any compressor parts
without first relieving the entire system of pressure.
2. Do not attempt to service any part while machine
is operating.
Do not operate the compressor at pressures in excess
of its rating.
Do not operate the compressor at speeds in excess of
its rating
Do not remove any guards, shields, or screens
while the compressor is operating.
)bserve terminal pressure gauge daily, to be sure
automatic control system is governing compressor
:oeration within proper limits.
8. Periodically check all safety devices for proper
operation.
9. Periodically test all warning lights.
Do not play with compressed air. Pressurized air
can cause serious injury to personnel,
Be sure no tools. raps. or loose parts are left on the
compressor or drive parts.
12. Do not use flammable solvents for cleaning.
3 Exercise cleanliness during maintenance and when
making repairs. Keep dirt away from parts by
covering parts and exposed openings with clean cloth
or kraft paper.
14. Do not operate the compressor without guards,
shields, and screens in place.
Do not install a check valve between the compressor
discharge and the receiver.
possibility of ingesting flammable or toxic fumes
17. Never disconnect (or jumper) high air temperature
switch and operate the machine. Serious iniury or
property damage may result
18. Know what mode a machine is in before working
around it. The power can be on and a machine
may be in auto restart mode.
19. INSPECT COMPRESSOR FOR OPERATING AND
SAFETY CONDITIONS AT THE START OF
EACH SHIFT,
Pressure vessels (receivers, aftercoolers, intercoolers)
may require A SME Code stamping to meet local codes.
Investigate code requirements before operation to make
sure all requirements have been met.
The owner, lessor, or operator of the compressor is
hereby notified and forewarned that any failure to
observe these safety precautions may result in
damage or injury.
Curtis Toledo expressly disclaims responsibility or
liability for any injury or damage caused by failure to
observe these specified precautions or by failure to
exercise that ordinary caution and due care required
in operating or handling the unit even though not
expressly specified herein.
12
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CURTIS TOLEDO
1905 Klenlen Ave.
St. Louis, MO. 13133
PHONE: 314-383-1300 FAX; 314-381-1439
RETAY SCREM STANDARD CONTROL
IRCHIHE: RO1RRY CfRE URftRU
G: CS629IOIRCRAMI sTAMDCONTURL ommu: 8-3-95
16
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-4m
IMMUJRE
VALVE
COMPR -ESSJR] CRFCE
OIL SCAVENCG O LfE
CHECX VMVE
S.T GI7LASS
CURTIS TOLEDO
1906 Kienlen Ave.
St. Louis, MO. 83133
PHOMEI 314-383.1300 FaX: 314-381-
ROTAY $CREW MODULATINO CONTROt
MCHNEt NOTAY 8CREW Di0ftAUI N: C8630
OACIAfMI NOO. CONTROL RAsu 81
S
-14-95
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INLET-VALVE DIAGRAM
'NORMALLY OPEN- [POWER TO CLOSEI- LINE PRESSUREFLOW AGAINST THE VALVE
SEATINO DISC WiL. OPEN THE VALVE. CONTROL PRESSURE APPLIED TO THE TOP OF THE
DIAPHRAGM WILL CLOSE THE VALVE (CONTROL PRESSURE SHOULD BE APPLIED AT PORT -C")
NO. DESCRIPT1ON STD.
CAST IRON
I1BDYI27N.P.T. *1 BODY
CAST BRASS 1 1 N. P.
SEAT 1 CAST BRASS *
2 A '*1.O CAST STN.STL
3 HEXLOCKNUT(M.20)
FORGED BRASS *
I CXSC PLATE SNSISTN. 51TL
SUNAN *
5 -RING ETH. PROP.
VITON
SUNAN *
6 DISC ET.PROP.
VITON
7 DISC HOLDER T
I GASKET
SUNAN a
9 0-RING | ETHPROP.
VITON
0- RiNG RETAINER BRASS *
f10 Sumer0toa tQe iT STL
FOCDBRAS
I1 DIAPHRAGM PLATE FOREDBRAS
STN STL
12 HEX LOCK NUT 5U16 .24,
CASTTON
CAST BRAW a
14 HEA HEAD CAPSCREW ira- 20 X 1 4)
15 IAPRAG |BUNAL Nt NYO Mil.
Is DAPHAUU| VYTON INOMNEK
I6 GASKET A
17 HEX NUT ( 194. 20)
BUNA N
it 0 . RING ETH. PROP.
19 SHAF
( 1 1/2" N. P. T. ) RN24534
(2" N. P. T. )
INLET VALVE 15-20-25-30 HP
INLET VALVE 10HP
1) Kit No. 24564
1) Kit No. 24552
2) Kit No. 24662
RN24539 (2 1/2" N. P. T. )
INLET VALVE 40-560HP
1) Kit No. 2456
2) Kit No. 24566
2) Kit No. 24564
CURTIS TOLEDO
1908 KIenlen Ave.
St. Louis, MO. 63133
PHONE: 314-383-1300 FRX: 314381-1439
INLET-VALVE DLAGRAM
MCNINES ROTrRY 1CREN IORAsIN: CS631
8-4-95
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REPAIR PARTS KITS
PART NO
SUNA N T SUNA N * UNA N
1 DIAPHRAGM & SEALS KIT
CONSISTS OF EN NOS. 424 RA 425 -RA 426 -RA
5.6. *,. 15. 16. Is
21 INTERNAL METAL PARTS IOT
NORMALLY OPEN MODEL
CONSISTSOFSTANDARD(.) 424.RF 425-RF 420RF
ITEM NOS. 3,4.7. 10.11, 12,10
RN24534 I
20
DIAICRAMEl INLET-VALVE Dultil:
CURTIS TOLEDO
115 V CONTROL WIRING SCHEMATIC
LI L2 L3
POWER DIST.
BLOCK
MS1 OL1 COMPRESSOR
MS2 OL2 COOLING FAN
NOTE: FUSE FAN MOTOR
FUSE FUSE
FUSE
115 V POWER ON
G INDICATOR
R--- 2 HIGH TEMP.
sTO, sTART 5 P L 122SWITCH
START / STOP SWITCH
R1-1 2 IANTI - START
PRESSURE SWITCH
1 14 TR 6 A2 -STANDBY
RI-2 1 1 'sINDICATOR
11i4 l CONST. AUTO NCAO
!4 15 Is 12
A COOLING FAN
COMPRESSOR
20 sCH cRE 2 PRESSURE SWITCHT- UNL / LOAD SWITCH
MstI UNLOADLOAD UNL. SOLENOID
PRESSURE H 2 HOURMETER
10 SWATCH I I HUIE
A1TA2 2 STANDBY TIMER
USED ON R/S, R/S-T 15 - 40
CURTIS TOLEDO
1905 Klenten Ave.
St. Louis, MO. 63133
PHONE; 314-383-1300 FAX; 314-381-1439
FDURL CONTR OL / DELAY ON AUTO
ciCt I M: ROTARY SCRI ORUIImC: CS632
D1IIA: W I R I NG oauH: 2-12-96
CURTIS TOLEDO
115 V CONTROL WIRING SCHEMATIC
Li L2 L3
POWER DIST.
BLOCK
MS1 OLl COMPRESSOR
---- ---- ------- ---- -
rC i - - '72
----------------
COOLING FAN
(AIR COOLED)
FUSE
FUSE
R1-2
-.
PRESSURE UNLOAD/LOAD y
SWITCH SWITCH UL
USED ON R/S, RIS - T 50
POWER ON
INDICATOR
HIGH TEMP.
INDICATOR
START I STOP SWITCH
ANTl - START
PRESSURE SWITCH
STANDBY
INDICATOR
MAIN MOTOR
FAN MOTOR
HOURMETER
TNIER. MINIMUM
SET 10 MIN.
AUTO DUAL RELAY
PRESSURE SWITCH
UNL / LOAD SWITCH
UNL. SOLENOID
CURTIS TOLEDO
1905 KIenlan Ave.
St. Louis, MO. 03133
PmoHNE: 314-83-1300 FAXI 314481-1439
DUAL CONTROL / DELAY ON AUTO
nCNIN OTARY scREIflfNtmIN: CS635
acann: IIR ING oamiu: 2-12-96
22
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CURTIS TOLEDO
115 V CONTROL WIRING SCHEMATIC
LI L2 L3
POWER DIST.
BLOCK
MS1 OL1 COMPRESSOR
FUSE
FUSE
POWER ON
INDICATOR
HIGH TEMP.
SWITCH
START / STOP SWITCH
ANTI - START
PRESSURE SWITCH
STANDBY
INDICATOR
COMPRESSOR
PRESSURE SWITCH
UNL / LOAD SWITCH
UNL. SOLENOID
HOURMETER
STANDBY TIMER
CURTIS TOLEDO
190 Klenhn Ave.
St Lois. MO. 431=3
PuO*H: 314-383-1300 PAX. 314-321-1439
RIS, R/S-T 15-40 WATERCOOLED
n....z s..t. .c.... aaaamc CS634
El5C.... SCHEMATIC o.nu. 2-26-97
I
CURTIS TOLEDO
115 V CONTROL WIRING SCHEMATIC
LI L2 L3
POWER DIST.
BLOCK
MS1 OLl COMPRESSOR
FUSE
FUSE
IT
PRESSURE UNLOAD/LOAD
SWITCH SWITCH UL
POWER ON
INDICATOR
HIGH TEMP.
INDICATOR
START I STOP SWITCH
ANTI - START
PRESSURE SWITCH
STANDBY
INDICATOR
COMPRESSOR
MOTOR
HOURMETER
TIMER RELAY
PRESSURE SWITCH
UNL I LOAD SWITCH
UNL. SOLENOID
CURTIS TOLEDO
1905 KIenhn Ave.
St. Louis, MO. 63133
PHNE; 314-383-1300 FRXt 314-381-1439
R/S, R/S - T 60 WATERCOOLED
nmCNINI: RCTARY ICIle OlitnwC: CS634A
DIaCIAn: SCHEMATIC IORnW: 2-26-97
I24
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ENGINEERING DATA
CURTIS TOLEDO, INC,
1905 Kienlen Ave.
St. Louis, MO. 63133
SUBJECT TO CHANGE WITHOUT NOTICE
CURTIS AIR COMPRESSORS
V-BELT SIZE
REV R/S, R/S-T 215199
MODEL HP V-BELT QTY
R/S 10 10 RN14307-1 2
R/S 15-E6 15 RN14308-1 3
R/S 15-B101 15 RN14310-1 3
R/S 20-E6 20 RN14310-1 4
R/S 20-B101 20 RN14307-1 4
R/S 25-E6 25 RN14307-1 4
R/S 25-B101 25 RN14308-1 4
R/S 30-E12 30 RN14315-1 4
R/S 30-B101 30 RN14311-1 4
R/S 30-B160 30 RN14310-1 4
R/S 40-E12 40 RN14316-1 4
R/S40-8160 40 RN14316-1 4
R/SS5-E12 50 RN14316-1 5
R/S 50-8160 50 RN14315-1 5
IOVE ARE FOR STANDARD UNITS 125 PSI.
RTIS WITH MODEL AND SERIAL NUMBER
RTIS: 4/99
CONSULT BILL OF MATERIAL (BOM) SHIPPED WITH UNIT, OR CALL
R/S R/S R/S R/S R/S R/S R/S
RS-T RST RST RST R'S-T R'ST R/S-T
MODEL 10 15 20 25 30 40 50
V-BELT
TYPE 3V 3V 3V 3V 3V 3V 3V
NUMBER
OFEELTS 2 3 4 4 4 4 5
OIL (GAL)
CAPACITY 2 4 4 4 4 7 7
AIR IN.
CONNECTION 3/4 3/4 1 1 1 1 1/2 11/2
OIL
GPM 6 8 10 12 13 13 15
BTU/M
OIL COOLER 400 600 750 950 1200 1550 2000
BTU/M
AFTER COOLER 60 70 110 150 200 240 270
COOLING
FAN - CFM 3000 3000 5000 5000 5000 7000 8000
U
CURTIS AIR COMPRESSORS
DRIVE ENGINEERING
V-BELT DRIVE DESIUN
# OF BELTS CURTIS MANUFACTURERS
USED MODEL NUMBERS H.P. RATING
2 R/S - R/S-T 10 17.90 H.P.
3 R/S - R/S-T 15 27.25 H.P.
4 R/S - R/S-T 20 41.60 H.P.
4 ' R/S - R/S-T 25 46.00 H.P.
4 R/S - R/S-T 30A 48.00 H.P.
4 RIS - R/S-T 30 59.20 H.P.
4 R/S - R/S-T 40 60.85 H.P.
5 R/S - R/S-T 50 73.86 H.P.
7he manufacturers of V - BELT Drives, i.e., belts and pulleys, recommend a drive design of 1.3 x H.P. for continuous
service in rotary screw compressors, Continuous duty service is considered to be a 16 to 24 hours per day.
CURTIS Air Compressors chooses to add an additional service margin in its design for belt driven compressors. The belts
chosen for use by CURTIS are 3VX cogged belts.
PROCEDURE FOR LONG TERM STORAGE OF COMPRESSOR
CURTIS Air Compressors recommends that the following procedure be used before storing any rotary screw compressor.
I Run compressor to achieve normal operating temperature for 10 minutes.
2) Drain old oil and replace all filters. Moisture may be emulsified in the old oil.
3) Replace oil with DuBois Chemicals MPO -10 or equivalent polymer oil
4) Replace all filters
5) Run compressor to achieve normal operating temperature for 10 minutes.
6) Shutdown and purge air from system.
Disconnect compressor from piping and plug all openings with appropriate NPT plugs, Teflon taped.
8) Cover air inlet with 6 mil plastic and tape in place.
9 Pull main power supply and disconnect power from machine.
0) Cover entire compressor with 6 mil plastic and secure in place.
26
PROBLEM
Beit slip, shiny cr glazed
sheave sidewall:;
Belts squeal
Belts turn over
Ws matched belts
elts break frequently
heave has shiny bottom
elts wear rapidly
Sheave has nicks or burrs
Metal flanges between
heaves have knife edges
kroove sidewalls have lip,
idge or are dished out
B
Keep all
CURTIS V-BELT TROUBLE SHOOTING CHECK LIST
POSSIBLE CAUSE CORRECTION
Not enough tension Replace V-Belt and apply proper tension
Belt slip or abrasive atmosphere
Apply proper tension
elt tensioning instructions for Curtis - Toledo Air Compressors.
elts tight. Belts should not be able to be depressed more than 118 inch
High starting load
Shock load
Inadequate tension
Broken cord caused by improper installation
Impulse loads
Mis-alignment
Worn sheaves
Excessive belt vibration
New belts mixed with old belts
Sheave grooves worn unevenly
Sheave shafts not oarallel
Inadequate belt tension
Heavy stating loads
Belt forced over sheaves by prying
Belt and / or sheave worn
Sheave grooves worn
Mismatched belts
Misalignment
Belts slip
Abrasive conditions
Foreign object in drive
Belt slip and / or abrasive atmosphere
Replace belts and install correctly
Tension properly
Realign sheaves
Replace sheaves
Check equipment for solid mounting
Replace entire set of belts
Replace sheaves
Realign drive correctly
Increase tension
Increase tension
Replace belt correctly by moving drive
Replace belt and / or sheave
Replace sheave
Always replace entire sets. Don't mix old
and new belts or different types of belts
Realign drive
Tension properly
Protect drive from dirt
Re-install belt guard
Replace belts and sheaves
Replace sheave
Protect drive against abrasives
Replace sheave
Protect drive against abrasives
CURTIS - TOLEDO
MAINTENANCE SCHEDULE
iAILY
I Observe oil level - Maintain at 1/3 level in sight tube do not overfill - center is maximum level.
2 Observe oil scavenger return line for oil flow.
Drain condensate separator.
WEEKLY
Inspect air inlet filter element..
Check belt tension.
3 Check heat exchangers for cleanliness.
4. Check for loose fittings and fasteners.
Drain air receiver.
- Drain condensate from oil sump.
INITIAL -100 HOURS OR 30 DAYS
1Change oil filter element.
1000 HOURS OR SIX MONTHS
Change oil filter element.
Inspect air filter element.
Perform daily and weekly maintenance.
Take oil sample if applicable.
2000 HOURS
Clean oil scavenger line orifice.
2 Clean blow down line orifice.
3 Observe unit for proper load/unload cycle.
4. Perform daily and weekly maintenance..
Check electrical connection.
6 Observe overall condition of unit - clean if necessary.
7. Change oil *
8 Change oil filter element.
9 Change air filter element.
* Oil change interval can be lengthened when using synthetic lubricant to 8000 hours or 1 year.
Maintenance schedule should be reduced by half if operating at 200 F, or in dirty ambients, or with frequent cold starts.
4000 HOURS OR 1 YEAR
1 Change oil/air separator element.
2. Change in-line filter element (scavenger tube)
3 Check v-belt or coupling alignment.
4 Perform daily and weekly maintenance.
28
SPARE PARTS KITS
4,000 HOUR KIT
INCLUDES
(1) SEPARATOR ELEMENTS
(4) OIL FILTER ELEMENTS
RN27542
RN28201
RN24020-1(2) AIR FILTER ELEMENTS
01 (AQUAMATIC INLET VALVE)
* R/S15
* RIS20
* R/S25
* R/S30
* LOT NO.
* R/S1OT SEPARATOR ELEMENTS
OIL FILTER ELEMENTS
AIR FILTER ELEMENTS
SEPARATOR ELEMENTS
OIL FILTER ELEMENTS
AIR FILTER ELEMENTS
RN27542
CS650
RN24020-1
RN27542
RN28201
RN24020-1
* LOT NO. 04 (AIR-CON INLET VALVE)
(1) SEPARATOR ELEMENTS
(4) OIL FILTER ELEMENTS
(2) AIR FILTER ELEMENTS
LOT NO. 02 (AIR-CON INLET VALVE)
(1)
(4)
(2)
(1)
(4)
(2)
SEPARATOR ELEMENTS
OIL FILTER ELEMENTS
AIR FILTER ELEMENTS
SEPARATOR ELEMENTS
OIL FILTER ELEMENTS
AIR FILTER ELEMENTS
4,000 HOUR KIT
R/S15
R/S20
R/S25
R/S30 (6101)
R/S1OT
(FOR UNITS WITH HEAVY DUTY INLET FILTER)
VGC538
VGC541
(1) SEPARATOR ELEMENTS
(4) OIL FILTER ELEMENTS
(2) HD MAIN ELEMENTS
(2) HD SAFETY ELEMENTS
(1) SEPARATOR ELEMENTS
(4) OIL FILTER ELEMENTS
(2) HD MAIN ELEMENTS
(2) HD SAFETY ELEMENTS
MOCEL NO KIT NO
VGA593
(1)
(4)
(2)
(1)
(4)
(2)
R/S15
R/S20
R/S25
VGC501
VGB560
R/S30 VGB513
R/S40 VGA594
RN27542
RN28201
VA 1144
R/S50 VGA595
RN27518
RN28201
VAl 144
RN27518
RN28201
VAl 144
RN27542
RN28201
RN24074-1
RN24074-2
RN27542
CS650
RN24074-1
RN24074-2
4,000 HOUR KIT (CONT'D)
R/S30 VGC539 (1)
(4)
(2)
(2)
VGC540R/S40
R/S50
(1)
(4)
(2)
(2)
SEPARATOR ELEMENTS
OIL FILTER ELEMENTS
HD MAIN ELEMENTS
HD SAFETY ELEMENTS
SEPARATOR ELEMENTS
OIL FILTER ELEMENTS
HD MAIN ELEMENTS
HD SAFETY ELEMENTS
8,000 HOUR KIT
(2)
(8)
(4)
(2)
(8)
(4)
SEPARATOR ELEMENTS
OIL FILTER ELEMENTS
AIR FILTER ELEMENTS
SEPARATOR ELEMENTS
OIL FILTER ELEMENTS
AIR FILTER ELEMENTS
* LOT NO. 01 (AQUAMATIC INLET VALVE)
(2)
(8)
(4)
SEPARATOR ELEMENTS
OIL FILTER ELEMENTS
AIR FILTER ELEMENTS
LOT NO 04 (AIR-CON INLET VALVE)
(2) SEPARATOR ELEMENTS
(8) OIL FILTER ELEMENTS
(4) AIR FILTER ELEMENTS
(2) SEPARATOR ELEMENTS
(8) OIL FILTER ELEMENTS
(4) AIR FILTER ELEMENTS
(2)
(8)
(4)
SEPARATOR ELEMENTS
OIL FILTER ELEMENTS
AIR FILTER ELEMENTS
12,000 HOUR KIT
(3) SEPARATOR ELEMENTS
(12) OIL FILTER ELEMENTS
(6) AIR FILTER ELEMENTS
(1) INLET VALVE KIT
(1) THERMO MIXING VALVE KIT
(1) MINIMUM PRESSURE VALVE KIT
(3) V-BELTS
RN27542
RN28201
RN24076-1
RN24076-2
RN27518
RN28201
RN24076-1
RN24076-2
R/S1OT VGC502
R/S15
R/S20
R/S25
VGB505
RN27542
CS650
RN24020-1
RN27542
RN28201
RN24020-1
- R/S15
- R/S20
" R/S25
VGB561
R/S30
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VG8514
RN27542
RN28201
RN24020-1
R/S40 VGB506
R/S50 VGB507
RN27542
RN28201
VA1144
RN27518
RN28201
VA1144
RN27518
RN28201
VA1144
R/S1OT VGC503 RN27542
CS650
RN24020-1
RN24569-2
RN42400-1
RN42124-1
RN14307-1
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12,000 -OUR KIT (CONT'D)
R/S10 VGC558 (3) SEPARATOR ELEMENTS RN27542
(12) OIL FILTER ELEMENTS
(6) AIR FILTER ELEMENTS
(1) INLET VALVE KIT
(1) THERMO MIXING VALVE KIT
(1) MINIMUM PRESSURE VALVE KIT
(3) V-BELTS
(3) SEPARATOR ELEMENTS
(12) OIL FILTER ELEMENTS
(6) AIR FILTER ELEMENTS
(1) INLET VALVE KIT
(1) THERMO MIXING VALVE KIT
(1) MINIMUM PRESSURE VALVE KIT
(3) V-BELTS
* LOT NO. 01 (AQUAMATIC INLET VALVE)
* LOT NO. 04 (AIR-CON INLET VALVE)
(3) SEPARATOR ELEMENTS
(12) OIL FILTER ELEMENTS
(6) AIR FILTER ELEMENTS
(1) INLET VALVE KIT
(1) THERMO MIXING VALVE KIT
(1) MINIMUM PRESSURE VALVE KIT
(3) V-BELTS
(3) SEPARATOR ELEMENTS
(12) OIL FILTER ELEMENTS
(6) AIR FILTER ELEMENTS
(1) INLET VALVE KIT
(1) THERMO MIXING VALVE KIT
(1) MINIMUM PRESSURE VALVE KIT
(3) V-BELTS
(3) SEPARATOR ELEMENTS
(12) OIL FILTER ELEMENTS
(6) AIR FILTER ELEMENTS
(1) INLET VALVE KIT
(1) THERMO MIXING VALVE KIT
(1) MINIMUM PRESSURE VALVE KIT
(4) V-BELTS
* LOT NO. Dl (AQUAMATIC INLET VALVE)
* LOT NO. 04 (AIR-CON INLET VALVE)
(3) SEPARATOR ELEMENTS
(12) OIL FILTER ELEMENTS
(6) AIR FILTER ELEMENTS
(1) INLET VALVE KIT
(1) THERMO MIXING VALVE KIT
(1) MINIMUM PRESSURE VALVE KIT
(4) V-BELTS
* LOT NO. 11
* R/S15 VGB508
CS650
RN24015-1
RN24569-2
RN42401-1
RN42124-1
RN14307-1
RN27542
RN28201
RN24020-1
RN24554
RN42400-1
RN42124-1
RN14308-1
RN27542
RN28201
RN24020-1
RN24569-2
RN42400-1
RN42124-1
RN14308-1
RN27542
RN28201
RN24020-1
RN24554
RN42401-1
RN42126-1
RN14308-1
RN27542
RN28201
RN24020-1
RN24554
RN42400-1
RN42126-1
RN14308-1
RN27542
RN28201
RN24020-1
RN24569-2
RN42400-1
RN42126-1
RN14308-1
* R/S15 VGB562
* R/S15 VGC559
* LOT NO. 11
* R/S20
* R/S25
VGB509
* R/S20
* R/S25
VG8563
12,000 HOUR KIT (CONT'D)
* R/S20 VGC560
* R/S25
* LOT NO. 11
R/S30
R/S30
VGB510
VGC561
* LOT NO. 11
* RIS30 ' VGC598
(3) SEPARATOR ELEMENTS
(12) OIL FILTER ELEMENTS
(6) AIR FILTER ELEMENTS
(1) INLET VALVE KIT
(1) THERMO MIXING VALVE KIT
(1) MINIMUM PRESSURE VALVE KIT
(4) V-BELTS
(3) SEPARATOR ELEMENTS
(12) OIL FILTER ELEMENTS
(6) AIR FILTER ELEMENTS
(1) INLET VALVE KIT
(1) THERMO MIXING VALVE KIT
(1) MINIMUM PRESSURE VALVE KIT
(5) V-BELTS
(3) SEPARATOR ELEMENTS'
(12) OIL FILTER ELEMENTS
(6) AIR FILTER ELEMENTS
(1) INLET VALVE KIT
(1) THERMO MIXING VALVE KIT
(1) MINIMUM PRESSURE VALVE KIT
(5) V-BELTS
(3) SEPARATOR ELEMENTS
(12) OIL FILTER ELEMENTS
(6) AIR FILTER ELEMENTS
(1) INLET VALVE KIT
(1) THERMO MIXING VALVE KIT
(1) MINIMUM PRESSURE VALVE KIT
(4) V-BELTS
RN27542
RN28201
RN24020-1
RN24554
RN42401-1
RN42126-1
RN14308-1
RN27542
RN28201
VA 1144
RN24570-2
RN42400-1
RN42126-1
RN14316-1
RN27542
RN28201
VA1144
RN24570-2
RN42401-1
RN42126-1
RN14316-1
RN27542
RN28201
VA 1144
RN24570-2
RN42401-1
RN42126-1
RN14316-1
* LOT NO. 13
12.000 HOUR KIT (CONT'D)
(3) SEPARATOR ELEMENTS
(12) OIL FILTER ELEMENTS
(6) AIR FILTER ELEMENTS
(1) INLET VALVE KIT
(1) THERMO MIXING VALVE KIT
(1) MINIMUM PRESSURE VALVE KIT
(5) V-BELTS
(3) SEPARATOR ELEMENTS
(12) OIL FILTER ELEMENTS
(6) AIR FILTER ELEMENTS
(1) INLET VALVE KIT
(1) THERMO MIXING VALVE KIT
(1) MINIMUM PRESSURE VALVE KIT
(5) V-BELTS
RN27518
RN28201
VA 1144
RN24570-2
RN42400-1
RN42126-1
RN14320-1
RN27518
RN28201
VAl 144
RN24570-2
RN42401-1
RN42126-1
RN14320-1
* LOT NO. 10
32
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R/S40 VGB511
* R/S40 VGC562
12,000 HOUR KIT (CONT'D)
R/S40 VGC599 (3) SEPARATOR ELEMENTS RN27518
LOT NO 12
(12) OIL FILTER ELEMENTS
(6) AIR FILTER ELEMENTS
(1) INLET VALVE KIT
(1) THERMO MIXING VALVE KIT
(1) MINIMUM PRESSURE VALVE KIT
(4) V-BELTS
(3) SEPARATOR ELEMENTS
'(12) OIL FILTER ELEMENTS
(6) AIR FILTER ELEMENTS
(1) INLET VALVE KIT
(1) THERMO MIXING VALVE KIT
(1) MINIMUM PRESSURE VALVE KIT
(6) V-BELTS
(3) SEPARATOR ELEMENTS
(12) OIL FILTER ELEMENTS
(6) AIR FILTER ELEMENTS
(1) INLET VALVE KIT
(1) THERMO MIXING VALVE KIT
(1) MINIMUM PRESSURE VALVE KIT
(6) V-BELTS
(3) SEPARATOR ELEMENTS
(12) OIL FILTER ELEMENTS
(6) AIR FILTER ELEMENTS
(1) INLET VALVE KIT
(1) THERMO MIXING VALVE KIT
(1) MINIMUM PRESSURE VALVE KIT
(5) V-BELTS
RN28201
VA 1144
RN24570-2
RN42401-1
RN42126-1
RN14320-1
RN27518
RN28201
VA 1144
RN24570-2
RN42400-1
RN42126-1
RN14320-1
RN27518
RN28201
VAl 144
RN24570-2
RN42401-1
RN42126-1
RN14320-1
RN27518
RN28201
VAl 144
RN24570-2
RN42401-1
RN42126-1
RN14320-1
R/S50
R/S50
VGB512
VGC563
* LOT NO 09
' R/S50 VGD501
- LOT NC. 11
COMPRESSOR MAINTENANCE LOG
MODEL SERIAL NUMBER
REFER TO THE COMPRESSOR INSTRUCTION MANUAL FOR COMPLETE MAINTENANCE
INFORMATION AND SCHEDULE. THE COMPRESSOR INSTRUMENT PANEL LISTS A BRIEF
MAINTENANCE OUTLINE
DO NOT REMOVE LOG FROM THIS UNIT
Record date in Date Column and hourmeter reading in the column under each item on which maintenance is performed
Record pressure differential gauge readings when any other maintenance is performed to provide running record of
approaching oil filter of separator change.
AIR FILTER
CLEANED CHANGED
PRESSURE DROP
OIL
FILTER
OIL
SEPARATOR
OIL
FILTER
CHANGED
OIL
CHANGED
OIL
SEPARATOR
CHANGED
OIL COOLER CLEANED
RADIATOR
CORE
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HEAT
EXCHANGER
TUBES
rn-i___
__
__________________ T______________________________ _______ ____ ____ _ ____ ____ _________ ___________________ _________________
r 14f1
DATE
NOTES
CURTIS-TOLEDO, INC.
1905 Kienlen Avenue, St. Louis, Missouri 63133
(314) 383-1300, Fax (314) 381-1439
curtiscomp@aol.com
Sales representatives in principal cities
1§%i.~JnrAjrt. - '4
cc to N
In t Th
Li N 9c~
ci I- ~ - L
LitnO
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~: t z
r -5
N- Co ~ (
I ,
ill-c) I - -. vcr3&o~~o
---------- r)
- C'.
L1 f tf
( I s7.
1&IIS-LNV
MS SSJJ IWvIS-UW
MS SSI& &lY
(C) MIMS dftl
(t) inliws Sill
(1) tmbWS donl
(1) Rmbos 'Anil
Thrjj h y I~ I'"'
- - M m - - - 0 m = m m m =
7610.490.46 c
COMPRESSED AIR FILTERS
20 scfm (0.57 m3/min) through 780 (22 m3/min)
INSTRUCTION MANUAL
General Safety Information
1. Pressurized devices
i AWARNINGi
e :c not exceed maximum operating pressure
rcicated on serial number tag.
- Make certain filter is fully depressunzed ber cre
servicing.
2. Breathing Air
Contents
FILTER IDENTIFfCATION ......... .....
0 O INSTALLATION
2.0 OPERATION .....
3.0 MAINTENANCE .
DIMENSIONS AND WEICHTS -
WARRANTY .. ...... .....
2
3
6
7
8
S.r :reated by this eculpment may not be swrc:
for breathing without further purfication -to OSHA standard 19 10.134 for breathing air
recuirements.
3. Flammable gases
A WARNING
While the materials of construction are comcatible
with many flammable gases. the following applicac[rc
limitations must be considered:
* Housing materials are slightly porous. The oros
must be used in a well ventilated area in the
absence of sparks or gnition sources. Do nct use
in Class I. Division 1. Croup D environments
- The type of area - forced exhaust system usehigh or low level) would be dependent on the
invcved.
- Eacn appi~cation (other than for air or inert gas
must be reviewed to minimize fire or expicsicr
hazard.
SERVICE DEPARTMENT: (724) 746-1100
Configuration
Capacity
Z!m /f/mmnj@ Connection Sizes*
Spsirg f7 gi/cml
50 li/2/
0 2v
1o /49
50 172
375 !111
.85 /141
525 18/
'-d 221
Features
Internal Automatic Drain Mechanism
Differential Pressure Slide Indicaltr
1112renNal Pressure Gaugelndicafor
LiQuid Level Indicator
Corrosion Proof Stainless Steel Een1oil
Exiernal Drain Adaoter
1. -114* or 1-1(2'
- - 1
-3P cr NPT availacle
Filter Identification
Ejements with a foam outer sleeve can oe identified by color
Description Type Outer foam color
r!icjlafe 'ier Jne ' cr n :110:aricu :, lne
.. :niai Secaratc :moac:;on :0e SoaaraIcr
:'J1z:ocse 2!r Ilne
.;!!ic:ency oil removal aer Hrgn ric:encv i99 99+%1 coalesces Rea
Jura nigh e!Iiciency oil removal tIer Ultra ;icn erticiency (99 999+%; :oesc:r Biue
I vaDor removal filter i Ac!vated carbon adsortbef Green
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1.0 Installation
A Where LUsed/Air Quality After Filtration
Grade Where used Solid particle Liquid removal Maximum inlet Remaining o
removal (maximum efficiency (at rated liquid loading content
size in microns) conditions) ppm w/w ppm w/w
MYe -2nGl Atertfier - lCwns: eam 1 3nf altercooler
Secara.' nrt-Jl-se - wnere 7o aftercooler is ... 95" a water 25,000s:alied uostream aerosols
.aralor -downs:;eam of an antercooler
Sr . %nt-oI-se - wnere no aftercooler s insatleil 3 99,o Otwater 25.000stream
e A|One a:eao :esiccant Jrvers d no Gil is 1000% of water 2,000
I C:erc,, cv
icownrsearn of pressure-swina
ess; iesic:-: vers
- se.-Fr-C aflercooler s inStaLCJ
one anaCo ol cescant and
' rE .s resent 001 99,990 of cil 1.000
...... ~c-laed orver
.0 -C ;. 4 r;:
100-.- 2a . ,'cionq !emen'
in Ainine or lHiqn Efficiency Oil Rlornrval
Rv ea:c a esent 001 Rem ves vaocrs only No liquid should
be present
I muil-ill- Lrckets Mount bracket to Filter head:
mIcve four 1 screws holding black plastic top
-c filter head
l- 'ricket 'n head over plastic coo
i*-::: ^urohod -:trh rcket.
Wall Mounting
Bracket
Top Cap
ZD..k
1 Before installing, blow out pipe line to remove scale
and other foreign matter
nrirt has DRvSEAL pipe threads, use pipe compcund or tape sparingly to male threads only.
3 Mounting Mechanical Separator. Separator, Airline
4 igh Efficiency Oil Removal, Ultra High Efficiency Cil
.erncval) - mount so that inlet and outlet connections
are horizontal (filter bowl vertical) to ensure proper
icuid irainage.
4 ?!ow Tirecion - install so that the air Flow is in the
direcocn of arrows on the Filter head
5 :ret FIter- o-Filter 'mcdular connecon - Filter
-e-s mav ce 'cined vithout using a cipe nipple
a :_vcne: c;ce heads - e -co (2' meular connec:s. nn, an- four '1) socket head cap screws
s 3l ks t'
am -cn
;rcAe
to na-:
clack piaszic :cp cap. appiv generous
F 'ubncan to c-ring, install c-ng in
and :nser c::nnec:crs. crew connectors
using socket head cap screws
use four carriage bolts, nuts and o-ring (sold as kit)
Remove black plastic top caps, apply generous
amount of lubricant to o-ring, install o-ring in
grcove, and nstal bcrts and nuts.
I I
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K~S
S
't'S'~' N.N, ~ -~-o---~ x 'A
~ ~*~s p"-s--N, %
N
-N
N- Make cercar tcw directicn thrcugh Filters is
.:ben~e ::n role used for aligning top cacp
Mecnanc; acarator. Separarcr. Airline, High Efficienc'/
Eemcval itra- mE45Fciency CH Removal and Oil Vapcr
er-vail .-rher hole is on szie :icsesrt2 vou. nlet
riuncaze o-ring with generous amount of lubri
cant before installation.
solatron valves and ty-pass piping - For ease of
sernce, solatton and by-pass valves are desirable In
critical acplications. tvo filters installed in parallel may
ce necessary to avoid interruption of air supply.
D Drain provisions
I nternal Automatic Drains - Drain line
-he bottom of internal automatic drains are provided
with 1/8' 'inside threads) For connection of a drain
ine if desired.
External Auto Drains - External auto drains may be
added as follows.
::s 20 scfm (0.57 mz/min) through 170 scfi
.4 9 m /min) - remove internal drain and install
adapter (available from factory). Adapter outlet
connection is 1/8" inside threads)
=lOWs 250 scm (7 2 rn ,min through 375 scfm
t 1 1 m/min) - remove adapter fitting from bottom
cf bcwl. 1/~ inside thread) port is available for
external drain connection
Flows 485 scfm 14 m'/min) through 780 scfm
22 m'/minm - remove pioe plug, I/2' (inside thread'
port is available for external drain connection
AWARNING Psc-arge is at system pressure. Jnchcr
rin line
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2.0 Operation
AWARNING Co not operate filter at pressures in excess of
Maximum \Vorking Pressure indicated on Serial Number
ag.
NCTE: Max mum Operating Temperature - 150*F. 66-C.
.cuid filtrat:on above 120CF. 49cC s not recommended
since there is typically oil present in a vapor state which
casses through the filter and condenses downstream.
NICE: Cil Vapor Removal Filter - If operated above 100*F.
78C may experience less than 1000 hours of life because
:f greater ail vapor content.
A. Liquid Draining - Mechanical Separator.
Separator, Airline, High Efficiency Oil Removal,
Ultra High Efficiency Oll Removal Filters
j~2 Collected licuids must be removed to ensure proper
ceraton
STE :ecrssunze slcwly, :o avcid filter element damage
qlanual [rin Turn to ,our rignt clockwise) to open
and to /cur left :untercIcckwise) to close.
-urmraic Cran-nuds will automatically discharge
n:r2 n cohn, :ccmulaten occurs
. nterrailv Mcunted Auto Crains These drains
may he manually drained by
turnirg to /our right clCck
esel -o open and to your left
ccun terclcckwise to close EMM
ci vianually drain internal auto
daily .o verify drain Functecn
3. Operational Checkpoints
All Filters
hec Ho'.v, ressure. and temperature to make
certain flter is being operated within design conditions.
Mechanical Separator, Separator. Airline, High
Efficiency Oil Removal, Ultra High Efficiency Oil
Removal Filters
Check pressure drcp acrcss the fiter
* 2resirc lifferential in excess cf 10 psi (0 7 kgf/cm
cressuie ndicator in red area - indicates that the filter
sleeve or element should be replaced.
NOTE: Eement shculd be changed annually or when
indicatcr chtnges to red, whichever occurs first.
rssureiS drop thould never exceed 50 psi
heck or -udden reduction in oressure drop. This
enin cl ic r
Mechanical Separator. Separator, Airline, High
Efficiency Oil Removal, Ultra Effleclency Oil Removal Filters
1. Check to see that filter is installed level to insure
prcper drainage.
2. Check that manual drains are drained periodicthat automatic drains are functioning,
3y On mczels with Liquid Level Sight glass - Check c:t
liquid level is below top of Sight glass.
Oil Vapor Removal Filter
ChecK cr an oily smell by opening the manual v an oily smell exists, the following should be checrec
a. Filter element adsorption capacity exhausted
C, LeaK1 across element c-ring seal
Leak through element due to physical damage
1. Presence of liquids because of lack of or faiure
creFilters
e l rw, ressure and temperatures outside dezr
onclt:cns
r. Presence of gaseous impurities which cannot cc
acscrced
A CAUTION Methane, carbon monoxide, carcon icanc iancus ;ncrganic gases cannot be removed by
actvated carbon filter.
C. Flow Capacity
Maximum air flow for the filters at 100 psig (7 kgf'
indicated in Table 1. To determine maximum air flo.vs a
inlet pressures other than 100 psig (7 kgf/cm , muitp:,
flow from Table 1 by air flow correction factor from -r
2 that corresponds to the minimum operating xress:
at the inlet of the filter.
NOTE: Fiters should not be selected by pipe size. Sele
using flow rate and operating pressure only.
Table 1 - Maximum Flow Capacity
@100 psig [7 kgf/cmI
seemin mm/
35 W/i5 /2
Ta l i A i
7F
Table 2 - Air Flow Correction Factor
[r A
t 0|G
C' 9
s -3.0 Maintenance
C-E: Airline, High Efficiency Cil Removat Ultra High
Eiclency Oil Removal, Oil Vacor Removal Fiters - corn:ete element:s reclaced; Secaratcr - unless separator
::re :s damaged cuter sleeve only :s reolaced.
Mecnanical Separatr
Element should not require replacement unless
onvsically damaged. if slucge accumulates, element
:an ce removed and leanec with scab and water
Secaratcr, Airline, High Efficiency Oil Removal, Ultra
-ign Effictency Cii Removal. Oil Vacor Removal Filter
a. nitial (ory) pressure drcc: I bsi CO 07 kgf/cml to
2 bsi (0.14 kgf/cn)
o. operating cressure droo: As filter becomes liquid
caded lweted). oressure troc will increase to 2 to
6 csi 0.14 tC 0.42 kgf/cmi. Further pressure drop
cc-urs as element loads with solid particles.
FOR MAXIMUM FLTRATICN EFFC[ENCY. REPLACE
L:MENT WHEN -REZSUR CROP REACHES 10 PSI
O 7 CF/CM JNCICATCR N RED APEA) OR ANNU-
ALY. WHiCHEVER OCCURS FiRST
: Zressure drce may temccrarilv :ncrease when Flow
a surned af1er fnbw sccCace Cressurn drco should
eturn to normal witnin one ncur
,ZTE igh Eficiencv Oil Remcval and Utra Hiqh Effienc; II Removai ~iter - -ur:nc roimar :cerann
ottom or foam sleeve will have a band of oil. Spotting
::ve the band indicates that lcuids are accumulating
-ster han they can be drained and that ,refiltration is
eu red.
: Gil Vacr Removal Filter (activated carbon filters)
a Adsorcton capacity - 1C00 hours at rated capacity.
Element life is exhausted when odor can be detected downstream of the filter
3. Procedure for Element Replacement
AWARNING THIS FILTER IS A PRESSURE CONTAINING
LEViCE DEPRESSURIZE BEFORE SERVICINC. If filter has not
:een depressurized before disassembly. an audible alarm
V1 scund when the bowl begins to be removed from the
read F this cc-urs. stop disassembly. isolate and comaletely depressurize filter before proceeding
solate Filter (close inlet and cutlet valves if installed) or
shut off air sucly.
Se'ressurnZe filter by slowly opening manual drain
valve.
5 Remove bowl
a For flows 2C O 57 m /min through
170 scfm (4.9 m'/min) - bayonet mount - rush
bowl up. turn bowl 1/8th turn to your left, and cull
bowl straight down
u or Fcws 250 (7 2 m /min, throuch
780 (22 rn min) scfm - threaded bowlIs - unscrewv
bowl from head using hand. strap wrench or
guanner
4. Clean filter bowl
a. Replacing complete element
1) Pull off old element and discard.
2) Make certain 0-o-ring inside top of replacement
=ier-ent is in clace and push element onto filter
head. For flows 485 (14 m3/min) to
780 (22 mrnmin) clace element in bowl and
secure with centering device.
NCTE: High Efficiency Oil Removal. Ultra High Efficiency -d
Removal and Oil Vapor Removal Filter - Do not handle
elements by outside foam cover. Handle by bottom end
cp only
NCTE. 20 scfm (0.57 m3/min) - Make certain to reinstadl
spacers under element.
b Lecarator - reclacing sleeve only
I) Pu e!ement straight down to remove.
i emove bolt and bottcm cac and remove
ciscsable flilter sleeve.
5) Clean separator core with soap and water if
necessarv.
J1 Elide new filter sleeve cver separator core and
-eclaca sottm ca and hand tighten bolt;
ake -erin -nng inside :co of element is n
ciace and cusn element onto niter head.
S rer maknr certain hat o-ring inside top -of to:
and on Dayonet mount heads. wave spring) are in
clace, reassemble bowl to head.
NOJE Make certain 0-ring is generously lubricated.
NOTE. Wave spring ends should be pointed down to
:rcvent the wav- £n from interfering with reassemblv
..... ....... l..
N07 E: Threaded bowl to head connection. generously
:uL'rcate threads with a high grade/temperature lubricant
ood uir 150 F. 66 C.
C. Auto Drain Mechanism
s rc--mmended that drain mechinism be reced
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* Dimensions and Weights
* - J
D
ECO
0 Y N~Ci-0 C
>
CM
CL,
oj --zr ~-o'E
CLC
-<~Ju M;l } ~~
-~~~~) z*Ii-,j I f
U -.
.4
D
-- - - --- - -
.4
(9
U'
'I J - - -.
'4G
- .9
~1 -
I
f~ j :1
-- a A -.
- -
-
WARRANTY
The manufacturer warrants the prcduct manufactured by it, when properly installed, operated, applied, and main-tained in accordance with Qrocedures and recommendations outlined in manufacturer's instruction manuals, to beFree rrom defects in material and workmanshi for a reriod of one (1) year from date shipment to the buyer by themanufacturer or manufacturer's authorized distrbutor provided such defect is discovered and brought to themanufacturer's attenticn within the aforesaid warranty period.
The manufacturer will recair or reclace any prcduct or cart determined to be defective by the manufacturer withinthe warranty period. crovided such defect occurred in normal service and not as a result of misuse, abuse, neglect oracident. Ncrmal maintenance items requiring routine replacement are not warranted. The warranty covers parts an',abocr for the warranty period. Recair or reclacernent shall be made at the factory or the installation site, at the soleotion of the manufacturer Any service performed on the product by anyone other than the manufacturer must firstbe authorized by the manufacturer
unauthorized service voids the warranty and any resuiting charge or subsequent -laim will not be paid.
3roducts recaired or reclaced under warranty shall be warranted for the unexoired cordon of the warranty applying tohe :rginal product.
-he foregcing is the exclusive remedy of any tuver of the manufacturer's croduct. The maximum damages liabiity zfhe manufacturer s :he original purchase price of :he crcduct or part.
THE FCRECOING WARRANTY iS EXCLUSIVE AND !N UEU OF ALL OTHER WARRANTIES, WHETHER WRITTEN, ORAL, OR STATU-RY. AND S EXPRESSED FN L:EU C E MPUEL NARRANTY 0F MERCHANTA;iLTY AND THE IMPLIED WARRANTY OF:FTNESS 2CR A PARTICULAR DURPOSE. THE MANUFAC-URER SHALL NOT BE LIABLE FCR LOSS OR DAMAGE BY REASON OFSTRICT IABILTY N CRT OR S NECUGCEJCE N WHATEVER MANNER INCL UDING DESIGN, MANUFACTURE OR INSPEPC7CNOF THE ECUIPMENT 32 ITS FAILUE TO DISCOER. REPRT, REPAIR. OR MCDIF -ATENT EEOTS INHERENT THEREIN
HE MANUFACTURER. HIS REPRESENTAT:VE CR ST-R!BUTOR SHALL NOT BE LIABLE FOR LOSS OF USE OF THE PRODUCT CROTHER :NCIDEN-AL CR CONSECUENTIAL COSTS, EXPENSES. OR DAMACES NCLRW BY THE BUYER, WHETHER ARISING=RCM BREACH OF WARRANT# NEGLIGENCE CR STRICT LIABILTY IN TCRT
The manufacturer does not warrant any product. cart, material, comoonent. or accessory manufactured by othersand sold or suoied in connection with the saie of manufacturer s croducts 1/96
AUTHORIZATION FROM THE SERVICE DEPARTMENT IS NECESSARY BEFORE MATERIAL IS
RETURNED TO THE FACTORY OR IN-WARRANTY REPAIRS ARE MADE.
SERVICE DEPARTMENT: (724) 746-1100
HANKiSON
Snap-Trap*
Models 503, 504, 507, and 508 AUTOMATIC
CONDENSATE
DRAINS
Instruction Manual
iT) 114;
1. GENERAL SAFETY
INFORMATION
CAUTION
1. Pressurized devices
This equipment is a pressure containing device.
* Do not exceed maximum operating pressure as shown on equipment serial
number tag.
" Make sure equipment is depressurized before working on or disassembling it
for servicing.
2. During each operation of the drain a small amount of system gas is discharged to
atmosphere.
N Where hazardous or explosive gases are present in the system, provisions for sate
disposal of the discharge must be provided.
11. GENERAL
Description:
This drains a pilot actuated, power operated,
automatic liquid drain device for use in
discharging collected liquids from a compressed air system.
it is recommended for use with air receivers.
drip legs, aftercoolers, separators, dryers, and
filters,
Typical compressed air system
COMPRESSOR
AFTERCOOLER RECEIVER DRYER
SERVICE DEPARTMENT: (724) 746-1100
1
510 717.6 1/96
~~2
III. INSTALLATION
1 Preparation:
remove inlet and drain thread protectors.
2. Location:
-s:ail eiow :he system drainage point to
assure iree ;ravity drainage of collected
iQuos :o :he inlet port. Drain must be
.nstalled verically to ensure proper float
oceration.
3. Connections:
a. iNet- The ;nlet pipe to the drain should
not oe smaller than the inlet connec:ion so tnat drainage is not restricted
avoid pioing "pockets').
A strainer to protect drain from undue
oarticulate and an isolation valve for
ease of servictng may be added to
:ne Grain line.
a. :rain- Tubing or piping may be run
from the drain connection to an
adequate sump or floor drain.
Note: Liquid discharge is at system
pressure and may require that
oiscnarge line be anctiored.
jcte: in many cases condensate
:ontains oil. Check regulations in your
area about proper disposal methods
or oil contaminated condensate,
Vent- tcitom inlet connection drains
only must be vented by running 1/4'
0.0. Tubing from the compression
itnrig on the top of the drain to a place
in the system where there is pressure
equal to the pressure in the device
being drained.
d. Floor clearance- Bottom connection
drains- A minimum of 3-3/4" clearance
between the floor and the bottom of
the equipment being drained is
required in order to keep condensate
from collecting inside equipment.
V
iNLET 'tNG
SOLATION VAVE
STRAMNR
V
sNT UBING
O&A4 LANE-
Top connection
V Ru LN
I
bcttom connection
x VENT Iu81iG
WIMMUM IL"A. -1M 5
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Do not drain two units with one drain
Observe minimum clearances to
prevent condensate accumulation
xI 1-M
Do not allow condensate to block condensate line. 11 unavoidable use vent tineI
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VI. MAINTENANCE
1 . Slow down:
pericdically blow down the bowl by manually
lurning the knurled manual drain connection
CLOCKWISE AS IEWED FROM THE BOTTOM
-0 YOUR RIGHT'.
his Nill remove solids which may collect in the
bottom of the bowl.
2. Cleaning:
Bowts and Sight glasses should be periodically
:!eaned to assure aisibility of the liquid level
and to verify tat :r e drain is operating
nroperly
USE ONLY A MILD OUSEHCLD DETERGENT
N AQUECUS SOLUTON.
Thorougnly :rinse with clean water.
D0 NOT use solvents such as acetone,
alconois, ketones, esters, or aromatic hydrocarbons, such as benzene, toluene, xylene, etc.
CAUTION:
This is a pressure containing device.
Depressurize before cleaning or servicing.
VII. SERVICING
1. REPLACEMENT PARTS
Servicing. Prior to servicng, depressurize.
Remove bowl and collar from head using a
strap wrench wheh necessary.
Remove bowl. When reassembling, put light
coat of lubricant on threads of head assembly.
~ Part No. Part No.
Part No. Model Model
503 & 507 504 & 508
I niemal trap Assenoly 15.4170-01 05.4170-02
2. Head-Sow 0-Rng 9320.551,8 9320.55i3
B. Replacement of internal trap assembly in
Models 507 & 508 Refer to drawing for
proper placement of drain assembly.
N'UNAa -S -
IMVuUR)J
I- -- TU F
DIMENSIONS & WEIGHTS
Model A B
mm inches mm I inches
50 5 3-3/4 162 16-23/
0 95 3-3/4 162 6-3/8l
508 3-2/4 7
ntel drain
Connection Connection
503 & 504 i/2 Female 511' Tube
507 & 5C 38 -Female 3/8 -!emaie
WARRANTY
The manufacturer warrants the product manufactured by it. when properly installed, operated, applied. and maintained n accordance with procedures andrecommendations outlined In manufacturers instrucuon manuals. to be free from detects in material and workmransiio for a period of one (1) year from the date ofshipment to the buyer by the manufacturer or manufacturers authonzed distributor. or eighteen months from the dale of shipment from Me factory, whicheveroccurs fIlrst (refrigerared dryers. models 25 thrul 2000 scim inclusive, for a penod of iwo years from the date of shipment from the factory), provided such defect isdiscovered and brought to the manufacturers atention within the aforesaid warranty period.
The manufacturer wil repair or replace any product or pan determined to be detective by the manufacturer within the warranty period, provided such defectoccured !n normal service and not as a result of misuse, abuse, neglect or accident. Normal maintenance items requiring routine replacement are not warranted.Par refngerated dryers model 25 mru 2000 scfm. the manufacturer will Include parts and labor for 18 months from the date of snipment from Me factory and partsonly for an additioinal six (6) months. On all other products. he warranty covers parts and labor for the warranty period. Repair or replacement shall be made atthe tactory or the installation site, at the sole option of the manufacturer. Any service performed on the product by anyone other than the manufacturer must firstbe autmlonzed by the manufacturer.
Unauthorized service voids the warranty and any resulting charge or subsequent clain w1 not be paid.
Products repaired or replaced under warranty shall be warranted for the unexpired portion of the warranty applying to he onginal product.
The foregoing is the exclusive remedy of any buyer of the manufacturers product. The maximum damages liability of tMe manufacturer is the anginal purchasepric, of the product or part.
HE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES. WHETHER WRITTEN, ORAL. OR STATUTORY. AND ISEXPRESSED IN ULIEU OF THE IMPLIED WARRANTY OF MERCHANTIBILITY AND THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULARPURPOSE. THE MANUFACTURER SHALL NOT BE LIABLE FOl LOSS OR DAWAGE BY REASON OF STRICT UABILITY IN TORT OR ITS NEGLIGENCEIN WHATEVER MANNER INCLUDING DESIGN. MANUFACTURE OR INSPECTION OF THE EQUIPMENT OR ITS FAILURE TO DISCOVER, REPORT.REPAIR, OR MOOFY LATENT DEFECTS INHERENT THEREIN.
THE MANUFACTURER, HIS REPRESENTATIVE OR DISTRIBUTOR SHALL NOT BE LIABLE FOR LOSS OF USE OF THE PRODUCT OR OTHER INCIDEN-TAL OR CONSEQUENTIAL COSTS, EXPENSES. OR DAMAGES INCURRED BY THE BUYER. WHETHER ARISING FROM BREACH OF WARRANTY,NEGLIGENCE OR STRICT LIABIUTY IN TORT,
The manufacturer does not warrant any product, part, material, component, or accessory manufactured by others andsold or supplied in connection with the sale of manufacturers products.
AUTHORIZATION FROM THE SERVICE DEPARTMENT IS NECESSARY BEFORE MATERIAL IS RETURNED TO THE FACTORY
OR IN-WARRANTY REPAIRS ARE MADE.
SERVICE DEPARTMENT: (724) 746-1100
Division Of Hansen Inc.
--.- iS O Canonsburg, PA 15317-1700 U.S.A.
I K IITCD MI ATI n~ Mi A I Tel 724-745-1555 - Fax 724-745-6040
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IV. DESIGN CONDITIONS:
1. Operating Limitations
MindMax.
Operating Pres.
BAR
Discharge
Operating Temp, Per
'F I C Operation
Nominal
Capacity
503 20/150 1.4/10.3 35/120 1 .,/49
507 f0 04 pints 0.3 gals. per hr504 20/175 1 212 35/120 7/49 (20) 120&cc per hr.
508
1
2. WARNING: Polycarbonale Bowls
Chemical attack of polycarbonate matenals on
models 503 & 507 care should be taken to avoid
exposure of drains to the chemicals listed
below.
These chemicals may be present in the
copressed air system, in the ambient air
surrounding the bowl, or in solvents used to
clean the bowl.
CHEMICAL AND SOLVENT RESISTANCE TABLE
LIMITED RESISTANCE:
Cyclohexanol
Gasoline (High Aromatic
Milk of Lime (CaOh)
Sulfuric Acid (Conc.)
Hydr
,0OT RESISTANT:
Acetaldehyde Ethane
Acepic Acid (Conc.)
Acetone
Acrylonitile
Ammonium Fluoride
Ammonium Sulfide
Benzene
Benzoic Acid
Benzyl Alcohol
Bromobenzene
Butyric Acid
Carbon Tetrachloride
Carbolic Acid
Caustic Potash Solution (5%)
caustic Soda Solution (5%)
Chlorobenzene
Cyclo Hexanone
Dimethyl Formamide
Ethylamine
Ehlyl Ether
DISSOLVED BY:
Chloroform
Cresol Methylene
Ethylene Dischlonde
Dioxane Pyridine
ochioric Acid (Conc.)
Ethylene Chlorohydrn
Formic Acid (Conc.)
CAUTION:
WHEN USING POLYCAR8ONATE BOWLS be
aware that the following circumstances could
adversely affect the polycarbonate material.
Care should be taken to:
AVOID:
- Instailation areas where high temperature
(1 20'Fj19*C or higher) exist or solvent fumes or
chemical vapors with an adverse affect on
potycarbonate are present in the atmosphere.
- Cleaning the pofycarbonale bowl with solvents
such as acetone, alcohols, ketones, esters or
aromatic hydrocarbons such as benzene, loluene.
xyiene. etc. Clean with a mild household detergent
)nly
- Adverse solvent fumes and chemical vapors beimg
orawn into the compressed air system via the
compressor intake.
- The use of polycarnonale bowls on air systems
where synthetic compressor lubrcants are
.ransnitted domvnstrnrm.
- Compressed air tem;r::urns above 12"F (48.9"C)
or pressures above 150 psig.(10.3 bar) are present
at inlet to drain.
Freon (Refrigerant & Propellant)Nitrobenzene
Phenol
Phosphorous Hydroxy Chloride
Phosphorous Trichloride
Propionic Acid
Sodium Sulfide
Styrene
Sulfuryl Chloride
Tetrachloride
Tetra Hydronaphtialene
Thiophene
Toluene
Xylene
Synthetic Compressor Lubricants"
Chloride
DuPont Trademark
Phosphate Ester Lubricant; where compressor lubricants other .j .
than normal mineral base lubricants are used, contact lubricant
manufacturer.
V. OPERATION
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3
As condensate begins to rise in the drain, the
float (1) remains in place, held by the magnet
(2).
When the buoyant force of the float overcomes
the magnetic hold, the pilot valve (3) opens.
increasing air pressure in the main discharge
chamber (4) forcing the piston (5) to snap
downwards.
This opens the main discharge chamber and
the condensate is forced through the drain titer
(6) into the lower portion (7) of the chamber.
and then through the outlet (8).
When sufficient condensate has been discharged, the float drops causing the pilot valve
(3) to close.
(he air supoly to the main discharge chamoer
(4) is then cut off, back pressure bleeds off
througn onfice assembly (9) and the piston (5)
rises, closing the main discharge chamber
lower Portion (7).
1 . 2
Model
PSIG I
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Serie Automated Ball Valve
Full Port, Forged Brass Construction, 800 psig (41 Bar), 320OF (1600C)DOirec Mount, Two Posiion Or Modulading Eectric AcMator
-- C E - F
DIMENSIONS .
A 26" 2."0 1 1%" 14 2" % 3'
B 6.130 6.199 6.574 6.700 8.291 8.623 9.177 9.61C 4.000 4.000 4.000 4.000 4.215 4.215 4.215 4.215D 2.638 2.980 3.350 3.657 4.126 4.805 6.496 7.4025.630 5.630 5.630 5.630 5.630 6.880 6.880 68802.310 2.310 2.310 2.310 2.430 2.430 2.430 2.430CW 15 25 35 46 80 110 310 360
A0
The Series ABV combines a durable full port, forged brass ball valve with aNema 4 electric actuator to provide a compact, low cost, automated package.The brass ball vAh'e utilizes PTFE seats and body seals for broad chemical com.pxatlility and bublil-ght ,hutoff. Double o-ring stem seals provide leak free)rprudon uitlhout the ned for adjutment. Chrome plated brass bal reducesfrict ion alowm:i 'i%,-iwr .rque ictua-lr. Full p.rt design offevr high CV's%ith minimal pnrssun drop. ISO mounting pad allows direct mouningofelec.tr:itactuor. Select from 115 VAC. two-position:actuaorforopen/closecontml,
or prnoide a 420 mA control signd for preci.e modulaung. Actuator featuressundard manual overide. in case of power loss. Optional spring return unitsare available .or fail-safe operation. For HVAC and Industrial applications.
Su1gested Spcificaton:
BaIl vave shall 1* forged bass, with chrome platd brass hall. Desin shall 1L-.11ui.eet. full Iurt mu Ii TI ' ea' and bodi I *Aatj Stem ,eal sal Lncorxrtedouble o-ring design. Vave shall be operated by direct mountedftuonXm iu~iun contol. Automiattd bidl udve shadl bet W E. Anderson .iodel
PHYSICAL DATA
Size: W -r
Mat.ia Vi- 3o -Brass;
Seat. Seas - Teflon O-ings - Vitons"
Actuator - Housing - Aluminum
Mat Pres. 600 Psig (41 Bar) (Waei. Oil.
STOCKED MODELS in bold
i Saze jSee901 Two Position
1*
1 A/C
2.5
2.5
2.5
25
ABV102
ABVIO3
-p 102
Max. T0e1 4 320F(60rC) - Vale;
Suppir., 1l5VACM4GWlp
Switch Ratingst ISA % HP 125/250VA C.5A i2SVDC
Cycle Tnt: 5 secow
Conol Input 4-20 mA
Enclosn : NEMA 4 (NEMA 7 coiornay -consuntwoABVI IOI
ABV1
A8V
" 5 - AVI " - I
3" 5 BV07AB.1
:1
a Division of Dwyer
SERIES ABV
Instruments, Inc.
AUTOMATED BALL VALVE
INSTALLATION, OPERATION AND MAINTENANCE MANUAL
W.E. Anderson Division, Dwyer Instruments, Inc.
P.O. Box 258, Michigan City, IN 46360, USA
I. BASIC INSTALLATION
1 OCerate valve manually and place in the open position. (NOTE: ALL ELECTRIC ACTUATORS ARESHIPPED INTHEOPEN'TTION.)
2. Remcve any mechrancal stops the valve might have. (DO NOT REMOVEANY PARTS NECESSARY FORTHE PROPER OPERA-iION OFTHEVALVE, SUCH ASTHE PACKING GLAND, PACKING NUT, ETC.)
3. Ensure that the actuatoroutput shaft and valve stem are aligned properly. If they are not, operate the valve monuctyuntil they are correct.
4. Mount actuak to valve.Do r tighten nuts and bolts at this time.
5 Removeacaorcover.
3ring power to the actuatcr. CAUTION:.Make sure poweris OFF at the main box.
7 Wire the actatcr certe diagram attached to the inside of the cover. Special actuators (those with positionersccrds, etc.) wil have diagrams enctosed inside the cover.
3. Securely tighten bolts used to mount the actuator to a mounting bracket or directly to the valve mounting pad i is I305211 complicnt.
9. Cycle the unit several times and check the open and dosed positions of the valve. Coms are pre-adjusted at the-cctcrv: due to the variety of valve designs and types, however, slight adjustments might be required. (SEE land Ill
'placecoverand tighten screws.
II. TO SET THE OPEN POSITION
1. Cycle the valve to the open position by applying power to terrnals #1 and #2. The top cam and switch control thisposition. In the open position, the set screw in the top cam will be accessible.
2. If the valve is not open completely:
A. Slightly loosen the 8-32 x '" set screw on the top cam.
B. Rotate the cam clockwise (CW) by hand until the switch makes
contact. Contact is made when a sight dick can be head. By making incrementalCW movements of the topcam, the valve can be positioned preciselyin the desired position.
C. When the top cam is set, tighten the set screw securely.
3. fthe valve opens too for:
A. Apply powerto terminals #1 and #3. Thiswill begin to rotate valve CW. When valve is full open and in theexact posifrn desired. rern ve powerfrom actuato
B. Loosen pe set screw in y top cam.
C. Rotate :4e top cam ccInlerclockwise (CCW) until the switch arm drops off the round portion of the cam ontothe flat sectlon. A slight click can be heard as the switch changes state.
D. Continue applying powerto terminals #1 and #3 until valve is in the desired position.
Il1. TO SET THE CLOSED POSITION
1. P- ly power to terminals #1 and #3 to move the valve toward the closed position. The bottom cam and switch
J the closed position. In the closed position, the set screw in the bottom cam will be accessible.
2. If the valve is not closed completely:
A. Slightly loosen the 8-32x V" set screw on the bottom cam.
S 5. Rotate the cam counter-dockwse (CCW) byhond until theswitch makescontact.Contact ismadewhen aslightcick conbe heard. By makng incremental CCW movements of thebottomcam, thevolvecan beposktioned p-ecisely in the desired position.
C. when the top cam is set, tighten the set screw securely.
if the valve closes too far
A. Apply power to terminals # I and #2. This wit begin to rotate valve CCW. When valve is fullyclosed and intheexactposition desiredrernovepowerfromactuator.
B. Loosen the set screw in the top cam.
C. Rotate the top cam cckwise (CW) unil the switch arm drops off the round portion of the cam onto the fatsection. i.light click carc e \heard as the switch is no longer making contactwith the round part of the cam.D. Ccnfin e applying pc erto terrninls #1 and #3 until valve is in the desired position.
V. MAINTENANCE
nce the actatcr has been property instded, it requires no maintenance. The gear train has been permanenity lubn-cred and in most caseswil never be disturbed. In the event it becomes necessary to open the gear boxforany reoscr
cweverShelCcrna #2geaseisrecommendedforredubicating.
. DUTY CYCLE
oststandard e4ectc actuators arerated for 25%duty cycle at 1. ambient temperature atthe rated torque.
VI THERMAL OVERLOAD
I l actuatrs are eauipped with terd oveicad protection to guard the motroganst damage due to overheating.
Vi MECHANICAL OVERLOAD
-tuatorsare deigned to withstand stal conditions. It is not recommended to subject the unit to repeated stall
londitions.
Il. SPARE PARTS
When rdering pcrts, pleasespecify
Mcdei# B.Serial# C. Part Description
1jecmmTendedspoepais-ricLde:.Standard actuc ta- set of cams and switches
B.Actuators w/positioner. setof cams and switches; IK potentiometer:valve positioner board
&. NEMA 7 ELECTRIC ACTUATORS
in general, operation and maintenance of a NEMA 7 electric actuatoris no different thatof a NEMA 4actuator. However.
precaulions mistbe folowed
1. DO NOT under c i circumstanc jr emove the coverof theactuatorwhile ina hazardous location. Removalof theI ver while in a hczardous locatiorcould cause ignition of hazardous atmospheres.
2. DO NOT underany circumstances use a NEMA 7 electric actuatorin a hazardous location that does not meet the
V cationsfarwich theactuatorwas designed.
3 Jys mount and cycle test the actuator on the valve in a non-hazardous location.
When removing the cover, care must be taken not to scratch, scar of deform the flame path of the cover and base of
the actuator, since this will negate the NEMA rating of the enclosure.
I
S. when replacing the cover on actuators rated for both NEMA 4 & 7, take care that the gasket is in place to assure
proper dearance after the covers secured. After thecoverscrewsare tightened. thedearancebetween thecoverand
The case should be checked. A .002" thick by %" wide feeler gauge is used for this; it must not enter between the two
-rtingfacesmore than. 125'
.All electncal connections must be in accordance with the specifications forwhich the unit is being used.
7. Should the unit ever require maintenance, remove from the hazardous location before attempting towokon the unit.
:f the actuator is in a critical application, it is advisable to have a standby unit in stock.
X. WARRANTY
wE. Anderson w 'ran'that ft period of twelve 12) months from the date of shipment of product it will
either recair or re, 'a at the Kimpany's discretion, any of its products 'hat prove to be defective in material
-r workmanship.
The customer agrees that this warranty shal be effective so long as the goods ore used solely for the normal purposes forwich they
:re nterded. This warranty does not coverdamage resulting from causes such as abuse. msuse, modfication a nonconforrnance
Mth installction, operating and maintenance spec:fications. Adation of these specifcations shdl void this warranty and relieve the
crccnyofanyodigation under ti warranty.
Av impied warranties, jnuded anyimied warranty by the comocny r any of its representatives, ore hereby exduded except as
Jeined by this written warranty. This warranty maynot be extended, altered a otherwise moded except by a written agreement
wtten ageement specifled and signed by this company. in no event sndl the comoany be iable forspecial. incidental, cr conse;uen tial damages arsing in con nec tion with the use of its oroduc ts. o for any delay n the performance of this warranty due to
causes beyond its control inctaing delays causea by unavacuity of mo tends, equipment, suppies. labor, governmental reguitons oracs of God.
:t ,customer receives any goods that ore deemed to be defective, the product or products maybe returnec
K Carbo-Bond at WE. Anderson in Michigan City. IN only after receiving a return authorization from the
cumpany. Products must be returned to the factory PRE-PAID for inspection.
X. TROUBLESHOOTING
SYMPICM
Actuator does notrespondto control signal
Actuator will not opei and/or close
completly
Valve oscillates
PROBLEM
Power is not on
Actuatawed incorrecty
incorectvdtage
ThemdOverltod
ActuatcrandVdvehnopposite
positionswhen actuatorinstaled
Travel limit switch set incorrectly
Vdve torque too high
Mechaicdstcpsnotrernoved
when instaling actuator
Torque of vdve too high
SOLUTION
Turn on Power
Checkwiingdagam: revre
Ming correct supply to actuator
Alow motor to cool: resets automatically
Removeactuatcrremcunt
after90deg. turn
Set cams perinstructions
Install correct unit
I
I
I
I
I
I
Rerrnoestops
Install correct unit
Actuatcrwithout brake installed
on butterfly valve
Motrbrkemsacied
Install brake
Adjust brake; tighten screw
Gear damaged/sheared pin Contact factory
I
I
Actuator motor runs but output
Section 4
American Industrial
Heat Transfer Inc.
Manufacturers of Quality Heat Exchangers
A CA SERIES
AIROCOOLED
AFTER COOLERS
FOR COMPRESSED AIR A
SThermal capacity to 120 hp (90 Kw).
* Computerized selection program.
* Standard ports NPT, optional ANSI straight
threador flange connections.
* Operating temperature of 4000 F & pressure of
150PSI.
ND GAS APPLICA 77ONS
- vertical designs with n
Visit our web site at www.aihti com
ounting legs
included for easy installation
- Custom designs to fit your needs.
- Cools: Compressors,Blobe5I al-$9 mi ePh uai&
systems, Vapor recovery systems etc...
MuuamcO
American Industrial Heat Transfer, Inc.
Sizing Program A!r/Ar COOLERtS
Performance of One Unit
Customer:
Model Selection:
Recuired Sq ft:
Uni:l Dcs:gn Sq.Ft:
Bisco
ACA
29.4
29.5
4 30 1 - 3
Date: May 9. 2C0:
CONDITIONS
'spc::fic Gravit~y
S Rate
- w RaCe!
crazing Pressure
pra:Lrng Pretssure
-- :erature Encerinc
*Tenperature Exiting
eA: Z. Temperatire
z Aeat
na.: t u/zr !:
DE SIDE
SCFM
SC FM
ACFM
ACFM
PSIG
In. H20
F
BT2/o-!s
C~s
7'2 F/f:t
FAN SIDE
AIR
1.000
250.00
250.C
0.0
302.1
0.0
14.0
200.0
117 . 6
1.6
0.250
0 .0 9o
0.0180
A-t.:.ce Sea Level .
FAN Flow
Atmcszher:ic Prcsstre
Calculation
Rt/hr 23235 23225
eign' 28 S' Ze.97
-. /ft' c.0622 0.3209
h. Rste Pas/ .2 15929 6
*Mss Vel. 1=/nr -ft*2 -6315 5 3
re-.t.re Drcp :r..wa ter.
-:tssare Zrcp ~P5 3.4:4
--e1oc;Ly (-beS ft/s c 22 53 Ex:erna Veloczy ft/Min 120. 57
EReyoids 5610 5446
U val-e clean 16.66 Dr: 26.63
I Selection
:ec-xred Area Sq.Ft. 29.40 ZMTD
47.4
*-Stface Area Sq.Ft. 29.45
Construction
- fe Diareter
7e wall Dia.
r. :ubes
Parallel -be Rows
b er Tubes
:Z iWeight Empty
7U5ES Copper
* MA:IFOLDS Carbon Steel
COATING Enamel
1 Size 30 ij 30
J ia P 0.50 Phase 3
Brazed coil care X
I Agner canI r
inch
inch
ir.ch
Ix s
0.375
0.025
30.0
4
120
8'.0
Fins Per :ncn
EsLirated pass is
Er.ter Number Passes
Est. Min Nozzel inch
Nozzel size Inch
Manifold incr.
Materials
FINS Aluminum CABINET Carbon Steel
GASKETS None
FAN Nylon Composite
Nozzel 3.0 NPT
Hert:/Volts 60 / 208 Class TEFC
Serviceable core
a 1
1
3.5
3.00
3.00
P% 1140
IZndustrial Heat urAser. :nc. 3905 Route 173 Zion. I1I1noi: 6009;
Tol Free: I-800-3J8-,959 Fax:04
7
.7)1-3440 Tel-8d771-100O
ft CM
PSIA
AIR
0
4450
Es1323
:4.696
100.0
34 . 9
0.24
C C16
0.C:6^
INTRODUCTION
ACA - 3182 through ACA - 4362 & ACA - 3181 through ACA - 4361
The American Industrial ACA series cools air
with air, compared to water or R12 refrigerated
systems. The unique compact brazed fin/tube
design provides efficient cooling even under
the warmest enviornmental conditions. By
simply connecting the electric fan morot to a
power source and attaching the air lines, the
equipment will be ready to cool.
Air coolers are an essential part of any
compressed air system, cooling the air and
condensing water vapor into a liquid form for
removal. When warm humid air is
compressed, the compression induces heat
into both air and water vapor. The ACA series
Air-cooled After cooler then cools the
compressed air and vapor, passing its dew
poinL Dew point is where the water vapor will
condense and again transform into a liquid
state. Once in a liquid state the water can be
removed wia a liquid seperator before entering
the receiver tank.
American Industrial provides custom
enhancements to all of our products. By applying an ACA series air-cooled after cooler, machine tools will reveive cool dry air,
:7ovide Longer truble free life, experience less down time, and be cost effictive to operate or a continuous basis compared to
'r less advanced systems.
HIGH PERFORMANCE TURBULA TOR
Exclusive American Industrial Turbulators (installed in every flow tube)
increase heat transfer by more than 100%.
American Industrial Turbulators eliminate the laminar flow condition
normally associated with other smooth tube heat exchangers. High
viscosity hydraulic and lubricating oils are easily cooled by this new stateo the-art turbulator.
TANKS
State-of-the-art 21st century high temperature brazing method
insures permanent bond and positive contact of tube to manifold,
eliminating leaks and providing maximum service life.
Standard Construction Materials Standard Unit Ratings
Tubes Copper Operating Pressure 300 psig
FIns Aluminum Operating Temperature 300 *F I
Cabinet & Pipes Steel
anOptional Materials AvaiLable Upo Request.
Fan Guard Zin plated Steel
Copyright C 2000 American Industrial Heat Transfer. Inc.
INTRODUCTION
ACA - 6361 through ACA - 6601 & ACA - 6362 through ACA - 6602
The American Industrial ACA series cools air
with air, comparea to water or R12 refrigerated
systems. The unique Serviceable coren' fin/
tube design provides efficient cooling even
under the warmest enviornmental conditions.
By simply connecting the electric fan morot to
a power source and attaching the air lines, the
equipment will be ready to cool.
Air coolers are an essential part of any
-4 compressed air system, cooling the air and
condensing water vapor into a liquid form for
removal. When warm humid air is
compressed, the compression induces heat
into both air and water vapor. The ACA series
Air-cooled After cooer then cools the
compressed air and vapor, passing its dew
point. Dew point is where the water vapor will
condense and again transform into a liquid
state. Once in a liquid state the water can be
removed wia a liquid seperator before entering
the receiver tank.
American Industrial provices custom
enhancemer:ts to all of our products. By applying an ACA series air-cooled after cooler, machine tools will reveive cool dry air,
provide longer trouble free life, experience less down time, and be cost effictive to operate on a continuous basis compared to
other less advanced systems.
SERVICEA3LE CORE-
Core covers disassemble for easy access and cleaning. Repairable
design for applications that require limited down time. Roller expanded
tune to tube-sheet joint.
100% mechanical bond. No braze or solder joint to fatigue fail, corrode,
crack, etc.. No rubber grommets to replace. Positive gasket seal is field
replaceable for field maintenance or repair.
SUPERIOR COOLING FINS
Copper tubes are mechanically bonded to highly efficient aluminum cooling fins.
Die-formed fin collars provide a durable precision fit for maximum heat transfer.
Custom fin design forces air to become turbulent and carry heat away more
efficiently than old flat fin designs.
Standard Conatruction Materials Standard Unit Ratings
Tubes Copper Operating Pressure 300 psig
Fins Aluminum Operating Temperature 30W *F
Cabinet & Pipes steel Optional Materials Available Upon Request
Fan Guard Zinc plated steel
Copyright C 2000 American Industrial Heat Transfer. Inc.
5yERFORMANCE
SELECTION
ROTARY SCREW COMPRESSORS
(2000F 0125 PSI & 36% relative humidity)
Model Size Selection
Approach Temperature "F
Compressor Average Air Dischar 5F 1 0F 15"F 20*F
(Horse Powell Cubic feet per minute Model
15 60 ACAM3302 'ACA-3242 'ACA - 3242 ACA - 3182
20 80 ACA - 3302 ACA - 3242 ACA - 3242 ACA - 3182
30 130 ACA -3362 ACA - 3302 ACA - 3242 ACA - 3242
40 165 ACA - 3362 ACA -3302 ACA-3302 ACA -3242
60 250 ACA - 4362 ACA- 3362 ACA- 3302 ACA - 3302
75 350 ACA - 6362 ACA - 4362 ACA - 3362 ACA - 3302
100 470 ACA - 6362 ACA - 6362 ACA - 3362 ACA - 3362
125 590 ACA - 6422 ACA - 6362 ACA - 4362 ACA - 3362
150 ! 710 ACA - 6422 ACA - 6362 ACA - 6362 ACA - 4362
200 945 ACA - 6482 ACA - 6422 ACA - 6362 ACA - 6362
250 1160 ACA - 6482 ACA - 6422 ACA - 6362 ACA - 6362
300 1450 ACA- 6542 ACA- 6482 ACA - 6422 ACA - 6362
350 1630 ACA-6542 AOA 6482- J.ACA -6422 ACA -6362
400 1830 ACA - 6602,t ACA - 6482 ACA - 6422 ACA - 6422
500 2150 ACA-6602 ACA 6542 ACA-6482 ACA-6422
To Size for Compressor
1) Select the correct HP compressor from the chart above.
2) Select the desired approach temperature from the "Model
Size Selection" area.
Approach temperature = Temperature desired out of the;
Heat Exchanger minus ambient air temperature. f
3) Move dowr the desired approach temperature row until the
HP (shown at the left) and the approach temperature intersect. The proper model number will be shown in the box.
4) Insert the model size number selected into the example
ordering code, as shown below.
Example ACA- 6362 - 3 - N
Model Series T
Drtve Motor
1 - I Phase
3 - 3 Phase
Model Sekction-i 5 - 575 volt
Connection
N - NPT
A - ANSI Range
Sizing Notes
When sizing for higher humidity and specific applications
not listed in our convenient selection chart, please consult
factory at 800-338-5959.
Copyright C 2000 American Industrial Heat Transfe. Inc.
G G
AC -
ACA -3181 through ACA - 4361
K T- G -G
ACA - 6361 through ACA - 6601
DIMENSIONS (inches)
Model A B C D E G J K L M N T
ACA-311 30.6 23.0 19.8 * 2.5 1.5 8.2 14.3 1.5 8.38 2.95 11.0 14.0
ACA-3241. 36.5 29.0 19.8 * 2.5 1.5 G 18.9 1.5 8.38 2.95 11.0 22.0
-A641 -- 4eB- -46.- 4 941. .. 20 f -6436-- -2.96-- 442- -4-
ACA -4301 423 350 19.8 ' 2.5 2.5 14.2 22!.8 15 8.38 3.45 11.2 28.0 4-
.- CA~l.- -6.---4.---46-...2 &E1 .30- ~ ~ - 4 88- -4."- -44q- -- a"0
ACA-4N1 48.3 42.0 19.8 2.5 2.5 17.2 27.2 15 8.38 3.45 11.5 32.0
ACA-6IP 48.5 43.9 19.8 * 2.5 3.0 17.2 26.0 1.5 8.38 6.45 12.7 32.0
ACA-64U.. 54.5 49.9 19.8 * 3.0 4.0 20.2 29.4 1.5 8.38 6.45 13.4 36.0
ACA8U6 60.5 55.9 19.8 3.0 4.0 23.2 34.2 1.5 8.38 6.45 13.1 42.0
ACA-654t$,s 66.5 61.9 24.4 * 3.0 4.0 26.2 38.6 ' 6.75 6.45 13.2 48.0
ACA-66MI 72.4 67.9 24.4 3.0 4.0 29.2 43.2 ' 6.75 6.45 13.2 48.0
WCopyrftigh ft 200 AmedeVn Indutda HeataTra*nsfer. nc.
Copyright C 2000 Amneriwn Industrial Heat Tintzer. Inc.
*ELECTRIC MOTOR
PTANDARD FEATURES
S AC ELECTRIC MOTOR DATA
ode i Horse Phase Hz Volts RPM NEMA Enclosure Full Load Service ThermalMdl IPower | Frame Type Amperes Farctor Overload
-A- 318X -1 .25 1 60-50 115/230-90/190 1725-1440 48 TEFC 3.2/1.6/2.8-1.4 * NO
.CA- 318X -3 .25 3 60-50 208 - 230/460 - 19021380 1725-1440 48 TEFC 1.3/.65/1.1-.55 - NOI ACA-324X -1 .25 1 60-50 115/230- 90/190 1140-950 56 TEFC
ACA- 324X -3 .25 3 60-50 208 - 230/460 - 190/380 1140-950 56 TEFC J -
ACA- 330X -1 .5 1 60-50 115/230 - 90/190 1140-950 56 TEFC j9.6/4.7-4.&10.4/5.2 1.15 NO
ACA- 330X -3 .5 3 60-50 208 - 230/460 - 190/380 1140-950 56 TEFC 2.4-2.7/1.35-2.5/1251 1.15 NO
aC' 211t I .5 3 an5 ' c 1140250 56 TEFC 2n . & ' AAor AIQA 1 .1 5 NO
ACA- 430X -3 . 3 60-50 20-3/C o c 1 140-&SQ. J 56 TEFO 2.41 ''p. "'l 1.15 NO -
ACA 2?SX I
-6 --le 'u
ACA- 336X -3 1.0 3 60-50 208-230/460 - 190/380 1140-950 56 TEFC ' -
ACA-436X -1 1.0 1 60-50 115/230-90/190 1140-950 56 TEFC *
ACA- 436X -3 1.0 3 60-50 1 208-230/460 - 190/380 1140-950 56 TEFC * -
ACA- 636X -3 3.0 3 60-50 ' 208-230/460 - 190/380 1725-1440 182T TEFC * -
ACA- 642X -3 5.0 3 60-50 208-230/460 - 190/380 j 1140-950 213T TEFC 8.2-7.6/3.8 1.15 NO
ACA-1648X -3 5.0 3 60-50 208-230/460 - 190/380 1140-950 213T TEFC 14.0/7.0 1.15 NO
ACA- 654X -3 7.5 I 3 60-50 1 208-230/460 - 190/380 1140-950 254T TEFC 20.4/10.2 1.15 NO
ACA- 66OX -3 10 3 60-50 208-230/460 - 190/380 1140-950 256T TEFC 28.0/14.0 1.15 NO
E-ECTRIC MOTOR NOTES:
Motor eectncal rungs are an appromamate guide and may vary between motor 4) Fan rotation is clockwise when facing the motor shaft
na.iacurrs Consul rmangs on mocordam plate pnorto installation and opeo. 5) The above motors contain factory lubncated shielded ball bearngs (no addniona
Explosaon proof. high teperatre.severeduty. chnemcaJ. [EC. Canadian Standards lubncaton is rrquird).
xscAcsauon, and Undewnter Labasory recogmnzed mirs are available upon 6) Abbrevialon Index
'uct- TEFC. ...........--Totaily Enclosed. Fan Cooled
.nenani idustnal resw the nght to enact chans to notor brand, type and EXP............ .... Explosion Proof
ratog5 regarding horsepower, RPMFA.and scvice famor for staundard poduct
mrthout notice All specific requuents will be honred w ithot change.
CLASS IDIV.1, GROUP D or CLASS II.DIV.2. GROUP F & G EXPLOSION PROOF MOTOR DATA
el Horse Phase Hz Vols RPM NEMA Enclosur Full Load Service ThePower I Frame Type Amperes Factor ead
ACA-318X .25 1 60 115/230 1725 48 EXP 5.8/2.8 YES
ACA- 318X -3 3 60 208-230/460 1725 48 EXP 1.4-1.3/65 * YES
ACA- 324X -1 **** *-*
1ACA- 324X-3 * **** ****
ACA-330X-1 .50 1 60 115/230 1140 56 9.4/4.8 * YES
ACA-330X-3 .50 3 60 460 1140 EXP 2.5-2.4/1.2 * YES
ACA-430X-1 .50 1 60 115W 1140 56 EXP 9.4/4.8 * YES
ACA-430X-3 .50 3 60 208-230/460 40 56 EXP 2.5-2.4/1.2 * YES
ACA- 336X -1 N/A I * *
ACA-336X-3 1.0 3 60 1140 56 EXP 3.8/1.9 * YES
ACA-435X-1 * * I ** * YES
ACA- 436X -3 1.0 3 j 60 230/460 1140 56 3.8/1.9 YES
ACA- 636X -3 * * *
ACA-642X-3 * * * I *
ACA-648X-3 * * * * * *
'A-654
*
-_- X -3 a aa
n E: Basic tI drl. Wins ar sm pd one the on pondn bg imeaed ront.
Copyright C 2000 American Industrial Heat Transfer. Inc.
American Industria __1_
Heat Transfer Inc.
Manufacturers of Quality Heat Exchangers
* HIGH QUALITY * LARGE SELECTION * LOW PRICES t
Below are just a few of the many services that we offer:
. Prompt Response to your technical questioris.
- Same Day Shipping on all n stock items.
- Custom Built heat exchangers and air/oil coolers to
meet your specifications.
- North American Stockinc Distribution.
- State-of-the-art CNC automated production facility.
- Interchangeanie A : clner manufacturer's heat
exchangers.
* Exoeoitec Se- ce- a: - zcttional charge.
- cstoner ,e:arve 'our choice.
- One year Warrant;
Shell & Tube Ar Cooled Oil Coolers
Our Hear Exchangers Are Offered With The Following orpst::
Shell & Tube Heat Exchangers
* 90/10 Copper/nickel & 316L stainless
steel tubing
* Brass end bonnets
* SAE, FBF or ANSI connections
* U-tube and Straight tube, available in
removable or fixed bundies
Air/Oil Heat Exchargers
- Built-in by-oass reiief valve
- Epoxy or heresite coating
- Copoer-Nicae Stee. or Stainiess steel
tuoing
- Exlosicr Dro 5~'5v 62z. 50Hz,
hyoraui. az: ::-e : - -notors
Copyright C 2000 Amcri n Industnrial Heat Transfer. Inc.Vii Our Web site a,,ww.2ihtixcom
HELL & TUBE HEAT EXCHANGERS STANDARD FEATURES
AOUNTING BRACKET 6- THREADED PORT m:nimized to provide for maximum heat transfer.
..v gauge steel mountirg brackets are adjustable in CNC precision tmreading to pronoe accurale lea-orcc*
aions to 360 degree;. connections. 10- HUB
oremium quality forging with full opening designed
7- BAFFLES !o- minimum pressure drop,
, into tubes with minimum restriction. One,
: i pass interchangeability
LOW CAVITY
e'zusIv sized to allow for minimum pressure drop
-ore uniform low.
JBES JOINT
e expanded tube joint to integral forged hub.
%BE SHEET
:sion-machined tube-sheet provides for long lastg- strenght service.
CNC manufac!.'ec ca-les !o p2 e -ax V
ence and heal l'anster wi"- a m - 2-u
drop.
8- FINISH
Gray semigloss enarrel sJ.:aZ e -Zd :-se' ^
be used as a case tor acn:tiona coats
9- SHELL & TUBE BUNDLE ASSEMBL'
CNC prec:sao. 7anutac:urec pars t: uara:ee-::0
fit between the Catles. tunes anc sne:! Ciearae:es ae
i d M7
11- FULL FACE GASKET
-ae :'mposite gasket for maximum seal under
zressu-e and temperature.
12- DRAIN PORT
Crain ports allow for easy draining of tube side.
::a zin, anode can be inserted in place of plug.
AB , AB-2000, SAE, STS & EAB
SERIES
F
AA , STA & FBF
SERIES
CS , STC & CK
SERIES
(if'
12:
2
.3.
4 4,
-a '12
Copyrghi & 2000 American Industrial Heat Transfer, Inc.2
K-
L
5:I
'1\~2
1
PIPING HOOK-UP, INSTALLATION & MAINTENANCE
B
|C.
A
AA
C
A
D
AA Series
D
ONE PASS TWO PASS FOUR PASS
Installation:
a) Plan your installation to meet the requirements indicated on the pipm; Imstallation diagram as illustrated. It is reconmendcd to put the hot fluid to hec
cooled through the shell side and the cold fluid through the tube Nide The
indicated port assembly sequence in the above diagram maximizes the performance. and minimizes the possibility of thermal shock. In instans a here the
luids arc required to be reversed. hot fuid in the tube .. ! ., II
shell, the heat exchanger will work with reduced performance.
b) When installing a series EAB beat exchanger (expansion bellows), it is recommended to use a shoulder bolt to allow the heat exchanger to move freey
tsile expanding ard contracting due to high differential temperatures.
his recommended to use flexible hose wherever possible to reduce sibraitoi
and allow slight movement. However. hoses are not required. Hydraulic camIng lines should be sized to handle the appropriate now and to meet 'vicm
nesurc drop requirememns based upon the systems parameters, and not based
the units supply and return connection size. We recommend that a lows
.,king pressure direct acting mlier valve be installed at the heat exchangzer
I N pit tom preume spikes by bnpamt III mill c 11e 11 stem
expenenices a high ow surge. It prelonlie ihIruii Is used it si auo Dic
located ahead of the cooler on both shell and tube side to catch any scale or
sludge for the system before it enters the cooler. Failure to install filiers ahiciJ
of the heat exchanger could lead to ponsible hea1 exchaner faiure II io hiLh
pr c'wure Il the )pi filter. plug.
d i Sunuard snell & tuo coolers arc built with a rolled tube-sheet and carry a
300 psi hel and 150 psi tube maximum working pressure riung at 300~F
Howevcer. the differenial operating temperature between the enterng shell side
fuid and the enteng tube side fluid should not exceed 150*F If this condition
ex>stt. a see nermal shock could occur leading to failure and mixing iof the
7 , - .._ .a I Ier.!; o epiIatuie, of 15u 1F or moure, we
recommend using senes EAB, UAB. or URAB to reduce the potential for the
effects of thermal shocL
c Unit, !hoM no b -lared into . corrosi I -nirnrr-- i ,-7d ALion of all exposed components could occur resulting in shortened life or failure. For proper material selection. or forextemal corrosive environments. please
coiiltu our toeton prior to installation.
0 wait' rerwrements varv from location to location. If the source or cooling
water is from other than a municipal water supply, it is recommended that a
water strainer be installed ahead of the heat exchanger to prevent dirt and densn from nIenrne and cloezine the now r Isse. f a rer mndrulain- i c
I iJ seu Ii reIINIIIInIded to he msll.d hlcif ile nlet in the coler in regulate the
wJter luw.
&I For sieam cr ice. or other related ipplications, pleaw consult lur engineerIng deparmnmn: fir ailiilnaF infonrmumn
2iiiuii ....... n Indoirm I lemuI trjntcr. iii.
AB A .......... Hot fluid to be cooled
B ........ ..... Cooled fluid
C .......... Cooling water in
D ............... .Cooling water out
SP ............ Single Pass
TP ............................. Two Pass
FP ............. Four Pass
C
FOUR PASS
D
IR / OIL HEAT EXCHANGERS PIPING HOOK-UP
FILTER
ONE PASS
ifi~-FILER
TWO PASS
AOCS - 1005 through AOCS - 3015
I F ILT E R
UINFILTER
TWO PASS 4'
AOCS - 201 through AOCS - 603
Copyright @ 2000 American Industrial Hea Transfer. Inc.
ONE PASS
4
INSTALLATION & MAINTENANCE
Installation: I) To clean the tubes, rermove the corn from the cabinet. I
a) Plan your installation in a location where there are no obstructions
to the inlet or discharge airflow path. If the unit is to be installed in a
-all, ample room ventilation should be provided. Duct work or additional cooling cores added to the housing of the cooler or in front of'
the cooler would increase the static pressure requirement of the fan
motor thus increasing the horsepower requirement of the motor. DuctIng shouldbe slightly larger that the core area with long radius turns to
prevent added static pressure. Prevailing winds should be considered
before installing. Winds blowing heated air back into the cooler could
cause loss of cooling especially on hot summer days.
b) Flexible hose or nonrigid plumbing can be used to reduce the risk
of failure due to thermal expansion of the core and hydraulic vibration. Hydraulic carrying lines should be sized to handle the appropriate flow to meet system pressure drop requirements based upon the
sy'stems parameters, and not based upon the units supply and return
connection size. We suggest that preventative filtration should be located ahead of the cooler to catch any scale or sludge for the system
before it enters the cooler.
The standard AOCH and AOCS oil coolers are built with a Serviceable Core1". W'e suggest that a three-way thermal bypass valve or a
direct acting low-pressure (60psi) relief valve be installed at the inlet
to the cooler to protect it in cold weather environments. Units should
not be placed into a corrosive environment. as rapid deterioration of
all exposed components could occur resulting in shortened life or failFor external corrosine cem ironmenL please coUlCI our factOI
or to installalion.
- Eieet-ic motcrs should be connnec oto a Nupplpeu er of thc
same characteristics as stamped on the electric motor nameplate. Prior
to saring. veriy that the motor and fan spin freely. Check carefully
! hat the fan tunis In the corct molon rn,:'I;,,n j roc9;-, C.
operate the fan in the proper direction could reduce performance and
cause serious damage to the heat exchanger.
d) It is importan: to apply the catalog recommended flow rate for the
hydraulic motor that corresponds with the specific model being used.
The proper flow rate and direction to the hydraulic motor are critical
to ensure fan direction and RPM. Exceeding the recommended RPM
could result in fin failure and cause severe damage to the heat exchan2cr.
Servicing sequence:
a) American Industrial has gone to great lengths to provide components that are imerchangeable and repairable. If your unit gets damaged, chances art that you can initiate the repairs in your own shop.
Most of the cabinet components of ourAOCH orAOCS heat exchangers are made of 18 or 7 gauge metals that can be repositioned after
extemal damnge. Most AOCH orAOCS core' mamtifactured nfter T:mi1 998 are Serviceable CoresTI. The Serviceable CorT". makes
.ssible to clean the tubing if it becomes fouled or plugged or repair
m11e core-tubes if they become damaged.
b) Follow the steps below for core disassembly & cleaning:
II) Mark the covers 2 & ( on both ends, so they can be replaced
into the same position.
Ill) Remove the manifold bolts 2 that join the core and the maifold cover $ from one side.
IV) Remove the manifold cover D; the tubing ' and turbulators 1
should now be exposed.
V) Repeat the above steps for the other manifold side.
VI) If you need to remove the turbulator that runs through ne
tubing, it will be necessary to first squeeze the flattened end
of the protruding turbulator. so that on end will fit through the
tube. From the opposite end pull the turbulator out. You may
need to use pliers to grip and pull the turbulators out, especially if there is debris lodged inside. As the turbulators come
out, most of the din will too so be prepared. You should wcar
gloves when handling the turbulators as they may be sharp
VII) We suggest the use of mild decreasing agens when flushing
the core. You may scrub the interior of the tubing with a clean
plastic bristle brush. Steel hrushes should be avoided s that
damage to the tubing does not occur.
VIII) If there are any leaking tubes, you can plug them by forcing a
tapered sout mecai piuc into the hole and tapping it ught. 'ou
may also weld a hole 'hut. Care should be taken (if this ,
donei not to induce heat into the surrounding tube joints. Excees heat on the surroundin tubing joint may cause the join
to loosen and leak.
the turbulators back into any open tubes. When the turbulators
protrude from the opposite end flatten them again so they are
:ighi and cannot be rcmos ed.
X) Replace the cover (, gaskets = & hardware 2 with new. Do
not reuse old hardware if possible. You may purchase gasket
kits from our factory. In most circumstances you will only
need to purchase an additional gasket set and bolts.
_6
A
Copyright 0 2000 Americn Industrial Hen Trnsfer. Inc.S
AIR / OIL HEAT EXCHANGERS PIPING HOOK-UP
FLUID
OUT
FLUID
N
I -
-- 'E\SSCADZ
AC & AOCH Series
For ms allation & sermcing sequence~piase re, e p e
FLUID
-
-- OU--
- .FLUID
IN
SSSS
EOC Series
~1'o
I- A RII
OUT
TW- PASS ONE PASS
ACA Series
- - N -- 2 : em Hea Transfer. Inc
PIPING HOOK-UP
Typical Piping Hook-Up for steam applications
URCS Series
-Vent Port
n o
Condensate out
- Fluid Out
Fluid In
Mounting
TYPICAL PIPING HOOK-UP FOR AIR APPLICATIONS
with air cooled heat exchanger
Water Out
A
- Air In
Mounting
4SOi S4,
Air Out
Water In TYPICAL HYDRAULIC CIRCUIT
waitt wtater cooled itear exchanger
Return une
Heat
Exchanger
TYPICAL HYDRAULIC CIRCUIT
with air cooled heat exchanger
Relief Valve
Return Une
Filter
Return Une
Y SDtner fi I M II.k v7m I
Copyrighc © 2000 American lndutrjil Hea Trnic n
-
Section 5
OUTLET
INLET
/
7
'1
DRAIN -
INLET/OUTLET
PLAN VIEW
TRUE ORIENTATION
ELEVATION VIEW
NOT TRUE ORIENTATION
DETAILED DRAWINGS AVAILABLE FOR INDIVIDUAL PRODUCTS
VF SERIES STANDARD DIMENSIONS
Model # (VF-) c 500 1000 2000 3000 5000 10000
Overall Height 4'8" 4'8" 6'8" 6' 8" 6'8" 7'8"
Footprint 3' x 3' 4'x 4' 4'x 4' 5'x 5' 6'x 8' 8'x 10'
Inlet/Outlet (150# FLNG) 4" 6" 6" 8" 10" 12"
Drain (FNPT) 1%2" /2" %A" %I3" %" %/"
GAC Fill (-bs) 500 1,000 2,000 3,000 5,000 10,000
Shipping Weight (Lbs) 900 1,450 2,650 4,500 7,100 14,500
Operational Weight (Lbs) 1,025 1,600 3,200 5,150 8,200 17,000
Rev. 10/17/2000
1200 E. 26th Street - Anderson, Indiana 46016
Phn: 765-643-3941 Fax: 765-643-3949 Email: info@tetrasolv.com
PRODUCT DMMNSONS
vF semes FUEL10
16" ACCESS
trosolv
Flitration
jaiasw
MODEL VF-500
-GENERAL DESCRIPTION
The VF-500 filter is a media filter vessel designed to treat vapor streams where pressure drop is a strong concern. While
the typical design application is a activated carbon adsorbtion unit, the filter can easily accommodate many medias. The
sturdy construction makes these filter vessels ideal for long term treatment units. Some applications include:
Soil Vapor Extraction Treatment
Air Stripper Off Gas Treatment
Odor Removal System
* Storage Tank Purge Vapor Treatment
* Pilot Study
* Industrial Process Treatment
VF-500 STANDARD SPECIFICATIONS
Specification Specification Value Options
Materials (Vessel) Carbon Steel Stainless Steel
Materials (False Floor) Carbon Steel Polypropylene, PVC, 304SS, 316SS
Internal Coating Polyamide Epoxy Resin Vinyl Ester, PVC
External Coating Epoxy Mastic (Light Gray) Any available coating
Maximum Pressure 3 PSIG Specials Designs Available
Maximum Temperature 250" F Up to 650" F
Cross Sectional Bed Area 9 FT2 Special Sizes Available
Bed Depth 2 FT (Using 500 Lbs. 4'10 GAC) Dependent upon supplied media
Bed Volume 18 FTJ (Using 500 Lbs. 4*10 GAG) NA
BED VELOCITY GRAPH
(Line Indicates Flow to Velocity Relationship)
Cal : Revieviwith fac rpior 1
lngadso rstoo rat. a
0 4 200 400 600 800 1000
Flow Rate (CFM)
PRESSURE DROP GRAPH
(As Filled - 4x10 GAC)
Rev. 1011712000
1200 E. 26th Street -Anderson, Indiana 46016
Phn: 765-643-3941 Fax: 765-643-3949 Email: info@tetrasolv.com
Section 6
A Full Range of Product Features
ina Gama Total de Caracteristicas del Producto
Superior Materials of
Constructiort: Complete AISI 316L
stainless steel I quid handling
components ar d mounting bracket
'or corrosion resistance, quality
appearance. ard improved strength
and ductility
High Efficiency Impeller:
Enclosed impel er with unique
oaling seal ring design maintains
maximum efficiancies over the life
or the Dump without adjustment
Casing and Adapter Features:
Stainless steel construction with
NPT threaded, centerline connections. easily accessible vent, prime
and drain connections with stainless
steel plugs. Optional seal face vent!
ush available
Mechanical Seal: Standard John
Crane Type 21 vith carbon versus
silicon-carbide faces, Viton
elastomers. anc 316 stainless metal
parts Optional agh temperature and
chemical duty sals available.
Motors: NEMA standard open dripproof. totally enclosed ran cooled or
explosion proof enclosures. Rugged
ball bearing de ign for continuous
duty under all operating conditions.
The vaious versons of the NPE are
idndied by a prcdu code numr
on the purnp lbt 1. This number is
also the catalog number for the pump.
The meanring of each dgit In the product
code number is shown at left
Materiales Superiores de
Construccidn: Componentes
compertos ora manepo de liquibs
en acero noxidable AiSl 36Ly
console para el montale par
resistenca a corrosion.
aoarenci de calidad j fuderza y
ductidad mneoradas
Impulsor de E/enricM
Superior: El impulsor encerado
con un atseio unco de anil del
sello (lotante, mantene sin ajustes, (a
eficenca maxima sobre la via
de (a bomba
Caracteristicas de la
Carcasa y del Adaptador:
Construccron en acem inoxidabke
con NProscao, conexnes
centraes, va/vulas oe fdol acceso,
conexiones de cebao y drene
con enchufes de acero inodable.
Cara ad sello valvulaIchorro opcaonal
disponible.
Sello M ecnico: Estnaar John
Crane Tmoo21 con carbon en
contraste con caras doe silconcarbide, eiastoneros de Vton y
partes meralicas de acero iodaole
316. Setls de a/ta temperatum y
productos quirmcos estsn
dispontbis.
Motores: Estandar NEMA a
prueba oe goteo, ventiladcr
rotalmente encerrado a recintos a
prueba de explosion Diseno robusto
de baineras de bc/s para trabao
continuo en todas las condiones
de funonamiento.
Las diferentes ierstones de (a NPE
se dentifcan con un noumer de
coigo del producto en [a etqueta
de (a Comba. Este nomero es
tambien el numero del cartlogo para
la bomba. El significado de cada
digito en el nomem de cbd'go del
producto se muestra a la izquierda.
NPE Product Line Numbering System
Linea de Producto NPE Sistema de Numeraci6n
Example Product Code,
Ejemplo Cddigo del Priducto
ST20A-
- Seal Vent/Flush Option,
Opcion de SeiJo ValvulalchorroSeal Von
rMechanical Seal nd 0ring
Fr opiicnal mechanical seal modify catalog order ro
vh ea code istead elow
Sello Mecnico y Anllo '0'
'ara sero necarrao> oxcnal mcinofi er nwmrc c do rdoi
i catalogo con et coago eel seio anotado abao
John Crane Type 21 Mechanical Seal i seal)
Selo MecAnico John Crane ripo 2 (sele de %-)
Seal mew P
Code,6l acode- Rotary Stationary Elan Puts. No..
Co" Rotativo Estaon a - Pares Piea
s I
Se toE 316ss
tacride oio o
Impeller Option ... No Adder Required
For wionnei moeller iameters modify catalog order no
ih impeller Code ns. Select ooal impeller diameter from
pumie uerrormance Curve.
Codigo del Impulsr Opacoi
%ra r:ousores con carretros opoonales modeicar e numenro de
omen oer camogo con ei codigo aoel impuisor anoado Escoger enmpi
con downerro opaonal oe a curva de fanconamiento de 0 bonba.
Impeller Code, Pump Size, Thmario de fa Bomb.
Cddigo del 1 x 1% - 6 1x 1%1-6 1% 2-6
1imPuar 1 Diameter IDiameter I Diameter
A 1 17, 4s%
3 5 7. 41A
I I St,4i, ViAc4s 4% 4%
E 4A 4%A 3%h
F 4" c%, Driver, Conductor
1 ' PH. ODP 7 3 PH. XP
2 -3 PH DP 8 575 V XP
3 = 575 V OP 9 = 3 PH. TEFC
4 - 1 PH. TEFC Premium Eff
5 = 3 PH. TEFC 0 1 PH XP
6 - 575 V TEFC
HP Rating, HP Potencia
C = HP E = 1 HP G = 2 HP I
D - s HP F = 1/; HP H = 3 HP
Driver: Hertz/Pole/RPM,
Conductor: HerdosPotloRPM
60 Hz. 2 Dole. 3500 RPM
2 -60 Hz, 4 cole 1750 RPM
3 =60 Hz, 6 pole 1150 RPM
4 -. 50 Hz. 2 pole 2900 RPM
5 50 Hz. 4 pole. 1450 R PM
Material
ST - Stainless steel. Acero noxdable
Pump Size, Tamano de la Bomba
. -- <1 .- 6 2 = 1 xI :-66
qG&L Pumps
Fir
frame ounted
version,
Substitute
the letters
APM
in these
positions
Pam Ia
ey ansz
ronteado,
susftq 4as
etras FRM
en estas
osis
3 =Ax2- 6
2
20 40 60 80 100 120 140 160 US. GPM
5 10 15 20
APACITY CAPA CDAD) 0
25 30 35
NOTES:
Not recommended for operation
beyond printed H 0 curve
For critical application conditions
consult factory
Not all combinations of motor.
impeller and seal options are
available for every pump model
Please check with G&L on noncataloged numbers
All standard 3500 RPM ODP and
TEFC motors supplied by Goulds.
have minimum of 1 15 service
factor Standard catalog units may
utilize available service factor. Any
motors supplied other than Goulds
check available service factor.
NOTAS:
No se romenda para
funcamnto supenor al Impreso
en la curva H-Q
Para condiones de apfracones
critkas consultar con la fbnca.
No todas las combinacones de las
opcones de motor, impuLsory sell
estin disponibes par cada modelo
de bombas Por favur wrfue con
G&L en los numeros no catalcgados
Todos los motores estandar de 3500
RPM, CODP (abuertos resguardados) y
TEC (totalmente encerados con
enfnamiento forzado) provwstos por
Goulds tienen un factor minino ae
servio de 115. Las undades
est~ndar de catslogo pueden uilizar
el factor de servicc disponible
Verfcar el factor de servico
disponible de todo motor no provsTo
por Goulds
RGEL Pumps
Performance Coverage (60 Hz)
Akance de Funcionamiento (60 Hz)
FEET
PiES
METERS
VETROS
50 -
401
30 1-
201-
10
0 - C'
0
0
3
NPE Close Coupled Pump Major Components: Materials of Construction
Bomba Cerrada Acoplada NPE Componentes Plndpales: Materiales de Construcci6n
100 101 347 370 513 184 108 383 123
349
S 1'h, 2 and 3 HP
412B 400 371 1%, 2y 3 HP Seal Face Vent/Flush Option,
Opcion Cara del Selo Vhuila/Chorro
Item No., Description, Materials,
Parte No. Descripdn Materiales
100 Ca'ng. casa
101 Ime||, mpuisor
AISI 316L SS.108 Mor adapte. Adaptador del motor AS 31& Ac oaidabe
108A Mcoadapt seal veniush.
Se/b vakuvahoro del adaptabr deq motor
123 Defector Deecor BUNA N
184 Sea housng. Abamiento dl seb
184 A Sea hosn seal vetush. AISI 316L SS.
Se/h v&hv4adctro dl aoamento del slo Q51316L Ace ronvdable
347 Guidevane. Difu
349 Seal nng. guidevae Anio selb, difuor Viron
370 Sodet head saews casNg: Alsl 410 SS.
Encz es cabezas d tomhdo carcasa Al 410 Acero nodab
371 Bo1 moor Rated steel,
Tor Mi motor Aceo chapeado
383 MeanI sea Seib ecan ".see dmar taba
408 Drain and ve plug. casing: AlsI 31& SS.
Endctes & drena/e y vava carcasa AJS1 3 &f Ace,, nodabe
4128 041r q dai and ert plug.
AndA 0, enchufe do drnae y aela Von
513 0-irg, cang. Ando 0, carasa
Mtor NWA standard. 56J flange
Motor NEMA estandar bnda 561
%, % and 1 HP
3, % y I HP
Footed notor for 1750 RPM and 5 HP OCP and TEFC,
all explosion proof see page 13.
Motor con pie para 1750 RPM, 5 HP ODPy TEFC a
prueba de explosiones en la pagina 13.
MG&L Pumps
184A
108A
4
Performarme Curves - 60 Hz, 3500 RPM
Curvas de FunCionamiento - 60 Hz, 3500 RPM
Model NPE I 1ST Size (Tamaio) 1 x 1%-6
RPM 3500 Curve (Curva) CN0231 R01
PIES
NPSH. - FEET
A 6Y DIA.-- .-
Impeller Selections for ODP & TEFC Motors
Seleccones cel impulsor para
Motores ODP & TEFC
(PIES) NOTE: Not recommended rU operation beyondrPIES) Rni H 0
NOTA: V. e worreno, para frconamenro
5' wperor a, ,reo eri la Curva H45 6'
1 x12'
NOTE: Although rot
recommended. the pump
May pass a /6' spere
NOT A: ben no se
recomend, la bomba puede
pasar una esfer de %6"
0 10 20 30 40 50 l US GPM
cAPACTf CAPAC0ADJ Q
Model NPE / 1ST Size (Tamaflo) 1 x 14-6 impeller Selections for Exp. Proof Motors
RPM 3500 Curve (Curva) CNO231R01 Selecoones deiimpuisor para Motores Exp. Proof
NOTE: No recommencec, or oeoro oeyond prined HQ curve
NPSH - FEET (PIES) NOTA: Nose ecomenoa ra unoonamento supenor a-11 rrpresOen 4 "a ra 0
5'
4548 60
1~
80
. 12'
Ordering
Code,
Cdigo
F
E
Standard
HP Rating,
st~ndar HP
PWtenda
3/4
D 1 4/,
C
B
1%
2 53/
A 3 6'
NOTE: Although not
recommended the pump
may pass a 'hb' sphere
NOTA: S, ben nose ecome
la boma pue&p asar una eser
de '%6.
- 03- -- -0 10 20 30 40
CAPACITY (CAPACIDAD) Q
METERS
METROS
50
40
30 -
20 -
10-
0 -
METERS FEET
VETRCS PIES
50 160:
Imp.
Dia.
spec40/1
50
10
[qGEIL Pumps
60 U S GPM
mYhr
6
NPE Close Coupled - Dimensions, Weights and Specifications
NPE Acop4e Cenrado - Dimensiones, Pesos y Espedfiadones
Clockwise Rotation Viewed from Drive End
Rotacidn en Direccid6n de las Agujas del Relof Visto desde el Extremo del Motor
DISCHARGE
DESCARGA
FILL AND VENT
CARGA Y VALVULA
4 _ " _
6 ,
ODP and TEFC %, %h and I HP, ODPy TEFC',. y 1 HP
Y WCMAX
8 DE MONTAJE
ODP and TEFC 1%, 2 and 3 HP, OPy TEFC 14 2 y 3 HP
Specifications
Especifcaciones
Capacities to:
75 GPM (283Lmin) at 1750 RPM
150 GPM (55C Umin) at 3500 RPM
Heads to:
39 feet (12 m) at 1750 RPM
150 feet (46 m) at 3500 RPM
Working pressures to:
125 PSIG (9 bus)
Maximum temperatures to:
212% (100' with standard seal or
250% (121'Q with optional high
temperature seal.
Direction of rotation:
Clockwise when viewed from
motor end.
Motor specifications:
NEMA 56 frame. 1750 RPM
% HP 3500 RPM % through 5 HP.
Open drip-proof. totally enclosed
fan-cooled or 2 HP explosion proof
enclosures. Stainless steel shaft
with ball bearings
Single phase: Voltage 115/230
ODP and TEFC. (3HP model 230 V only) Built-in overload with
auto-reset provided.
Three phase: Voltage 208 230/
460 GOP, TEFC and EX PROOF
NOTE: For three phase motors.
overload protection must be
provided in starter unit Starter and
heaters must be ordered separately.
Capacidades:
75 GPM (283Urmin) a 1750 RPM
150 GPM (550Umin) a 3500 RPM
Cargas:
39 pies (12 m) a 1750 RPM
150 pies (46 m) a 3500 RPM
Presidn de raba
125 P5G (9 baraS)
Temperatura maxima:
212*F (10010 con sello estendar o
250T (121 t con selb opconal
para alta temperarum.
Direccidn de rotacin:
En direcoon de las agujas del reloj
visto desde el extremo final Del
motor
Motores:
Armazdn 561 NEMA 1750 RPM
32 HP 3500 RPM 'M a 5 HP
Cubertas abertas resguardadas
totalmente encerradas enfiadas por
ventilador o a prueba de explosines
de 2 HP Eje de acero inoxdable con
balineras de boas
Monofiskos: Votaje 115/230
ODPy TEFC(rodelo 3 HP - 230
v/tics solamente) Se proporona
proteco6n teirmca contra sobrecarga
constvuda con resewe avtomr~ad
Trifiskos: Vokas 208-230/460
ODP, TEFCy&E'KPROOF
NOTA: Pam motore trf ssos se
debe de proporcionar la protecodn
termica contra sobrecarga en la
unidad de arranque. El arrancador y
los calentadores se deben pedir por
separado.
[G&L Pumps 12
NPE Close Coupled with Footed Motor, 1750 RPM and Explosion-proof Motors
NPE Acople Cerrado con Motor con Patas, 1750 RPM y Motores a Pneba de Explosi6n
DISCHARGE
CESCARGA
All 1750 RPM Motors
All Explosion Proof Motors and 5 HP ODP and TEFC
Todos los motores son de 1750 RPM
Todos los motores son a prUeba de explosiones, 5 HP, ODP (abiertos
resguardados) y TEFC (totalmente encerrados con enfriamiento forzado)
I
DRAIN PLUG /s --
ENCHUFF BE DRENAJE I,
Dimensions - Determined by Pump,
Dimensicries - Determinadas por [a Bomba
Pump, Suction, Discharge,
Bombi succidn Descarga HP W X Y L M
1ST % 1 13 3 4% 2 4% 7%A,
2ST 1W 1% -5 3% 4h 2% 5% 7%
3ST 2 1% 13 4% 2% 5% 7%
Available Motor Weights and Dimensions,
Pesos y Dimnensiones Disponibles del Motor
Mot"r Weights, MW delMoto C Max.
HP 1 Phase, Monoflskos 3 Phase, Trfhsicos Length,
OoP TEFC EXP 01DP1 TEFC EXP (I0111
W 16 21 47 19 18 27 9/1
9 4 24 41 21 21 30 10%
1 22 26 49 23 21 30 11
11 28 35 56 27 27 37 11%i
2 33 39 60 32 33 44 127,
3 40 43 - 41 37 - 127,
42 - - 42 45 - 14%.
Dimensions n inches. weights in pounds
D,rrn re e puloadai pesos en Aba
NOTES:
1. Pump will be shipped with top
vertical discharge position as
standard. For other orientations,
remove casing bolts, rotate discharge
to desired position, replace and
tighten 6mm bolts to S - 6 lbs.-ft
2. Motor dimensions may vary with
motor manufacturers.
3. Dimensions in inches, weights
in pounds
4. For explosion proof motor
dimensions consult factory for
information.
5. Not to be used for construction
purposes unless certified.
NOTAS:
L Las bombas se transportaren con
(a descarga mrtiai supenor come
estjndar Para otras onentacones
retirar los tomillos de la carcasa, rotar
la descarga ala posicn deseaa /
reemplazar y apretar os tornillcs de
6mm a 5 - 6 libras-pies.
2 Las dimensnes del motor pueoe
que vaien con los fabncantes.
3. Dimensones en pulgadas pesos
en libras,
4 Para las dimersenes de os
motores a prueba de explosion
consultar con /a fbnca para
Infomaloxn,
5 No usar para prop6sitos de
construc6n sin certiicar.
MGEL Pumps
FILL AND VENr
CARGA Y VALVULA
SUCTION
SUCCION
13
NIGEL Pumps
Installation, Operation anc
Maintenance Instructions
Model NPE/
NPE-F
DESCRIPTION & SPECIFICATIONS:
The Models NPE (close-coupled) and NPE-F (frame-mounted) are
end sucnin, single stage centrifugal pumps for general liquid
transfer service, booster applications. etc. Liquid-end construction is
all AISI Type 316 stainless steel, stamped and welded. Impellers are
fully enclosed, non-trimable to intermediate diameters. Casings are
fitted withb a diffuser for efficiency and for negligible radial shaft
loading.
Close-coupled units have NEMIA 48J or 56J motors with C-face
mounting and threaded shaft extension. Frame-mounted units can
be coupled to motors through a spacer coupling, or belt driven.
1.1. Inspect unit for damage. Report any damage to carrier/dealer
imnediateiy.
1.2. Electrical supply must be a separate branch circuit with fuses or
circuit breakers, wire sizes, etc., per National and Local electrical
codes. Install an all-leg disconnect switch near pump.
CAUTION
Always disconnect electrical power when handling pump or
controls.
1.3. Motors must be wired for proper voltage. Motor wiring
diagram is on motor nameplate. Wire size must limit maximum
voltage drop to 10%/b of nameplate voltage at motor terminals, or
motor life and pump performance will be lowered.
1.4. Always use horsepower-rated switches, contactor and starters.
1.5. Motcr Protection
1.5.1 Single-phase: Thermal protection for single-phase units
is sometimes built in (check nameplate). If no built-in
protection is provided, use a contactor with a proper overload.
Fusin, is permissible.
1.5.2. Three-phase: Provide three-leg protecnon with properly
sized -nagnetic starter and thermal overloads.
1.6. Naxinum Operating Limits:
Liquid Temperature: 212* F (1000 C) with standard seal.
2500 F (120" C) with optional high
temp seal.
Pressure: 75 PSI.
Starts Per Hour: 20, evenly distributed.
1.7. Regular inspection and maintenance will increase service life.
Base schedule on operating time. Refer to Section 8.
-s 4S
-0'
2.1. General
2.1.1. Locate pump as near liquid source as possible (below
level of liquid for automatic operation).
2.1.2. Protect from freezing or flooding.
2.1.3. Allow adequate space for servicmg and ventilation.
2.1.4. All piping must be supported independently of the
pump, and must "line-up" naturally.
CAUTION
Never draw piping into place by forcing the pump suction and
discharge connections.
2.1.5. Avoid unnecessary fittings. Select sizes to keep friction
losses to a minimum.
2.2. Close-Coupled Units:
2.2.1. Units may be installed horizontally, inclinedor vertically.
CAUTION
Do not install with motor below pump. Any leakage or
condensation will affect the motor.
2.2.2. Foundation must be flat and substantial to elimnate
strain when tightening bolts. Use rubber mounts to minimize
noise and vibration.
2.2.3. Tighten motor hold-down bolts before connecting
piping to pump.
2.3. Frame-Mounted Units:
2.3.1. It is recommended that the bedplate be grouted to a
foundation with solid footing. Refer to Fig. 1.
1 -, --o
12 1o3.4>
11 owance
or lnehog
Woodl
Carre .
MO13R05
Grout hole R
4
-
... Lrtigwedges OF shen,,-JeftAplc
Figure I Goulds Pumps
<& ITT Industries
2.3.2. Place unit in position on wedges located at four points
(two below approximate center of driver and two below
approximate center of pump). Adjust wedges to level unit.
Level or plumb suction and discharge flanges.
2.3.3. Nlake sure bedplate is not distorted and final coupling
alignment :an be made within the limits of movement of motor
and by shimming, if necessarv.
2.3.4. TigF ten foundation bolts finger tight and build dam
around fotundation. Pour grout under bedplate making sure the
areas under pump and motor feet are filled solid. AIvow grout
to harden 48 hours before fully tightening foundation bolts.
2.3.5. Tighten pump and motor hold-down bolts before
connecting the piping to pump.
3. Suction Piping:
3.1. Low static suction lift and short, direct, suction piping is
desired. For suction lift over 10 feet and liquid temperatures over
120 F, consult pump performance curve for Net Positive Suction
Head Required.
3.2. Suction pipe must be at least as large as the suction connection
of the pump. Smaller size will degrade performance.
3.3. If larger pipe is required, an eccentric pipe reducer (with
straight side up) must be installed at the pump.
3.4. Installation with pump below source of supply:
3.4.1. Instail full flow isolation valve in piping for inspection
and maintenance.
CAUTION
Do not use suction isolation valve to throttle pump.
3.5. Installation with pump above source of supply:
3.5.1. Avoid air pockets. No part of piping should be higher
than pump suction connection. Slope piping upward from
liquid source.
3.5.2. All jonts must be airtight.
3.5.3. Foot valve to be used only if necessary for priming, or
to hold prime on intermittent service.
3.5.4. Suction strainer open area must be at least triple the pipe
area.
3.6. Size of inlet from liquid source, and minimum submergence
over inlet, must be sufficient to prevent air entering pump through
vortexing. See Fis. 2-5
3.7. Use 3-4 wraps of Teflon tape to seal threaded connections.
Figure 2 H Figure 3
a H 5
vnv1 2 34 6S 1 )O 1*3l4161
=GPM x 0.321 GPM x 04085
a D2a
Figure 4
23
Figure 5
4. Discharge Piping:
4.1. Arrangement must include a check valve located between a gate
valve and the pump. The gate valve is for regulation of capacity, or
for inspection of the pump or check valve.
4.2. If an increaser is required, place between check valve and
pump.
4.3. Use 3-4 wraps of Teflon tape to seal threaded connections.
5. Mlotor-To-Pump Shaft Alignment:
5.1. Close-Coupled Units:
5.1.1. No field alignment necessary.
5.2. Frame-Mounted Units:
51.1. Even though the pump-motor unit may have a factorv
alignment, this could be disturbed in transit and must be
checked prior to running. See Fig. 6.
Parallel
Angular
Figure 6
5.2.2. Tighten all hold-down bolts before checking
the alignment.
5.2.3. If re-alignment is necessary, always move the motor.
Shim as required.
5.2.4. Parallel misalignment - shafts with axis parallel but not
concentric. Place dial indicator on one hub and rotate this hub
360 degrees while takmg readings on the outside diameter of
the other hub. Parallel alignment occurs when Total Indicator
Reading is .005", or less.
5.2.5. Angular misalignment - shafts with axis concentric but
not parallel. Place dial indicator on one hub and rotate this hub
360 degrees while taking readings on the face of the other hub.
Angular alignment is achieved when Total Indicator Reading
is .005", or less.
5.2.6. Final alignment is achieved when parallel and angular
requirements are satisfied with motor hold-down bolts tight.
CAUTION
Always recheck both alignments after making any adjustment.
6.1. Correct rotation is right-hand (clockwise when viewed from
the motor end). Switch power on and off quickly. Observe shaft
rotation. To change rotation:
6.1.1. Single-phase motor: Non-reversible.
6.1.2. Three-phase motor: Interchange any two power supply
leads.
7. Operation:
7.1. Before starting, pump must be primed (free of air and suction
pipe full of liquid) and discharge valve partially open.
CAUTION
Pumped liquid provides lubrication. If pump is run dry,rotating
parts will seize and mechanical seal will be damaged. Do not
operate at or near zero flow. Energy imparted to the liquid is
converted into heat. Liquid may flash to vapor. Rotating parts
require liquid to prevent scoring or seizing.
I
I
I
I
I
I
I
I
7.2. Mal e complete check after unit is run under operating
conditions and temperature has stabilized. Check for expansion
of pipmg. On frame-mounted units coupling alignment may have
changed due to the temperature differential between pump and
motor. Recheck alignment.
8. Maintenance:
8.1. Close-Coupled Unit. Ball bearings are located in and are part of
the motor. They are permanently lubricated. No greasing required.
8.2. Frame-Nounted Units:
8.2. . Bearing frame should be regreased every 2,000 hours or
3 month interval, whichever occurs first. Use a #2 sodium or
lithium based grease. Fill until grease comes out of relief
timngs, or lip seals, then wipe off excess.
82.:. Follow motor and coupling manufacturers' lubrication
instrictions.
8.2.3. Alignment must be rechecked after any maintenance
work involving any disturbance of the unit.
Complete disassembly of the unit will be described. Proceed only as
far as required to perform the maintenance work needed.
9.1. Turn off power.
9.2. Drain system. Flush if necessary.
9.3. Clost-coupled Units: Remove motor hold-down bolts.
Frame-\launted Units: Remove coupling, spacer, coupling guard
and frame hold-down bolts.
9.4. Disasemblv o Liquid End:
9.4.1. Remove casing bolts (370).
9.4.2. Remove back pull-out assembly from casing (100).
9.4.3. Remove impeller locknut (304).
CAUTION
Do not in;en screwdriver between impeller vanes to prevent
rotation of close-coupled units. Remove cap at opposite end
of motor. A screwdriver slot or a pair of flats will be exposed. Using
them will prevent impeller damage.
9.4.4. Remove impeller (101) by turning counter-clockwise
when looking at the front of the pump. Protect hand with rag
or glcve.
CAUTION
Failure to remove the impeller in a counter-clockwise direction may
damage threading on the impeller, shaft or both.
9.4.5. With two pry bars 180 degrees apart and inserted
between the seal housing (184) and the motor adapter (108),
careft dly separate the two parts. The mechanical seal rotary
unit (383) should come off the shaft with the seal housing.'
9.4.6. Push out the mechanical seal stationary seat from the
motor side of the seal housing.
9.5. Disassembly of Bearing Frame:
9.5.1. Remove bearing cover (109).
9.5.2. Remove shaft assembly from frame (228).
9.5.3. Remove lip seals (138 & 139) from bearing frame and
bearing cover if worn and are being replaced.
9.5.5. Use bearing puller or arbor press to remove ball bearings
(112 & 168).
10. Reassembly:
10.1. All parts should be cleaned before assembly.
10.2. Refer to parts list to identify required replacement items.
Specify pump index or catalog number when ordering parts.
10.3. Reassembly is the reverse of disassembly.
10.4. Obsen-e the following when reassembling the beanng frame:
10.4.1. Replace lip seals if worn or damaged.
10.4.2. Replace hall bearings if loose, rough or noisy
when rotated.
10.4.3. Check shaft for runout. Maximum permissible is
.002% T.R.
10.5. Observe the following when reassembling the liquid-end:
10.5.1. All mechanical seal components must be in good
condition or leakage may result. Replacement of complete seal
assembly, whenever seal has been removed, is good standard
practice.
It is permissible to use a light lubricant, such as glycerin, to
facilitate assembly. Do not contaminate the mechanical seal
races with lubricant.
10.5.2. Inspect casing 0-ring (513) and replace if damaged.
This 0-ring may be lubncated with petroleum jelly to ease
assembiv.
10.5.3. Inspect guidevane O-nng (349) and replace if worn.
CAUTION
Do not lubricate guidevane O-ring (349). Insure it is not
pinched by the impeller on reassembly.
10.6. Check reassembled unit for biding. Correct as required.
10.7. Tighten casing bolts in a star pattern to prevent 0-ring
binding.
MOTOR NOT RUNNING
(See causes I thru b)
LITTLE OR NO LIQUID DELIVERED:
(See causes 7 thru 17)
POWER CONSUMPTION TOO HIGH:
(See causes 4, 17, 18, 19, 22)
EXCESSIVE NOISE AND VIBRATION:
(See causes 4, 6, 9, 13, 15, 16, 18, 20, 21, 22)
PROBABLE CAUSE:
1. Tripped thermal protector
2. Open circuit breaker
3. Blown fuse
4. Rotating parts binding
5. Motor wired improperly
6. Defective motor
7. Not primed
8. Discharge plugged or valve closed
9. Incorrect rotation
10. Foot valve too small, suction not submerged, inlet
screen plugged.
It. Low voltage
12. Phase loss (3-phase only)
13. Air or gasses in liquid
14. System head too high
15. NPSHA too low:
Suction lift too high or suction losses excessive.
Check vith vacuum gauge.
16. Impeller worn or plugged
17. Incorrect impeller diameter
18. Head too low causing excessive flow rate
19. Viscosity or specific gravity too high
20. Worn bearings
21. Pump or piping loose
22. Pump and motor misaligned
I
RGEL Pumps
NPE Standara Repair Parts List
item Description Materials of
No. Construction
100 Casing
101 Impeller
10A Motor adapter with foot AISfr316L
108B Motor adapter less foot Stainless Steel
108C Mor- adapter with foot and Flush
10D Moto- adapter less foot with Flush
123 Deflector BUNA-N
184A Seal housing sid.
1848 Seal housing with seal flush
| Motor support 300 S.S.
Rubber channel Rubber
304 Impeller locknut AISI 316 S.S.
347 Guidevane AISI 316L S.S.
Viton Standard
349 Seal-Ring, guidevane EPR
BUNA
370 Socket head screw, casing AISI 410 5.5.
371 Bolts, motor Steel/plated
383 Mechanical seal
408 Drain and vent plug, casing AISI 316 S.S.
Viton, standard
I 412B 0-Ring, drain plugs EPR
BUNA
Viton, standard
513 0-Ring, casing EPR
BUNA
.<48
NOTE: OPTIONAL SEAL FLUSH COMPONENTS
NOTE: Close coupled units supplied with '/ HP
1750 RPM, '/, - 3 HP Explosion Proof or 5 HP motors,
utilize motor adapter less foot and a footed motor.
NOTE: Frame mounted units (NPE-F) utilize the XS Power frame and
motor adapter less foot. For repair parts for the power frame refer to
the XS-Power frame repair parts page in the parts section of your
catalog. To order the power frame complete order item 14L61
Goulds Pumps and the ITT Engineered Blocks Symbol are registered
trademarks and tradenames of ITT Industries.
Visit us at wv.gculds.com
c) 2002 Goulds Pump;
Printed ins USA
4
Item 383 Mechanical Seal (%/" seal)
Rotary Stationary Elastomers | Metal Parts Part No.
CarbonEPR
OK
Viton 1OKSS
Sil-Carbide EPR 31655 1OK1
Sil-Carbide Viton 1OK62
GOULDS PUMPS LIMITED WARRANTY
This warranty app ies to all water systems pumps manufactured by Goulds Pumps.
Any part or parts found to be defective within the warranry period shall be replaced at no charge to the dealer during the warranty period. The warranty period shall exist
for a period of twc Ise (12) months from date of installation or eighteen (18) months from date of manufacture, whichever period is shorter,
A dealer who believes that a warranty claim exists must contact the authorized Goulds Pumps distributor from whom the pump was purchased and furnish complete details
regarding the Jaim. The distributor is authorized to adiusc any warrants claims utilizing the Goulds Pumps Customer Service Department.
The warranty excludcs:
(a) Labsor, transportation and related costs incurred by the dealer;
(h) ReinitalRation costs of repaired equipment;
(c) Reinstallanon cos ts of replacement equipment;
(d) Consequential damages of any kind; and,
te) Reimbursement for loss caused by interruption of service.
For purposes of this warranty, the following terms have these definitions:
(1) "Distrbutor means any individual, partnership, corporation, association, or other legal relationship that stands between Goulds Pumps and the dealer in purchases,
cosignments or ontracts for sale of the subiect pumps.
(2) 'Dealer mlea* s any individual, partnership, corporation, association, or other legal relationship which engages in the business of selling or leasing pumps to customers.
(3) "Customer" mieans any entity who buys or leases the subject pumps from a dealer. The "customer" tay mean an individual. partnership, corporation, limited liability
company, assoLiaion or other legal entity which may engage in any rvpe of business.
THIS WARRANTY EXTENDS TO THE DEALER ONLY.
Goulds Pumps
<& ITT Industries
I
Section 7
Low Pressure Diaphragm Gauge
Series 1490, Grade A (2-1-2%)
- 2%~ and 3 ~ dial size sures This gauge uses a very sensitive
* Glass- Filled polysulfore case diaphragm capsule to measure low
material, won't rust or dent pressure and vacuum. The gauge is
specifically designed for use whenever
* Beryllium copper diaphragm the pressure medium is a gas that is not
- Brass socket corrosive to beryllium copper, brass,
- Wetted materials of beryllium polysulfone and RTV silicone. The
copper, brass, polysulfone and polysufone case is suitable for intermitRTV si'icone tent or continuous service on natural gas
provided a .013~ throttle plug is installed
- Exclusive autoclavable feature in the socket. Typical applications are,
but not limited to, vacuum pumps, gas
The Ashcroft* Type 1490 low pres- leak detectors, air compressors, air fil- I
sure diaphragm gauge is designed to ters, gas burners, gas measurement,
measure pressure from 10 in.H20 to vacuum ovens, suction regulators and 15 psi, both positive and negative pres- respirators.
SELE Il ABL
DIAL SIZE TYPE WETTED MATERIAL CONN. SIZE A TYPE CONNECTION L CATION RANGES OPTIONAL FEATURES
Code Das. Code Detrpoia Code Description Cod Dnescrisuion Code Descnrplio Code Gescoiption Code 8.criplion
25 2/ 9 LowPressure A BerylliumCloper 21 'eNPT L ower 101W 0:0 10H;0 XAK Autoclavable
35 3,'' Diathragm Gauge Brass Socket 32 ", NPT 3 Center Back XAN 1% Opt Accuracy
Polysulfone HD f c Tuing Hose Bar' i T Top See Chart for XDA Dial Marking
RTV Silicone tE - D Tubing Hose Bart2' D 3 0 Clock Entire List Of XNH Stain. Steel Tag
,F 4 D Tubing Hose Bartn E 9 0 Clock Ranges XNN Paper Tag
HG uOD0 olyubeHse~aa XTU" Throtte Plug
HH 10-32-2B Female Thread"' XUC" J-clamp
XZY FlutlerGuard'
i1 A throttle p ug must be insialed in the socket whenever the gauge is used for nterrnitent or continuous service on natural gas
(2) u-cump iu-nisled when ose barb or iemale thread is soecified. EXAMPLES: 25 1490A 021 10 VW XNN
(3) Tlrotle piLg nol available with hose barn or termae thread connectioris
Pressr. Fgpre inteval.s MInor Grdasatio Vauum Figure larval. MIOrGraduation Pressur. F i, beral Min Gradwatlon
0/10m inH 01 15.0 0 5 02 0/60cn M, 1D
/15ir HiO 1 5 02 30/0inH,0 5 05 0c2.5kPa 0.5 005
0/0in HO 1 5 0.5 600m 10 1 0/4kPa 1 0.1
0/ in H,O 10 1 1o / in H 0 10 t 1 0/10 kPa 1 1
0/1 min Ho t 10 1 200/ in HO 20 2 0/16 kPa | 2 0.2
0/160 in. HO 20 2 15o on i 5 0.2 0/25 kPa 5 05
/200n H,0 20 2 30/0 orm 5 0 5 0/4 kPa 10 1
0/300n 4,0 50 5 60/ 1orin O 1 0/100 kna t 101
0,10to 1 01 ow in ' '0 1 1 Vacuum
0/15out- in 5 02 Compound 2SOkPa 05 1 005
0/30ozin' 5 05 -30,30AHO 10 1 -l/OuPa 1 01
0/6Otin to 1 -30/30ioz.,in 10 i 1 O0Pa 1 0 1
0/100Oozh to I 1 -10/10 iHO 2 i 12 1i0 Pa 2 02
0/160 nzmr 20 2 Duat Scale 25/0 kPa 5 50/250 oz/in 7 50 5 I Grdatins 40/lipsa 10 1
0/3 psi 0 5 005 100/O ka 1 0
0/5 psi 1 0 1 Range lner Scale Outer Scale Compound
0/10 usi 1 0 2 oer Scale ou rer scale Figure j Minor Figure nor -10/60 c H 0 10 1
1,/15 psi | i. Intervals Grind. Intervas Grad. --10/N80cm H:0 10 1
o/9czn' I /15inH 1 02 5 02 -20/4acm Ho 0 10 1 10I2 ,,, -. 10IH tO
0/20ozm 0/35 nHO 5 10 5 5 -10/100cmH0 20 2
0/350cm 0/60.HO 5 . 05 10 1 -10n20 cmH 20 2
O60 minm 0/'C00mHOI1 10 1 o1 1
hN., uvaiton ibo n Cur- .
Select: 25 1490 A 02L XXX 10-1,0
1, Dial size - 2/ (25). 3W (35)
2. Case type
3. Wetted material
4 Connection size -% (02). A (01)
5 Connectio1 location - Lower (L), Rack (B)
6. Optional features - see page 108
7 Standard pressure range - 10 1,0
Reference Bulletin DG-2 Consult factory for guidance in product selection , sr|NMM
Phone (203) 378-8281, FAX (203) 385-0499 or
visit our web site at www.ashcroft.com
4iASHCROFT Commercial Hydraulic GaugesType 3005, 30D5P,
Grade B (3-2-3%)
- 304 sta/nless steel case liquidtilled, dy or field-fillable (Type 3005)
-ABS case, liquid-filled, dry or fieldtillable iType 3005P)
* Patented PowerFlex"' movement
with polyester segment
- Pressure ranges from vacuum to
15,000 psi and compound
- Two-year warranty on liquid-filled
gauges
- True Zero "' indication, a unique
safety f ature
Type no.: 3005, 3005P
Size: 63mm (2W~)
Case:
3005: 304 stainless steel, dry or
liquid filled
3005P: Black ABS, dry or liquid filled
Fill fluid: Glycerin
Ring: None
Window: Polycarbonate with 0-ring seal
Black figures on white
background, aluminum
Pointer: Black, aluminum
Bourdon tube: "C" shaped bronze (Vac600 psi and compound)
Helical bronze (1000-M psi)
Helical stainless steel
(10,000-15,000 psi)
Movement: Patented PowerF/ex
Ashcroft* Type 3005 gauges provide superior performance in applications where vibration, pulsation,
mechanical shock and pressure
spikes are common factors thus
making them the ideal choice for
hydraulic applications.
These gauges offer a feature only
available in Ashcroft gauges-the
patented PowerFex movement with
polyester segment. This unique
movement was designed to provide
superior performance in stressful
applications, resulting in extended
gauge life.
True Zero indication, a standard
feature on these gauges, reduces
the potential risk of installing a damaged gauge on your equipment.
Socket:
with polyester segment
Brass, 0-ring case seal
Restrictor: 0.013~ orifice brass throttle
plug in all ranges except
vacuum and 15 psi
Connection:
3005:
3005P:
A NPT lower and back
X NPT lower only
Ranges: Vac.-15,000 psi and compound, equivalent metric
scales available.
Accuracy: ASME B40.1, Grade 8 3-2-3%
Operating
temperature:
FlutterGuardM is available for dry
gauges to eliminate pointer flutter and
extend gauge life.
Factory variation code in
Case:
Mounting
hardware:
Socket:
Sealed case, fillable (XLJ)
U-clamp (UC), Front Flange
(FF), Retrofit Flange (RF),
back connection only
Throttle plugs, 0.007~, 0,013~
0.020, 0.063orifices
Connections: JIS, DIN, SAE and others
available on application
Others:
Dry gauge: -40F to 1500F
Glycerin filled: 20"E to 150cF
Customized dials
Nonstandard ranges
FlutterGuard (SF)
Special calibration on
application
Oxygen clean, ASME B40.1
Level IV cleanliness- dry
gauges only (68)
TOORDER | -TYPE3005AUGE:
Select
1. Dial Size: 2/2. Patented PowerFex" Movement
3. Case Type Number: 3005
4 Socket Material: Brass
5. Liquid Filied Case:
6. Connectio Size/Location: 'A NPT lower
7. Range: 10)0 psi
Referenco Bulletin CG-35
MADE IN U.S A.
63 W 3005
-j Consult factory for guidance in product selection
Phone (859) 986-9333, FAX 1-800-282-3732 or
visit our web site at www.ashcroft.com
3005 shown
Dial:
L 1000#
IluMumx
F _ _ 85
IGAUGE SP:CIFICATIONS I
* r w~ 7-?W -- M,
* -~~y~J)& tsQ ~i
As.. B .. ' C . mnta)
-3*T 'T 14. 11l i asV- 76.2 mm' 2.55 mm 17.38 mm 6.35 mm specified
I 27 mm 133.35 mm 23 81 mm *1 11 mm specified
.. MENSioNS = i l 58 'nmj
* Catalog Numbers MODEL 33 MODEL 53
Stem Lencith Dial Size Dial SizeInches Millimeters 3- 76.2 mm 5' 127 mm
2 2 63.5 33025 -iao2
5 '524 33060 53060
9 228.6 33090 53090
12 304.8 33120 53120
15 :810 33150 53150
- 33180 53180
24 609.6 33240 53240
Standard Ranges - Dual Scale (Oth'erRanges A vallable)
Fahrenheit (outer scale) 44k* O ' Celsius (inners'iale)
Range Fig. Interval Div. . tleAW Range Fig. Interval Div.
-100 to 150* 20* 2" - sK&70 to 70* -10*- 1*
- 40 to 120* 20* 2" -40 to 50* 10 1*
25 to 1250 10* 1* - 5 to 50' 5' 1 2*
0 to 140* 100 1* -20 to 60* 5* ' 2*
0 to 200* 20* 2" -15 to 900 10* 1*
0 to 250* 20* 20 -20 to 120' 10' 1*
20 !o 240' 20- 2- - 5 to 115- 10- 1 .
3- 9 20" 2" 10 to 10 '' *
50 to 400' 50 * 5* 10 to 2000 20* 2'
s* * *0
100* 10*
.1000* 0 0* 100
No recommended !or cortnuous use over 800*F or 425*C.
65 to400*
100 to 540=
500
50'
5*'
0
Or com0eie t51 of availadail ranges. including celsius only and Fahrenheit only.
This high quality, low cost thermometer is
designed for applications where a weather
resistant, tamper proof case is required.
Specifications
CASE. Corrosion resistant 304 stainless
steel.
PAL. Anti .arallax heavy gauge aluminum
.vitt :Iac marko;fgs or vrte mane tn.sr
Dished form with Celsius on lower plane
and Fahrenheit on raised plane. Also
available with single scale and custom
cesign.
CRYSTA L: Heavy duty clear glass. gasketed and sealed to insure weather tight
irtegnty.
--EME7;C SEAL. Per ASME 840.3.
STEM/CONNECTION: Type 304 stainless
steel, 1/4 inch (6.35 millimeter) diameter
with standard lengths to 24 inches (609
m:illmeters). 1/2 inch NPT connection is
standard.
BI-METAL ELEMENT: An extremely
responsive temperature sensing helix
which has been carefully sized and tested.
heat treated and aged to relieve inherent
stresses and insure continued accuracy
ACCURACY: One percent full scale
(Grade A per ASME B40.3).
CPTIONS: Special ranges, dial layouts. ac
curacies. stems, connections and windows
How to Order
The catalog number shown indicates
only the dial size, angle form and stem
length. For complete, descriptive part
number please use the tables listed on
page 13.
See General Specifications on this
page for construction features and for
available accessories and Options.
instruments, inc.
1 750*
.rksdale Temperature Switches
MLII Description:
Single Setting
Local Mount
Watertight and Dusttightindoor and Outdoor (NEMA 4)
Oiltight and Ousttightndoor (NEMA '3)
Enclosed Terminal Strip
tamoerproof Exterial Adjustment
THERMOWELL MODELS ONLY
(See -WS Designation)
In"11 "5 0rIy'll
- ~~sCreW cucu
NRhutMOWEL LJI
nc" cAi
07Ars-cc xrme*1 iL
uperating Characteristics - Ordering Data * 1J34IJ
Meda Temperature Limits Adlustable Range DIfferental Catalog NumbersIProof (Approx Liquid
Calibrated Dial
Adjustment
Caibrated
2' Subdvision
125' Span -- a-i
"F
Low High
-100 +250
Cg * F
Low. High
-C-
"F
-CV -5 is-0 -250 11m rifa 2? 5 * 2 *20 13
304 stainlessBrass Sensor Steel Senso
Cj "1 e fleem :eeleeansor
e~nsea~nei -ew.n.waa..
304 Stainless
Steel Sensor
W/316SS
Thermo welt
ML1H-H201S.WS
-100 -400 ?73 %205 1*65 *290 j44l4-0+40I 2Oj22 301t97 1 to 63U 33 MMH53 LHH5S
Calibrated 5 -100 -'250 -' 2211 -50 '200 j -45bFtIZ, 3 II o3-5 bgSubdivi.sion 250, soan -100 +400 Q31-M2S I~0 35
Calbrated 5'
Subdivision 150 Span
0
0
0
+500
+500
+500
18 260
ofv 6
71i 26i0
.150 +300
+230 +380
+300 +450
t46__C_ 3
3
3
to 6
toG6
to 5
ML1H.H451S ML1H.14451S.WS
ML1 H.H452S ML1H.H452S-WS
MLIH-H453S MLIH.H453S-WS
103 MLIH-H451 1
;so 3 MLlH.H4452
Calibrated 10 0 +500 181 26 0 150 +450 +66 2321 3o6 11.6t3.3 M -.11H4545 MLtH.H454S.WS
Subdivsion 300" A CM I 1n
is' cnditions and media used could atfect differential. Acprox. Shipping Weight 1% lb.
Detail Data Optional Modifications Electrical Characteristics: All models incorporate Underwriters' Laboratories, Inc. MANUAL RESET AVAILABLE. Consult factory for price and delivery.lsted single pole double throw snap-action switching elements. Electrical rating Green epoxy paint available on exterior surfaces of completely assembled andcontinuous inductive) 10 amps 125 or 250 volts AC. 3 amps 480 volts AC. t.e -s .oAutomatically reset ty snap-action of switch. For more details and other switch tested housed models. classes, see page 1.. Alt models on this page have the followlng UL. and C.S.A. listings:
''itricz Connection: Screw terminals on covered terminal strip through %" npt Juit connection. Underwriters' Laboratories. Inc.
erminals Identlfled: , (Common). N. C. (Normally Closed). N.O. (Normally Open) remperature indicating and regulaling equ pment. File No. E56247. Guide N
Wire Coding: Purple (Common), Blue (Normally Closed). Red (Normally Open) XAPX.
Adjustment Instructkns: Turn adjustment knob clockwise to increase actuation Canadian Standards Associaion listed for temperature indicating and regulaing
Pont (sw tc setting : equipment. File No LR34555. Guide NO. 400-E-0. Class 4813.
ML1H
sAOusolw
scaene
0FIOLMAL
Ao JUst Ati
OiFriuulaL
-50 +75 1 to 3
BULLETIN NO. A-27
OPERATING INSTRUCTIONS and PARTS LIST
Magnehelic* Differential Pressure Gage
SPECIFICATIONS
Dimensions: 4-3/4" dia. X 2-3/16" deep.
Weight: 1 lb. 2 oz.
Finish: Baked dark gray enamel.
Connections: 1/8 NP.T high and low pressure
taps, duplicated, one pair side and one
pair back.
op Use Accuracy: Plus or minus 2% of full scale, at
70"F (Model 2000-0, 3%; 2000-00, 4%).
.20 Pressure Rating: 15 PSI.
104 Znl % Ambient Temperature Range: 20* to 140'F
+i/ Standard gage accessories include two 1/8"
N.PT. plugs for duplicate pressure taps,
MAGNEC. &C two 1/8" pipe thread to rubber tubing
adapters, and three flush mounting
adapters with. screws.
Caution: For use with air or compatible gases
only.
For repeated over-ranging or high cycle rates,
contact factory.
Hydrogen Gas Precautionary Note: The rectangular rare earth magnet used in the
standard gage may not be suitable for
use with hydrogen gas since a toxic and
expiosive gas may form. For hydrogen
service, consult the factory for an alternate gage construction.
h1 FOLE IN PANEL
FOR LOW PRESS.
BACK CONNECTION
WHEN SURFACE MOUNTED.
(3) 1." DIA. HOLES -
IN PANEL FOR SURFACE
MOUNTING ON 4/."DIA. BOLT
CIRCLE. PARAGRAPH 3.
DW YER INSTRUMENTS, INC. Telephone 2191879-8000
P .Fax 2191872-9057P.O. BOX 373 -MICHIGAN CITY, INDIANA 46360, U.S.A. Lic-by-fax: 8881891-4963
www.dwyer-inst.com
e-mail: infoOdwyer-inst.com
MAGNEHELIC* INSTALLATION
1. Select a location free from excessive vibration
and where the ambient temperature will not
exceed 140*F Also, avoid direct sunlight which
accelerates discoloration of the clear plastic
cover. Sensing lines may be run any necessary
distance. Long tubing lengths will not affect accuracy but will increase response time slightly. Do
not restrict lines. If pulsating pressures or vibration cause excessive pointer oscillation, consult
the factory for ways to provide additional damping.
2. All standard Magnehelic gages are calibrated
witn the diaphragm vertical and should be used
in :hat position for maximum accuracy. If gages
are to be used in other than vertical position, this
should be specified on the order. Many higher
rarge gages will perform within tolerance in other
positions with only rezeroing. Low range Model
2000-00 and metric equivalents must be used in
the vertical position only.
3. Surface Mounting
5. To zero the gage after
installation
Set the indicating pointer exactly on the zero
mark, using the external zero adjust screw on the
cover at the bottom. Note that the zero check or
adjustment can only be made with the high and
low pressure taps both open to atmosphere.
Operation
Positive Pressure: Connect tubing from source
of pressure to either of the two high pressure
ports. Plug the port not used. Vent one or both
low pressure ports to atmosphere.
Negative Pressure: Connect tubing from source
of vacuum or negative pressure to either of the
two low pressure ports. Plug the port not used.
Vent one or both high pressure ports to atmosphere.
Differential Pressure: Connect tubing from the
greater of two pressure sources to either high
pressure port and the lower to either low pressure port. Plug both unused ports.
When one side of gage is vented in a dirty, dusty
atmosphere, we suggest an A-331 Filter Vent
Plug be installed in the open port to keep inside
of gage clean.
a. For portable use or temporary installation, use
1/8" pipe thread to rubber tubing adapter and
connect to source of pressure with rubber or
Tygon tubing.
b. For permanent installation, 1/4" 0. D., or larger,
copper or aluminum tubing is recommended. See
accessory bulletin S-101 for fittings.
Locate mounting holes, 1200 apart on a 4-1/8"
dia. circle. Use No. 6-32 machine screws of
appropriate length.
4. Flush Mounting
foeo 'w
cttoCqfq,
Provide a 4 Y" dia. opening in panel. Insert gage
and secure in place with No. 6-32 machine
screws of appropriate length, with adaptors, Part
No. 360c, firmly secured in place. To mount gage
on I X"-2" pipe, order optional A-610 pipe mounting kit.
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Page 21
MAINTENANCE
Maintenance: No lubrication or periodic servicing is required. Keep case exterior and cover
clean. Occasionally disconnect pressure lines to
vent both sides of gage to atmosphere and rezero. Optional vent valves, (bulletin S-101),
should be used in permanent installations.
Calibration Check: Select a second gage or
manometer of known accuracy and in an appropriate range. Using short lengths of rubber or
vinyl tubing, connect the high pressure side of the
Magnehelic gage and the test gage to two legs of
a tee. Very slowly apply pressure through the
third leg. Allow a few seconds for pressure to
eqLalize, fluid to drain, etc., and compare readings. If accuracy unacceptable, gage may be
returned to factory for recalibration. To calibrate in
the field, use the following procedure.
Calibration:
1. With gage case, P/N 1, held firmly, loosen
bezel, P/N 4 by turning counterclockwise. To
2void damage, a canvas strap wrench or similar tool should be used.
2. Lift out plastic cover and "0" ring.
3. Remove scale screws and scale assembly. Be
careful not to damage pointer.
4. The calibration is changed by moving the
clamp, P/N. 70-b. Loosen the clamp screw(s)
and move slightly toward the helix if gage is
reading high, and away if reading low. Tighten
clamp screw and install scale assembly
5. Place cover and O-ring in position Make sure
tie hex shaft on inside of cover is properly
engaged in zero adjust screw, P/N 230-b.
6. Secure cover in place by screwing bezel down
snug. Note that the area under the cover is
pressurized in operation and therefore gage
will leak if not properly tightened.
7. Zero gage and compare to test instrument.
Make further adjustments as necessary
BULLETIN NO. A-27
Page 3
Caution: If bezel binds when installing, lubricate
threads sparingly with light oil or molybdenum
disulphide compound.
Warning: Attempted field repair may void your
warranty, Recalibration or repair by the user is not
recommended. For best results, return gage to
the factory. Ship prepaid to:
Dwyer Instruments, Inc.
Attn. Repair Dept.
55 Ward St.
Wakarusa, IN 46573
Trouble Shooting Tips:
- Gage won't indicate or is sluggish.
1. Duplicate pressure port not plugged.
2. Diaphragm ruptured due to overpressure.
3. Fittings or sensing lines blocked, pinched, or
leaking.
4. Cover loose or "0" ring damaged, missing.
5. Pressure sensors, (static tips, Pitot tube, etc.)
improperly located.
6. Ambient temperature too low. For operation
below 20*F order gage with low temperature,
(LT) option.
- Pointer stuck-gage can't be zeroed.
1. Scale touching pointer.
2. Spring/magnet assembly shifted and touching
helix.
3. Metallic particles clinging to magnet and interfering with helix movement.
4. Cover zero adjust shaft broken or not properly
engaged in P/N 230-b adjusting screw.
We generally recommend that gages needing
repair be returned to the factory. Parts used in
various sub-assemblies vary from one range of
gage to another, and use of incorrect components may cause improper operation or failure.
Gages repaired at the factory are carefully calibrated and tested to assure "like-new" operation.
After receipt and inspection, we will be happy to
quote repair costs before proceeding.
Consult factory for assistance on unusual applications or conditions.
Use with air or compatible gases only.
DWYER INSTRUMENTS, INC.
P.O. BOX 373 - MICHIGAN CITY, INDIANA 46360, U.S.A.
Telephone 219189-8000
Fax 219872-9057
Lit-by-lax: 8881891-4963
www.dwyer-inst.com
e-mail: infoedwyer-inst.com
IBULLETIN NO. A-27
Page 4
b_ CT: :aY: e 0
Magnehelic* Gage
EXPLODED VIEW
Series 2000
A
1. Case
2. Cover with zero adjust assy.
3. "0" ring seal
4. Bezel
5. Diaphragm sealing plate
6. Retaining ring
70. Range Spring assembly
a. Clamp set screw
b. Clamp
c. Mounting screws (2 req'd)
d. Clamping shoe (2 req'd)
e. Clamp plate screw
f. Spacer (2 req'd)
g. Clamp plate
14. Range Spring with magnet
150. Wishbone Assembly -consists of:
a. Front jewel
b. Locking nut
c. Wishbone
d. Pointer
e. Mounting screws (2 req'd)
f. Helix assembly (not shown)
g. Pivots (2 req'd) (not shown)
h. Rear jewel (not shown)
230. Zero adjust assembly-consists of:
a. Foot saews with washers (2 req'd)
b. Adjust screw
c. Foot
d. Finger
260. Scale Assembly-consists ofa. Mounting screws (2 req'd)
b. Bumper pointer stop (2 req'd)
c. Scale
330. Diaphragm Assembly -consists of:
(Arbor press needed to install)
a. linkage assy., complete
b. Front plate
c. Diaphragm
d. Rear plate (not shown)
e. Plate washer (not shown)
360. Mounting Hardware Kit
a. Adapter -pipe plug 1/8" NPT to
rubber tubing - (2 req'd)
b. Pipe plug 1/8" NPT-(2 req'd)
c. Mounting lug (3 req'd)
d. Long screw (3 req'd)
e. Short screw (3 req'd)
Ordering Instructions:
When corresponding with the factory regarding Magnehelic* gage problems, refer to the
call-out numbers in this view. Be sure to include model number, pressure range, and any
special options. Field repair is not recommended; contact the factory for repair service
information.
@Copyright 1993 Dwyer Instruments, Inc.
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1
Printed in U.S.A. 6/93 12-440212-00
BULLETIN F-50
SERIES DS-0 FLOW SENSORS
Installation and Operating Instuctions,
Flow Calculations
INSPECTION
Inspect the sensor upon receipt of shipment to be certair
it is as ordered and not damaged. If damaged, contact
camer.
INSTALLAT1ON
General - The sensing ports of the flow sensor must be
correctly positioned for measurement accuracy. The instrument connections on the sensor indicate correct positionng. The sde connection is for total or high pressure and
should be pointed dpstream. The top connection is for
static or iow pressure.
Location - The sensor should be installed in the flowing line
with as much straight run of pipe upstream as possible.
This wil provide a flow profile as ideal as possible. A rule of
thumb is to allow 10-15 pipe diameters upstream and 5
down. The table below lists recommended up and down
piping:
PRESSURE AND TEMPERATURE
Maximum 200 psag at 200'F
UPSTREAM AND DOWNSTREAM DIMENSIONS IN TERMS OF INTERNAL DIAMETER OF PIPE
SEE NOTE #1
MINIMUM DIAMETER OF STRAIGHT PIPE
UPSTREAM CONOITION UPSTREAM
DOWNSTREAM
IN-PLANE OUT OF PLANE
One Elbow c ee 9
Two 90'Ber'ds n Sme 0a ne 8 12 5
Two 90 BerdIs in C fferent Plane -824 5
Reducers or Expanders 8 8 5
All Valves
See~jt2 i2.4 245'See Note 2
Note *1 ValLes shown are recomnrded spacti.in terms of nternal diameter for norm industral metenng requrements
For aborlotry or high accuracy work. add 25% to values
*Note *2: Includes gate. globe, plug and other throtting valves that are only Dantlay opened, if valve is to be fully open.
use values for ppe size change. CONTROL VALVES SHOULD BE LOCATED AFTER THE FLOW SENSOR.
POSITION
Be certain ther is sufficient clearance between the mounting position and other pipes, wails, structuires, etc, so that
the sensor can be inserted through the munting unit once
the mouning unit has been installed onto the pipe.
Flow Sensors should be positioned to keep air out of the
instrumert connecting lines on liquid flows and condensate
out of the Ivies on gas flows. The easiest way to assure this
is to install the sensor into the pipe so that ai will bleed
into, or condensate will drain back to. the pipe.
For air or gas flow:
tueamt or P"
For iiqd or steam flow:
Quaant o nip.
cAndensat drains
bak to We
At pi.M bac
to pipe.
INSTALLATION
1. When using an A-160 thred-o-let, weld it to the pipe
wall. If replacing a DS-200 unit. an A-161 bushing
{/' '/,) will be needed.
2. Dill through the center of the thred-o-let into the pice.
with a drill that is slightly larger than the flow sensor
diameter.
3. Install the packing gland using proper pipe Sealat. If the
packing gland is disassembled. note that the tapered
end of the ferrule goes into the fitting body.
-4. Insert The sensor until it bottoms against the opposte
wall of the pipe, then withdraw 1/16' to allow for thermat
expansion.
5. lighten packing gland nut finger tight. Then tighten tne
nut with a wrench an additional 1'J turns. Be sure to
hold the sensor'body with a second wrench To prevent
tne sensor from turning.
INSTRUMENT CONNECTION
Connect the side pressure tap to the high pressure port of
the Magnehelic (air only) or Capsuhelic gage or transmitting
.nstrument and the top connection to the low pressure port.
See the connection schematics below.
Bleed air from nstrument piping on liquid flows. Drain any
cordensate from the nstrument piping on air and gas flows.
Open valves to instrument to place flow meter into service.
For permanent installations, a 3-valve manifold is recommended to allow the gage to be zero checked without
interrupting the flow The Dwyer A-471 Portable Test Kt
includes such a device.
r L H
DRAIN DRAIN
L H
-I
L
FLOW I
SENSOR
PIPE
AIR OR GAS FLOW
Page 2
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WATER FLOW
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Page 3
SERIES DS-300 FLOW SENSORS
FLOW CALCULATIONS AND CHARTS
'445
-4 1
7- --
Using the appropriate differential pressure equation from page 4. caiculate the differential pressure generated by the sensor
under normal operating conditions of the system. Check the chart below to determine if this value is within the recormended operating range for the sensor. Note that the data n this cnart ;s umited to starcarc conditions of air at 60 F 15.6 C
and 14 7 psia static iine pressure or water at 70 F (21 C), To determine recommended operating ranges for other gases. hquds and, c r ocerating conditions. consult the factory.
Note the column on the right side of the chart which defines velocity
resuit :n damage to the flow senscr caused by excess vibration.
ranges to avoid Continuous operation within these can
Pipe Size
(Schedu le 40)
I7 ,M
Flow
Coefficient
K"
0 52
0.53
O 58
3 64 I
162
0 67
0 71
067
0 70
Operating Ranges
Air @0 F & 14.7 psia
(D/P Inches W.C.)
1 1C to 186
1 15 -o 157
0 38 to l'
175 to'5
S72 to 53
339o 35
0.28 to 34
2 64: *i I
C 0-o (0
: -o 2
Operating Ranges
Water 0 70T
(D/P Inches W.C3
4 K4J 'a 675
4 18 to 568
1 36 to i -'
2 70 oa ,
'2 lo 193
'3 to 127
- 'G 1t23
2.31 u o
03:oF 37
,i )- -1
Velocity Ranges
Not Recommended
(Feet per Second)
'46 to 220
113 to 170
96 to '-4
71 to '08
56 to 35
42 :c 64
28 'o 43
15 to 23
951o 15
6to 10
The following niformation contains tables and equations cr
determining the differential pressure developed by the DS
300 Flow Sensor for various flow rates of water. steam. air
cr other gases in different pipe sizes.
This information can be used to prepare conversion crarts
:o translate the differential pressure readings being sersed
into the equivalent fow rate. Where direct readout of flow s
required, use this nformation to calculate the full flow -:iferential pressure in order to specify the exact range or
Dwyer Magneheic or Capsuhelic gage required Spec:ai
-arges and calculations are available for these gages at
minimal extra cost. See bulletins A-30 and F-41 for acdit:onal information or Magnenetic and Capsuhelic gages
and OS-300 flow sensors.
or acditcral useful nformation on mak~ng flow calcuauors.
the following reference is recommended: Crane Valve Co.
echnical Paper No. 410 'Flow of Fluids Through Valves,
Fittings and P pe." ;t .s available from Crane Valve Co.. 'Cd
N. Chicago St. Joliet. IL 60431. Phone 915/727-2600. Price
nciucirg shipping s S20.00
4i m y i
Page 4
FLOW EQUATIONS DIFFERENTIAL PRESSURE EQUATIONS
1. Any Liquid
O (GPM) - 5.668 x K x D2 x .. P/Sf
2. Steam or Any Gas
Q (lb.Hr) = 359.1 x K x D2 x p x -AP
3 Any Gas
O (SCFM) - 128.8 x K x D2 x P'x AP
(T+460) x Ss
1. Any Liquid
.P (in. WC) 2. Steam or Any Gas
zZP (in. WC) =
3. Any Gas
ZP (in. WC) 02 x Sf
K2 x D4 x 32.14
02
K2 x D4 x p x 128,900
02 x S x (T+460)
K2 x 04 x P x 16,590
TECHNICAL NOTATIONS
The following notations apply:
P = Differential pressure expressed in inches of water column.
o = Flow expressed in GPM. SCFM or PPH as shown in equation.
K - Flow coefficient - See Values Tabulated on page 3.
D = Inside diameter of line size expressed in inches. For square
& rectangular ducts use D- 4 x Height x Width
I:r
P = Static Line pressure (psia)
T = Temperature in degrees Fahrenheit (plus 460=0 Rankint
p = Density of medium in pounds per cubic foot
St 3 Sp Gr at flowing conditions
Ss = Sp Gr at 600 F
SCFM TO ACFM EQUATION
SCFM ACFM x
ACFM - SCFM x
POUNDS PER STD.
CUBIC FOOT
(14.7 A PSIG
14,7/( 14,7
14.7 + PSIG
( 6520' F
460.520 'F
POUNDS PER ACT. x i 1-4. \)
CUBIC FOOT 14.7 - PSIG /
POUNDS PER ACT. - POUNDS PER STO. x { 14.7 - PSIG \
CUBIC FOOT CUBIC FOOT 14.7 9
( 4604-F)\
0 520 !F
{ 520 \
460 + -Ff
1 CUBIC FOOT OF AIR - 0.076 POUNDS PER CUBIC FOOT AT 60'F AND 14.7 PSIA
'(520 --- 460 60 ) Std. Temp. Rankine
N6vyq - .e Intnt96s oc. Prrteo Un S A &6
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FR 72-440451 01
BULLETIN NO. E-57
SET POIT
ADJSTMENT SCREW
SERIES 1950
INTEGRAL EXPLOSION-PROOF PRESSURE SWITCHES
Specifications - Installation and Operating Instructions
UL and CSA Listed, FM Approved For
CL IGR CD - CL a GR. E.FG - CL III
Model 1950 Switches: Operating ranges and dead bands.
Operng
Range
w.C.
007to 015
O Sto 0.5
04 to 16
.4 10 55
30 110
4 0' 20.0
Operatng Range
5 10e 2 Of
1l5bo 30
3 0 'o 15 0
4 0 to 25 0
150 050
Dead Sand
At In. At MIa
set Po"n Sol PoirtAliw.- M6sa
004 005
0 10 0 15
0.15 020
0 3 0,442 04g
04 05
1. 0.8-
Arosknaf Owd Bond
"-M see Poin 'I set Point
0.3 PSI 013 PSI
1 0 PSI 1 0 PSt
0 9 PSI 0.9 PSI
07PSI 0 7PSI
1 0 PSI 5 Psi
VENT DRAIN PLUG
The New Model 1950 Expiosion-Prool Switen combines the
best 'eatures of the popular Dwyer Senes 1900 Pressure
Switch with a compact explosion-proof housmngThe Lnis U.L and CSA uisted, FMapprovedforuse inClass
I. Groups C & D, Class 11, Groups E. F & G and Class Il
atmospheres It s also totalIy ra.n-tight for outdoor installations. Twelve models allow set-points from .03 1o 20 inches
W.C. and from .5 to 50 PSI.
Easy access to the SPOT switch for eloctncal hook-up is
provided by removing the top plate of the theae-p lu inum housing. ACustment to re set point of the switch can
be made without Disassembly of the housing. The units very
Compact, about half the weigni and bulk of equivalent convetoral explosion-proof switches.
CAUT1ON: For use only woth ar or compatbie gases. Use ol
the Model 1950 swrcr wth explosive rnedia connected to
the Low D'essu'e port (includiug differential presure app caticns an uch media) is not ecommended. Switch contact
arcing can cause an exrlosion inside the switch housing
wh<: wile contained. may render the switch nopelanve. if
switc is coing used to sense a single posdive pressue relative 1o atmsoshere. run a I-e 'rom te low pressure port to a
ron hazardcus area free of combustlble gases. This may
increase response tme on -0 and -00 -rodelis
EEN
P. 80BX237 aIH
PHYSICAL DATA
romperusr Limn: 40' to '40'F -40' to 6ret 1950P-8. 15 25 s 50
0* to 14 (- 7 '* to 6c. 1950-C -30'to l30*F -34.4*l1 54 A'C)
Rated Pressue: 1950 - 45IN WC. 1950P - 35 PSI. 1I-50lt - M PS
Maxilmus surge pressure: 1950 - 10 PSI 195 - 50 PSI. 1950P-50 tr
- 90 PSI
Pressure Conuecion.: Ie NFt
EIeCrIIC Rang I5 an '25 250 400 . 61 A C Rnfin '(Ig H P
zt !25 voli. '/4 HP a 250 volt. 60 HA. ArWiling coectcne. 3 smav tvoc comtmot. "rI Oe and nWm Close
Condui conncteons: 11 Pr
Set point adustnent: Screw tne n top or re9. F alsae
Housig: Aroemd caurienrm
Oiphragm: Mded %orsacone ruber 02 modl. S*I on von
Calibrstion Spring: Stanless Stee
InstaIiallon: Moto im anidrati n in 4r1cal Silion
Wesght: 3, ibs 02 meei. 4 its 7 or
Response Time: Because of restrictive effect of flame
arrestors. sw:tch response time may be as much as
10-15 seconds where applied pressures are near set
point.
NOTE: The last number-letter combination in the
1950 model number identifies the switch electrical
ratIng (number) and diaphragm material (letter). The
2F combination is standard as described in the
physical data above. in the case of special models
a number I rating is the same as 2: a number 3 or 4
rating is 10A 125. 250. 480 VAC - K HP 125 VAC. %
HP 250 VAC; and a number 5 or 6 rating is 1A 125
VAC A letter 8 indicates a Buna-N diaphragm. N
Neoprene. S; Silicone, and V. Viton.
48 60 .
ELECTRICAL
CONCrT
CONNECTn"
10 order
Mode
Number
1950o0
'9500
1 50.1
1950-10
1950-20
1950P- 15
i9P-25
950P-50
SERIES 1950
INTEGRAL EXPLOSION-PROOF PRESSURE SWITCHES
Installation and Operating Instructions
ULLEriN E-57
ft" 2
17B64DIA MTG HOLES f21
RANGE ADJUSTMLN T
SCREW
L NPT
ELEC.
CONCUIT
CONNLC fO1N
NPT HIGH
PRESSURE PORT -
Us NPT LOW
PRESSURE
PORT
ENr DRAIN Pt.
For c1pil amnion 0"
dasmg 2-mmal em o u
cstmeseaone -wi
UG -
1950 SWITCH OUTLINE DIMENSIONS
INSTALLAT1ON
I Nk6eM A ktion free from .-. ces v*iatarM eA rro'ww tar1phem.
where temp.rAture. wdl be wthM the Limits nted under Physai
74te 1A -on 1. Swit mVlV ta. araA*MI the
lnt of, rxlaa elal. .46 Page ja f-r twordle t"e .4 ImaardixAU
. iei ont .*aad ulmAw es 010 the .phragm ca a eci plani an
with .watch loitering and Dwyer nameplato in u, upright poation.
:Sn e wrtr, ar ptaon ,eutjw tal may not rmet propely tam.ie
they are mKa4npted with the Jiaphragm vertil. Specal ue atin he fue
naihed !or f iwr than rtwal motinng arravngements if requirie.
L Conna i swi to nre prt.ur, vvuum .'r dflerential preetvir.
Mrt. tubing with hI (H.D. A reonded. but asy (tai which will
wi retriet - he air f'ow can he twenI iine. the two i NIPT
irnalt, ivea plA a l noed t
A Diffetb.A prmeore - oan.t ipe. .r tubes W enq douree .4
gr.ater pranur to high prsur- part marked 1I10J l 'RlS.
at fimm -ure lower proure to low prutre pirt marked
LOW PRSS-.
H Pri.aur anly (abe ainupherc .onttet 'utbe fpma vurnt
4 prw to ing pregre part. Tho Jr. presre jart a left
.qxn to snmotipre. See tICMrON in pagr 1.
C. Viseum pnr abo amaherc pro-urol -menect tube frem
mur .4 cmuim to kw pre-oUre pot. The high prmitur pol
:0 l.-1 .. on to .Ma$nphe
. , mal6. elercal tflfaecanr. ,rm'n. the thre es heal crw frmer,
the roier arzi after hi.mening the .uth artr ,cre. stwtrg the cer
iaido. F3ectri cenecionA to the tflurd rngk pefit. doule bruw
-ap aritch are preidad by nies .4 'enw (ormaa mateal 'cmmn.' 'nonm open.' and 'nreni ewd The normally pn" cuitacte
ci. And dt noti iAred 6 . tmi'ci -jn wshen peautr ticenes
hayond hbe wepbnt. Switch Ihalr for itarlard m.l.ts *hould not
opyN '90 7 Dwye retAnin c
a. . -a
.- i the tanah ut' p -c i cr ting U 4 U ap nau
Swek, Mpbhtlm ft ercae wit an neitae in ambient temperratur.
aTo i Ilt fa.r s riing mat. W1,.*,rr a App"Ca inew .wo
ni'.n of thew. 6d,rs Qwt .uer mtin l itdoIrihLe to irut the ,wntd,..I
ADJUSTMENT
rItbanv the ptpmnt
ARum.'. the pliar tp AM turn the iloudi Adutmvierm & ,r a
the top 4 the houwng cokwtine to ruise the poAc pfe r arl
amuntwcckwnte in mr the dpuot After calibration. repiar
the plaic cap and relek the ApOnL
H. The r re-redd prokure kr caliiraug or chteling calibratta
a ue Ar n y with the e te utasg kink, a3l " Arti
n ;.a.ea J and (te entire aembl diering tmnmufh flow restn.. *Au one xad to the proewure swnch. another to a manaeter
of knon acennary and appnWale mrni aad appt p rvfne
hiog the third ulv. Mak- flnod appriadh to e ntptnt 'ry
4kney N." that amnoetr aid prsu switch ai hmv differ
nt moponie atm-e due 1o different Internal volumes. length of
tubing, flhid drainage, etc. He certain the .w*ih is de.ied in the
p.iaatso it will asnme in u it. anth dhphnin in a ertial plane
and .arb ltterinm and Dwrr namplate in an upright pndwta
I' ., oruighy eria .ppicbna check the etpir.t .aautn& alM if
neve ary, r,'st it "a turd A Wep A
MAINTENANCE
The nysng ptI if tha,. awtche rneed no mainteance er hubricatAn
fle ooly .uttnent ja that tf the iotpiit. reabldj be taken to kire:
It' swtdh rnnaly rican. Prlcticaly the wit drini plug shokl trnrAtml then reurned to ha crignal pition. 'Th will diaknlr de.pte
whidi aid .ecamulate in applicationR when thar sn e onea
to.n withm the v.ritdk
Pnn o nUSA A9
moSmagw
FmS-4MD D
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PRESSURE PORT
PNEUMATIC IN-LINE FLGWME TERS
With Multi-Pressure Flow Scales
Shown smaller
than actual size
1148
Basic Unit
For a complete selection of pressure
gages and pressure transducers, see
the Pressure, Strain and Force
Section of this Volume
INLET PRESSURE
Meter Inlet Pressure (psig)
1- Easily Installs
In Any Position
Rugged Anodized
Aluminum Body
- Multi-Pressure Flow
Scale, 40 to 130 psig
- Accuracy ±2% FS
to Repeatability ±1%
t- Easy to Use With
Direct Reading,
Multi-Pressure
Flow Scales
L)
LLa
C-)
'C,
Meter Inlet Pressure (psig)
OMEGA multi-pressure pneumatic
flowmeters feature a rugged
anodized Eluminum body design
and easy installation. For air/
compressEd gas applications, these
flowmeters include ranges from
5-5.0 SCFM to 50-1000 SCFM, at
operating pressures up to 1000
psig. Their multi-pressure scales
(from 40-1:30 psig) mean accurate
flow measurements can be made
without the need for conversion
calculation for pressure variations.
SPECIFICATIONS
Accuracy: :2*o FS
Repeatability: ±1*0 FS
Materials: Anodized aluminum body
,ih ichrorr ate sealed anodized
2umnumn co~ne and piston.
u316S spring, and polyphenylene
sulfideceraric magnet
Temperature Rating:
116 C (240') Max
Pressure Rating: 1000 psig Maximum
MOST POPULAR MODELS HIGHLIGH TED!
To Order (specify Model Number)
Flow Range Dimensions
Model No. Price (SCFM) Port Size O.D. Length Weight
FL2904A $148 0.5-5 48 x 43 mm 122 mm 114 g I
FL2909A 148 1-10 ' (1.9" x 1.7) 4.8" (4 oz,
FL2918A 148 2-20
FL2924A 148 3-30
FL6920A 154 2-25 61 x 53 mm 168 mm 318 g
FL6960A 154 5-50 1" (2.4 x 2.1") 6.6" (11.2 ozi
FL6911A 154 10-100
FL6915A 154 15-150
FL7918A 222 4-25 74 x 64 mm 183 mm 680 g
FL7950A 222 5-50 " (2.9 x 2.5") 7.2" (24 OZ'
FL7990A 222 10-100
FL7915A 222 15-150
FL7922A 222 20-250
FL8925A 571 20-200
FL8945A 571 40-400 119x104mm 310 mm 31 kg
FL8960A 571 60-600 1"1 (4.7 x 4.1") 12.2" (6.75 it,
FL8980A 571 80-800
FL8910A 571 100-1000
Ordering Examples: FL7990A, multi-pressure in-line flowmeter, TO-too SCFM,
FL-8980A, multi-pressure in-line flowmeter, 50-800 sctm, S571.
S222;
B-50
o 40
30
20
10l
INDICATOR
CENTER
LINE
)0
C-'
wur-~......
-
S 8 8
Multiple-Stage Switches: Vertical MountInnovative
Solutions
ILS-700 Series Custom Switches with a Maximum Length of 4'
The ILS-700 series level switches
are individually designed from over 360
component parts to create a custom
switch available in lengths of from one
foot (304mm: to four feet (1.2m).
' To specify, review the choices in
mounting types, stem and mounting,
float sizes, switching points and electrical specifications that appear on these
two pages.
Product Configuration Choices:
Mounting:
Materials:
Float Size:
Length:
Up to 12 choices; see table A-1 below.
Up to 14 choices; see tables A-2 and A-3 below.
See table B, opposite page.
1 foot (304mm) minimum: 4 feet (1.2m) maximum
s. Component Choices:
1. MOUNTING TYPES
2. MOUNTING AND STEM MATERIALS
1W
3. FLOAT MATERIALS
4. SWITCH TYPES
-. 1. 20 watt SPST
2 50 wAatt SPST
3. 100 watt SPST
4. 20 watt SPDT
1. Buna-N
2. Polypropylene
3. Kynar
4. PVC
S. OP V
--. 6.316SS
8. 321/347 SS
9. HC-276
10. IN 600
11. CuNi
12. T 6 Al 4V
13. Ti Grp 2
1. Brass
2. Polypropylene
3. Kynar
4. PVC
-*. 6. 316 SS
8. 321/347
9. HC-276
10. IN 600
11. CuNi
12. Ti 6 Al 4V
1. 1/8" NPT
2. 1/4" NPT
3. 3/8" NPT
4. 3/8 - 24
5. 1/2" NPT
6. 3/4" NPT
7. 1.00" NPT
8. 1.250" NPT
9 1 Cfn- PT
10. 2.000" NPT
12. 3.625" dia. flange
13. Ti Grp 2
14. Teflon-PFA
[I ICt
'I
ILS-700 Series
Switches
IVr
B. Series 700 Components and Operating Parameters (Selected Options Shown)
Mounting Types Materials Operating Parameters Float Dimensions
Stem & Mount Float Specfic Gravty
1,2,.3,4, 5,
6, 7, 8.9,10,11,12.
1,2.3.5,
6,7,8.9,10.11.
316 SS,
Brass,
or PVC.
H20: to +180F0.65 (+82'C)Buna-N minimum OIL' -40'F to +220'F
(-40'C to +104'C)
PVC
cm.1, 2, 3 4, 5..
6, 7. 8, 9. 10, 11, 12.
316SS 316SS
0.7
minimum
0.9
minimum
0.7
minimum
To +140'
(+60' C)
-40'F to +300'F
(-40'C to +149'C)
Part 11010 BN
160 psig Diameter1.00'
(11 Bar) (25mm)Height 1.00'
(25mm)
50 psig
(3 Bar)
750 psig
(52 Bar)
. Part 1 1117 BN
Diameter 1.1875'
(30mm)
Height: 1.75'
(M4mm)
Part #1010 PV
Diameter 1.00'
(25mm)Height 1.00
(25mm)
Part 1 1012
Diameter: 1.00' (25mm)
Height 1.00' (25mm)
Part I 2000
Spherical Diameter 2.00' (50mm)
C. Switching Points and Electrical Specifications
Each switching point requires one
Joat. For special applications, a single
float can be used to activate two switch
zoints, though these points must have a
minimum separation of 1/8" (3mm). The
maximum number of actuation levels
depends on the winng type selected.
Ratings: 20VA 0 120 VAC SPST
SOVA 0 240 VAC SPST
Connection: 24' Free Leacs
#22 AWG. PVC jacketed.
Mounting Attitude: Vertical +/- 30'
Group 2 SPST
lndependent Circuit.
-
SPST Switch Wire Code
Common Wire
L1
L2
L3
1 to 5 switch points I to 3 switch points
Only two actuation points are shown above.
Group 1 Group 2
Black None
NO/NC SW Corn I NO/NC
Red Red/Red
Yellow Yellow/Yellow
Blue Blue/Blue
L4 Brown
L5 Orange
D. Actuation Level Dimensions
A = Minimum distance from actuation -point to bosom of mounting.
B = Minimum distance between
actuation levels.
C = Minimum distance from end of
unit to lowest actuation point.
D = Minimum distance between
actuation points when a single float
is used to actuate two switches.
Notes: LO
1. A, B, and C dimensions are
based on a specific gravity of 1.0.
2. One float for two actuation levels
can be used only with a 20VA switch,
3. Actuation levels are calibrated on
descending fluid level, with water as
the fluid, unless otherwise specified.
4. Standard tolerance on actuation
levels is +/- 1/8" (3mm).
Dimensions
Float Type A a C 0
Buna-N 1' 1-1/8' 1-1/2' 2-3/16' 1/8'
(25mm) (27mm) (37mm) (53mm) (3mm)
m Ii mm PVC 1' 1-1/8' 1-1/2'
(25mm) (27mm) (37mm)
SS 1. 15/16' 1-3/4'
(25mm) (23mm) (42mm)
SS 1-3/4' 1-1/8' 1-1/2'
(25mm) (27mm) (37mm)
2-3/16' 1/8'
(53mm) (3mm)
2-7/16' 1/8'
(59mm) (3mm)
2-3/16' 1/8'
(53mm) (3mm)
Inn0aVuIve
Sl u Hans
a Tempershre PrssINur
II
0 rt:
0
> at0 D X
ILI
Ur 0s t<,jI. wIc
C) Orv)L iCzIz
I (L Q
S( L i
'0Ark
Combustible Gas
Diffusion Transmitter
Operator's Manual
PROPRIETARY STATEMENT
Thermo GasTech owns proprietary rights in the information disclosed within. By receiving this
document, the recipient agrees that neither this document nor the information disclosed within
nor any part shall be reproduced or transferred to other documents or used or disclosed to others
for manufacturing or for any other purpose except as specifically authorized in writing by
Thermo GasTech.
COPYRIGHT STATEMENT
Information contained in this document is protected by copyright. No part of this document may
be photocopied, reproduced, or translated to another program or system without prior written
authorization from Thermo GasTech., C 2000. Thermo GasTech.
TRADEMARK STATEMENT
Protected through use andor registration in the United States and many foreign countries are the
trademarks and service marks of Thermo GasTech. The use of the & symbol indicates
registration in the United States only; registrations may not have been issued at present in other
countries. All other product names and logos are trademarks of their respective owners.
GASTECH® is a trademark of Thermo GasTech and is registered with the U.S. Patent and
Trademark Office.
DISCLAIMER
Under no circumstances will Thermo GasTech be liable for any claims, losses, or damages
resulting from or arising out of the repair or modification of the equipment by a party other than
Thermo GasTech or its authorized service representatives, or by operation or use of the
equipment other than in accordance with the printed instructions provided by Thermo GasTech
or if the equipment has been improperly maintained or subject to neglect or accident. Any of the
foregoing will void the warranty.
EXPORT STATEMENT
Export of the information and products in this manual from the U.S.A., or re-export from
another country, may require written authorization from the U.S. Department of Commerce.
Printed in the U.S.A.
REVISIONS TO MANUAL
All information contained in this manual is believed to be true and correct at the time of
printing. However, as part of its continuing efforts to improve its products and their
documentation, Thermo GasTech reserves the right to make changes at any time without
notice. Any revised copies of this manual can be obtained by writing Thermo GasTech.
71-0024-01 - REV DJi
WARNING
NOTATION CONVENTIONS
Notices are used in this operator's manual to alert you to hazardous conditions to person or instrument and to notify you of additional information.
This operator's manual uses the following notices.
WARNING
Notifies you of potential danger that can result in personal injury
or death.
CAUTION
Notifies you of potential damage to equipment.
71-0024-01 - REV D
THIS INSTRUMENT IS DESIGNED TO DETECT ONE OR MORE OF
THE FOLLOWING:
FLAMMABLE VAPORS, OXYGEN CONTENT, AND/OR TOXIC GAS AND TO
GIVE WARNING BEFORE THEY REACH HARMFUL CONDITIONS. IN ORDER
TO ENSURE THAT IT WILL WARN OF DANGEROUS CONCENTRATIONS, IT
IS ESSENTIAL THAT THE INSTRUCTIONS IN THIS MANUAL, PARTICULARLY
THOSE CONCERNING START UP, OPERATION, CALIBRATION, AND
MAINTENANCE, BE READ, UNDERSTOOD, AND FOLLOWED.
v 'V
4 NOTE
Notifies you of additional or critical information.
iii
SERVICE POLICY
Thermo GasTech maintains an instrument service facility at the factory as
well as authorized service facilities around the world. Should your instrument
require service, you may contact us toll free at 1-877-GASTECH (427-8324)
for US only or 1-510-745-8700, or visit our website www.gastech.com for
authorized service locations.
For warranty or non-warranty repairs, call us to complete a Return Material
Authorization (RMA) form, obtain billing and shipping information and tell
us the nature of the problem. For non-warranty repairs, you will need to
provide a purchase order number. If you need to set a limit to the repairs costs,
state a "Not to Exceed" figure. If you need a quotation before you can
authorized the repair costs, so state, but understand this will incur additional
costs and may delay processing of the repair.
You may send the unit, prepaid, to: Thermo GasTech, 8407 Central Ave.,
Newark, CA 94560-3431, Attn.: Service Department. Enclose the copy of
the RMA (Return Material Authorization) that was previously faxed to you.
Pack the instrument and all its accessories (preferably in its original packing)
and any special instructions.
Repairs are warranted for 90 days from the date of shipment. Sensors have
individual warranties.
4O NOTE
Thermo GasTech assumes no liability for work performed by
unauthorized service facilities.
71-0024-01 - REV Div
WARRANTY STATEMENT
Thermo GasTech (the "Company") warrants that the Products will operate
substantially in conformance with the Company's published specifications,
when subjected to normal. proper. and intended usage by properly trained
personnel, for a period of one (1) year after shipment to Customer (the
"Warranty Period"). The Company agrees during the Warranty Period,
provided it is promptly notified in writing upon the discovery of any defect and
further provided that all costs of returning the defective Products to the
Company are prepaid by Customer, to repair or replace, at the Company's
option, defective products so as to cause the same to operate in substantial
conformance with said specifications. Replacement parts may be new or
refurbished. at the election of the Company. All replaced parts shall become
the property of the Company.
Lamps, pump diaphragms, valves, batteries, fuses. bulbs, and other expendable
items are expressly excluded from the warranty.
The Company's sole liability with respect to equipment, materials, parts, or
software furnished to the Company by third party suppliers shall be limited to
the assignment by the Company to Customer of any such third-party supplier's
warranty, to the extent the same is assignable. In no event shall the Company
have any obligation to make repairs, replacements, or corrections required, in
whole or in part. as the result of( i) normal wear and tear, (ii) accident, disaster,
or event of force majeure, (iii) misuse, fault, or negligence of or by Customer,
(iv) use of the Products in a manner for which they were not designed, (v)
causes external to the Products such as, but not limited to, power failure or
electrical power surges, or (vi) use of the Products in combination with
equipment or software not supplied by the Company.
ANY INSTALLATION, MAINTENANCE, REPAIR, SERVICE,
RELOCATION, OR ALTERATION TO OR OF, OR OTHER TAMPERING
WITH, THE PRODUCTS PERFORMED BY ANY PERSON OR ENTITY
OTHER THAN THE COMPANY WITHOUT THE COMPANY'S PRIOR
WRITTEN APPROVAL. OR ANY USE OF REPLACEMENT PARTS NOT
SUPPLIED BY THE COMPANY SHALL IMMEDIATELY VOID AND
CANCEL ALL WARRANTIES WITH RESPECT TO THE AFFECTED
PRODUCTS.
THE OBLIGATION TO REPAIR OR REPLACE A DEFECTIVE
PRODUCT SHALL BE THE SOLE REMEDY OF CUSTOMER IN THE
EVENT OF A DEFECTIVE PRODUCT. EXCEPT AS EXPRESSLY
PROVIDED IN THIS SECTION, THE COMPANY DISCLAIMS ALL
WARRANTIES, WHETHER EXPRESS OR IMPLIED, ORAL OR
WRITTEN. WITH RESPECT TO THE PRODUCTS, INCLUDING
WITHOUT LIMITATION ALL IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.
THE COMPANY DOES NOT WARRANT THAT THE PRODUCTS ARE
ERROR-FREE OR WILL ACCOMPLISH ANY PARTICULAR RESULT.
71-0024-01 - REV D v
vi 71-0024-01 - REV D
TABLE OF CONTENTS
Chapter 1
Introduction
Overview .............................................. 1
Description ............................................ 1
Specifications .......................................... 4
Chapter 2
Installation
M ounting the Transm itter ................................... 5
Wiring theTransmitter ..... .............................. 6
Starting Up ........................................... 7
Chapter 3
Calibration
Calibration Kit .......................................... 9
Calibration ......................................... 9
Chapter 4
Maintenance
Preventive Maintenance .................................. 15
Troubleshooting ........................................ 16
Replacing the Detector .................................... 18
Replacing the Amplifier .................................. 19
Appendix A
P arts L ist .............................................. 2 1
71-0024-01 - REV D Vii
Combustible Gas Transmitter Operator's Manual
viii 71-0024-01 - REV D
r INTRODUCTION
Overview
These instructions describe the components of the combustible gas diffusion
transmitter and how to install, start up, maintain, and calibrate the
transmitter.
Description
A combustible gas diffusion transmitter includes an amplifier, junction box,
and detector assembly.
Detector
The complete combustible gas detector assembly includes the sensing
elements, flame arrestor, detector housing, and detector leads.
Detector Leads
Mounting Threads
Detector Housing
Flame Arrestor
Figure 1-1 Combustible Gas Detector
SENSING ELEMENTS
Two sensing elements are mounted within the detector assembly. Through a
series of thermal and electronic reactions, the sensing elements produce the
reading on the display screen.
71-0024-01 - REV D 1
Combustible Gas Transmitter Operator's Manual
'7 CAUTION
Catalyst poisons such as chlorine and silicone compounds can
desensitize the detector sensing elements. A "poisoned" detector is
less responsive or unresponsive to combustible gases. Avoid
exposing the detector to catalyst poisons or samples that contain
vapor from catalyst poisons.
FLAME ARRESTOR
The porous flame arrestor allows the sample to diffuse into the detector and
contact the sensing elements, and contains any sparks or flames within the
detector.
DETECTOR HOUSING
The sensing elements and flame arrestor are mounted within the detector
housing. Mounting threads (1/2 in. NPT) at the top of the detector housing
allow the detector assembly to be screwed into the junction box.
DETECTOR LEADS
Three color-coded leads extend from the top of the detector assembly and
connect to the amplifier.
Amplifier
The amplifier transmits the output of the detector to the controller. The
amplifier includes the terminal blocks, zero and span potentiometers, volt
adjust potentiometer, and test jacks. (refer to Figure 1-2).
Volt Potentiometer
Test Jack
(-) Blue
Zero Potentiometer
1 o
10a r , fl ( y Terminal Block
Terminal Strip
Figure 1-2 Combustible Gas Diffusion Transmitter Component
Location
2 71-0024-01 - REV D
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Introduction
AMPLIFIER TERMINAL BLOCKS
The 6-position detector terminal block connects the amplifier to the
combustible gas detector. The 3-position terminal block connects the
amplifier to the controller.
ZERO POTENTIOMETER
The zero potentiometer adjusts the gas-free output of the amplifier during
start-up and calibration procedures.
SPAN POTENTIOMETER
The span potentiometer adjusts the response output of the amplifier during
the calibration procedure.
VOLT POTENTIOMETER
The volt potentiometer is used for setting the voltage to the detector, and is
factory set. The user should not adjust this component.
TEST JACKS
The color-coded test jacks allow you to measure the test signal
(100 to 500 mV proportional to the 4 to 20 mA analog output signal) of the
amplifier during start-up and calibration procedures. The white jack is
positive (+) and the blue jack is negative (-).
Junction Box
The explosion-proof junction box protects the amplifier and connections
from the monitoring environment for remote installation. The junction box
has two 3/4 in. NPT conduit hubs, one for the detector and one for wiring to
the controller. The amplifier is mounted within the junction box.
The threaded cover on the front of the junction box allows access to the
interior.
71-0024-01 - REV D 3
Combustible Gas Transmitter Operator's Manual
Specifications
Table 1-1 Specification
Detection Range 0 to l00%LEL
Low Alarm Setting* 10%LEL
High Alarm Setting* 50%LEL
Amplifier Output 4 to 20 mA analog signal (to controller)
100 to 500 mV analog test signal (at test jacks)
Response Time 90% in less than 30 seconds
Accuracy 5% of detection range
Repeatability 2% of detection range
Temperature Range -4*F (-20 0 C) to 140*F (60 0C)
Area Classification Class I, Division 1, Groups B, C, and D
Standard Accessory Operator's Manual
Optional Accessory Calibration kit
* Indicates standard specifications. Can be changed by the user.
71-0024-01 - REV D4
r INSTALLATION
This section describes mounting and wiring procedures for the combustible
gas transmitter assembly.
Mounting the Transmitter
CAUTION
Mount the junction box with the detector pointing down.
1. Select a mounting area that is representative of the monitoring
environment. Choose an area where the transmitter is not likely to be
accidentally bumped or disturbed. For lighter gases (hydrogen and
methane for example), mount the junction box near the ceiling. For
heavier gases, or for vapors from liquids, mount the junction box near
the floor.
2. Secure the junction box to a vertical surface using 1/4 in. bolts or
screws through the mounting lugs.
4.0'[10.1cm] ,
49'12.4cm] 314" NPT
4.4" {1l 2cm]
5.1[ [13 0cm]
1. T- [4 3cm]
27 DIA--/ 1
2 Places
SIDE VIEW TOP VIEW
Figure 2-1 Outline and Mounting Dimensions
71-0024-01 - REV D 5
Combustible Gas Transmitter Operator's Manual
Wiring the Transmitter
7W WARNING
Make sure all power to the controller is turned off during all wiring
procedures.
Use a three-conductor, shielded cable, or run the wiring within metal
conduit to reduce Radio Frequency Interference (RFI) and
Electromagnetic Interference (EMI).
Use 18 AWG wire or larger. The one-way wire resistance must not
exceed 25 ohms.
1. Remove the junction box cover.
2. If you are using shielded cable, screw a cable bushing into the top
conduit hub of the junction box, then route the cable through the
bushing. Do not ground the shield at the junction box. If you are using
metal conduit, screw the end of the conduit directly into the top
conduit hub of the junction box.
3. Connect the detector leads to the detector terminal block of the
amplifier as follows:
Green to terminal 4 (R)
Red to terminal 5 (A)
White to terminal 6 (C).
The position for each color is marked on the amplifier PC board.
4. Guide a three-conductor, shielded cable or three wires in conduit
through the top conduit hub of the junction box, and connect the wires
to the controller connection block.of the amplifier and to the
controller terminal strip as shown in the following table.
Table 2-1 Combustible Transmitter Wiring
Connections
Amplifier Terminal Controller Terminal
Block Strip
I(+) +
2(-)
3 (FB) FB
5. Ground the shielded cable or metal conduit by connecting it to the
SHIELD terminal at the controller.
6 71-0024-01 - REV D
Installation
i CAUTION
Always ground the cable shield at the controller and never at the
transmitter.
Start Up
Complete the following procedure to place the controller and the
combustible gas transmitter into normal operation. If more than one
combustible gas transmitter is in use, perform the start-up procedure for each
transmitter.
Preparing for Start Up
1. Complete the mounting and wiring procedures described earlier.
2. Connect incoming power to the controller as described in the
Installation chapter of the controller manual.
NOTE
Allow the detector to warm-up for a minimum of 15 minutes after
power is introduced to the controller.
Setting the Channel Parameters at the Controller
When you install the combustible transmitter, set the parameters for that
channel at the controller. For instructions on setting the channel parameters
at the controller, see the Start Up section of the controller manual. Standard
settings for the combustible gas transmitters are listed in Table 2-2.
Table 2-2 Standard Ranges and Alarm Setpoints for
Combustible Gas Transmitter
71-0024-01 - REV D 7
Combustible Gas Transmitter Operator's Manual
Setting the Zero Reading
WARNING
In locations classified as hazardous (National Electric Code Article
500) and with power on, the area must be certified gas-free before you
open the junction box cover. Consult prevailing national, local, and
corporate requirements for certification. If you suspect the presence of
combustible gas during the start-up procedure, use the calibration kit
described in the calibration chapter and the zero-emission are cylinder
to introduce fresh air to the detector and confirm an accurate zero
setting.
1. Confirm that the controller is on.
2. Remove the junction box cover.
NOTE
Some controllers have a feature that enables you to disable the alarm
LEDs, buzzer, and relays during the calibration procedures, response
tests, and so on. Refer to the controller manual for information. Make
sure you re-enable full alarm functionality after the calibration
procedure is complete.
3. If the alarms have not been disabled, disconnect one of the wires from
the terminal block, and confirm that the controller FAULT or FAIL
light is on and the buzzer sounds. Reconnect the wire to the terminal
block.
4. Plug the positive multimeter lead into the white(+) test jack; plug the
negative lead into the blue (-) test jack.
5. Confirm 100 mV on the multimeter. If necessary, adjust the zero
potentiometer until the reading is 100 mV.
7 CAUTION
Do not adjust the span potentiometer during the start-up
procedure.
6. Remove the multimeter leads from the test jacks, and secure the
junction box cover to the junction box.
The combustible gas transmitter is now in operation.
8 71-0024-01 - REV D
r CALIBRATION
Calibration Kit
This section describes the optional calibration kits used for calibrating the
combustible gas transmitters. See the Parts List of this insert for ordering
information.
WARNING
Accurate calibration of the transmitter is essential to ensure
accurate readings of combustible gas concentration. Incorrect
calibration can impair the performance of the transmitter and
place you in unnecessary danger if hazardous conditions exist.
The combustible gas calibration kits include the following components:
- Storage Case: Safely houses the components of the calibration kit while
you are not using them.
- Gas Cylinder: Contains known concentrations of gas. Gas cylinders are
available from Thermo GasTech for a variety of combustible gases.
- Regulator: Controls the gas flow to the detector.
- Test Cup: The test cup slides over the detector. Two screws secure the
cup to the detector.
- Tubing: The 5/16 inch vinyl tubing directs the gas from the regulator to
the test cup.
Calibration
This section describes how to prepare the Calibration kit and transmitter for
calibration, calibrate the transmitter, and return the transmitter and the
controller to normal operation.
71-0024-01 - REV D 9
Combustible Gas Transmitter Operator's Manual
Preparing for Calibration
This section describes the procedure necessary for preparing the combustible
gas transmitter for calibration. The procedure includes step-by-step
instructions for preparing the Calibration kit and the transmitter.
Vf WARNING
Calibrate the transmitter in a fresh air environment (environment
known to be free of combustible gas).
PREPARING THE GAS CYLINDER
1. Make sure the flow control knob on the regulator is closed.
CAUTION
Closing the flow control knob too tightly will damage the
regulator.
2. Carefully screw the regulator onto the gas cylinder.
3. Attach the sample tubing to the regulator.
4. Attach sample tubing from the outlet connector of the regulator to the
hose connection tube of the test cup.
5. Slide the test cup onto the detector, and secure it with the screws. Do
not overtighten the screws.
Flow Control Knob
Regulator
To Detector on
Transmitter
inder
Tubi
Figure 3-1
I
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Diffusion Calibration Kit with Gas Cylinder
10 71-0024-01 - REV D
Gas Cyl
Test Cup
Calibration
SETTING THE ZERO READING
VF WARNING
In locations classified as hazardous (National Electric Code
Article 500) and with power on, the area must be certified gas-free
before you open the junction box cover. Consult prevailing
national, local, and corporate requirements for certification.
1. Unscrew the junction box cover.
2. Select the millivolt (mV) range on the multimeter. Plug the positive
multimeter lead into the white(+) test jack: plug the negative lead into
the blue (-) test jack.
NOTE
Verify that the transmitter is in a "fresh air" environment (known to be
free of combustible gases and of normal oxygen content).
If you cannot verify the absence of combustible gas in the calibrating
environment, you will need to use a zero-emission air cylinder to
introduce combustible-gas-free air to the detector (see Appendix A,
parts list). The zero-emission air cylinder is not part of the standard
calibration kit.
3. If you are not using the zero-emission air cylinder, go to step 5. If
using the zero-emission air cylinder, attach the tubing from the
regulator to the zero-emission air cylinder.
4. Open the flow control knob on the regulator.
5. When the reading on the multimeter stabilizes, confirm a reading of
100 mV. If necessary, adjust the zero potentiometer on the amplifier
until the multimeter reading is 100 mV.
6. If you used the zero-emission air cylinder, close the valve on the
regulator, and remove the regulator from the cylinder. Leave the
multimeter leads connected to the amplifier test jacks.
71-0024-01 - REV D 11
Combustible Gas Transmitter Operator's Manual
SETTING THE RESPONSE READING
Vf WARNING
In locations classified as hazardous (National Electric Code
Article 500) and, with power on, the area must be certified gas-free
before you open the junction box cover. Consult prevailing
national, local, and corporate requirements for certification.
Either the 4 to 20 mA analog signal at the output terminals of the transmitter
amplifier or the 100 to 500 mV test signal at the test jacks of the transmitter
amplifier can be used to calibrate the transmitter. The following formulas
describe how to calculate the output signal and the test signal as a function of
test gas concentration:
Output signal =
((test gas concentration/full scale) x 16 mA) + 4 mA
Test signal =
((test gas concentration/full scale) x 400 mV) - 100 mV
The following instructions describe how to use the test signal to calibrate.
1. If not already connected, attach the regulator to the gas cylinder.
2. Open the flow control knob on the regulator.
3. When the reading on the multimeter stabilizes, compare the reading to
the calibration chart.
500
U,
4-
C
i C,
C
-C
w (2
(I
4-
U,
0
I-.
400
300
200
100I
0 20 40 60 80 100
Sample (% LEL)
Figure 3-2 Calibration Chart, 0-100% LEL
12 71-0024-01 - REV D
I
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I
Calibration
If the multimeter reading corresponds to the concentration of the gas
cylinder, the transmitter is calibrated correctly, go to step 5.
1 P CAUTION
If the reading on the multimeter has not stabilized after two
minutes, match the reading two minutes to the calibration chart
4. Adjust the reading on the multimeter with the span potentiometer to
match the calibration chart.
5. Close the flow control knob.
6. Remove the multimeter leads from the test jacks, and secure the
junction box cover to the junction box.
7. Perform the steps described in the Returning to Normal Operation
section.
Returning to Normal Operation
This section describes how to put the combustible gas transmitter into
normal operation and to disassemble the calibration kit.
1. Remove the sample tubing from the test cup.
2. Loosen the screws and pull the cup off the detector.
3. Unscrew the regulator from the gas cylinder.
4. Store the components of the calibration kit in the storage case. Leave
the components of the calibration kit connected for convenience.
The combustible gas transmitter is now ready for normal operation.
71-0024-01 - REV D 13
Combustible Gas Transmitter Operator's Manual
71-0024-01 - REV D14
U.q
MAINTENANCE
V WARNING
If possible perform all maintenance activities in a non-hazardous
environment. Calibrate the transmitter in a fresh air environment
(environment known to be free of combustible gas).
This section describes preventive and corrective maintenance procedures for
the combustible gas transmitter. A preventive maintenance schedule
describes daily, monthly, and quarterly procedures to ensure the
performance and durability of the transmitter. The troubleshooting guide
describes problems you may encounter with the combustible gas transmitter.
Procedures for replacing components of the transmitter are at the end of this
chapter.
Preventive Maintenance
This schedule describes daily, weekly, monthly, and quarterly procedures to
ensure the performance and durability of the combustible gas transmitter.
Daily
1. Confirm that the controller is on. If the controller is not on, see the
Troubleshooting section in the Maintenance chapter of the controller
manual.
2. Confirm that the display reading is near 0, and investigate significant
changes in the display reading.
Monthly
1. Assemble the calibration kit, and introduce the calibration gas to the
detector as described in the Calibration chapter.
NOTE
The concentration of the gas cylinder used for this procedure should
be approximately 50% of the fullscale value.
2. Confirm that the display reading for the appropriate channel increases
as the gas is introduced to the detector.
3. Confirm that the status indicator lights and buzzer operate correctly as
the reading rises above the alarm setpoints.
71-0024-01 - REV D 15
Combustible Gas Transmitter Operator's Manual
4. Disassemble and store the calibration kit as described in the
calibration chapter.
Quarterly
CAUTION
Calibrate the combustible gas transmitter at least once every 3
months. Some applications may require a more frequent
calibration schedule.
Perform the calibration procedure as described in the Calibration chapter of
this manual.
Troubleshooting
This troubleshooting guide describes symptoms, probable causes, and
suggested responses for problems you may encounter with the combustible
gas transmitter.
Fault Condition
Symptoms:
The controller displays one or more of the following fault indications:
- FAULT or FAIL light is on
- Audible alarm
- Fault relay in the fault position
- In addition, some types of controllers will display a negative reading.
Probable Causes:
- The detector or amplifier wiring connections are incorrect or
incomplete.
- Detector circuit drift.
- The detector or amplifier is bad.
Suggested Response:
1. Confirm that the wiring to the controller terminal strip and to the
terminal block of the amplifier is complete and correct.
2. Confirm that the detector leads are secure and connected correctly to
the terminal block of the amplifier.
3. Set the zero signal as described in the Start Up section in the
Installation chapter of this manual.
16 71-0024-01 - REV D
Maintenance
If the fault condition continues, further isolate the problem as follows:
4. Disconnect the transmitter wires at the controller terminal strip, and
connect them to the terminals of a different channel or controller
known to be operating correctly. If the fault condition clears, the
controller terminal strip or the controller main circuit board is bad.
Contact Thermo GasTech for further instruction. If the fault
condition continues, go to the next step.
5. Disconnect the detector from the amplifier, and connect them to a
combustible gas amplifier known to be operating correctly. If the fault
condition clears, replace the detector. If the fault condition continues,
go to the next step.
6. Connect a detector known to be operating correctly to the amplifier in
question. If the fault condition clears, replace the amplifier.
7. If the fault condition continues, contact Thermo GasTech for further
instruction.
Difficult or Unable to Calibrate, Slow or No Response
Symptoms:
- Unable to accurately calibrate the transmitter.
- Slow or no response to gas during monthly response test.
- Transmitter requires frequent calibration.
NOTE
Under normal conditions, the transmitter requires calibration
approximately once every 3 months. Some applications may require a
more frequent calibration schedule.
Probable Cause:
- Sample in gas cylinder is low or exhausted.
- Detector voltage is too low.
- Bad detector.
Suggested Response:
1. Make sure the gas cylinder has an adequate supply of fresh gas.
2. Replace the detector.
3. If calibration difficulties continue, contact Thermo GasTech for
further instruction.
71-0024-01 - REV D 17
Combustible Gas Transmitter Operator's Manual
Replacing the Detector
1. Unplug or turn off all incoming power at the power source.
2. Unscrew the junction box cover.
3. Disconnect the detector leads from the detector connection block of
the amplifier.
4. Unscrew the detector from the junction box and pull the leads out
through the hub.
5. Guide the leads of the replacement detector through the conduit hub
and screw the detector into the junction box.
6. Connect the detector leads to the detector terminal block of the
amplifier as follows:
7. The position for each color is marked on the amplifier PC board.
Green to terminal 4 (R)
Red to terminal 5 (A)
White to terminal 6 (C)
8. Perform the calibration procedure described in the Calibration chapter
of this manual.
71-0024-01 - REV D
I
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18
Maintenance
Replacing the Amplifier
1. Turn off all incoming power at the power source.
2. Unscrew the junction box cover.
3. Disconnect the detector leads from the amplifier.
4. Disconnect the wires from the controller terminal strip.
5. Remove the three screws that secure the amplifier circuit board to the
base plate standoffs.
6. Remove the amplifier from the junction box.
7. Place the new amplifier in the junction box so the holes in the
amplifier are over the standoffs.
S. Screw in the three screws removed in step 5 to secure the amplifier to
the standoffs.
9. Connect the detector leads to the new amplifier.
I O.Connect the controller wiring to the new amplifier.
I LPerform the start-up procedure described in the Installation chapter
of this manual.
12.Perform the calibration procedure described in the Calibration
chapter of this manual.
71-0024-01 - REVD 19
Combustible Gas Transmitter Operator's Manual
20 71-0024-01 - REV D
I
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PARTS LIST
Table A-1 Parts List
Part No. Description
06-1002 Tubing, vinyl, 5/16", for calibration kit
25-0102-01 Junction box housing
25-0104 Junction box cover
35-5175 Splash guard
57-7045-01 Combustible gas amplifier
61-0101 Combustible gas detector
65-5001 Combustible gas diffusion transmitter
71-0024-01 Combustible Gas Diffusion Transmitter Manual
8 1-0002 Gas cylinder, hydrogen in air (50% LEL)
81-0004 Gas cylinder, propane in air (45% LEL)
81-0007 Gas cylinder, hexane in air (40% LEL)
81-0012 Gas cylinder, methane in air (50% LEL)
81-0076 Gas cylinder, zero-emission air
81-1003 Regulator
81-1110 Test Cup
81-6413-01 Calibration kit, methane
81-6413-02 Calibration, hydrogen
81-6413-03 Calibration, propane
81-6413-04 Calibration kit, hexane
82-0005 Adjustment screwdriver
71-0024-01 - REV D 21
VERS ON: Data Sheet COMBUSTIBLE
GTI-HC6-02206 TransmifferG J& H 6.0 V SENSOR
Sensor Principle: The Gas Tech Combustible transmitter uses a sensor that works on the electrochemical principle.
Within the sensor is a sensing, a reference, and a counter electrode. Gas diffuses into the sensor
and oxidizes on the surface of the sensing electrode. This chemical reaction creates a current
flow between the sensing and counter electrodes proportional to the concentration of Combustible
present in the atmosphere.
Specifications
Standard Range: 0 - 100% LEL of Methane Temcerature -:mits: -40 to 60*C
Cperatirg Voltage: 6.0 VCC for methane Relative tumic:, 3 - 100 %o RH
Signal Cutput: 4 - 20 mA Zero Drift: 3% of full scale/moth
Output Linearity: Linear Soan Drft: - 5% full scale/month
Repeatability: ± 2% of reading Estimatec Cell ife: 1 to 2 years
Accuracy: ± 5% of reading
Response time to 90%: 30 seconds Sampling Method: Diffusion
Recovery time to 10%: 30 seconds Warranty: 1 year
Cross Interference Chart
Gas Type LEL in Conversion
% Vol Factor
Acetone ((CH3)2CO) 2.5 1.5
Benzene (CSH6) 2 2.2
Butadiene (CH2(CH)2CH2) 2.0 2.1
Carbon Monoxide (CO) 12.5 1.7
Hexane (CH3(CH2)4CH3) 1.1 2.2
Hydrogen (H2) 4.0 1.0
Methane (CH4) 5.0 1.0
Pentane (CH3(CH2)3CH3) 1.5 1.6
65-5001
Gas Characteristics
General Description: Lower Explosive limit: 5.0%
Methane s a colortess, odorless, flammable gas. Vapor Density (Air = 1): 0.55
Molecular Weight: 16
CAS Registry No. 74-82-8
Ignition Temperature ('C): 537
Water Soluble: No
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PROCONTROL
SERIES 2PA/Is USER MANUAL
Version 2.X
PRCC'NTROL SRICS iI-
*i Etce A 6... N!* Sysem, StatusY.- O0
ProControl User's Manual v2.X
ILIMITED WARRANTY
EOS Research Ltd. (EOS) warrants its products to be free from defects in materials and workmanship for a
ieriod of one year from the date of purchase. Its obligation under this warranty is limited to repairing or
replacing, at its sole option. any such defective products. This warranty includes parts and labor. This warrant'
Joes not apply to equipment which has been damaged by accident, negligence or misapplication or has been
altered or modified in any way.
EXCEPT AS PROVIDED HEREIN. EOS RESEARCH LTD. MAKES NO WARRANTIES. EXPRESSED OR
%IPLIED. INCLUDING WARRANTIES OF MECHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE. Some states do not permit limitation or exclusion of implied warranties, therefore the aforesaid
limitation(s) or exclusionis) may not apply to the purchaser.
This warranty gives you specific legal rights and you may also have other rights which varv from state to state.
IMPORTANT SAFETY PRECAUTIONS
Any complex hardware or software may be difficult to document, explain or understand. It is important to
consider the consequences or unexpected or abnormal behavior which may be caused by a defect or human
riilure to comprehend. In order to protect people and property from damage. a thorough safety analysis should
always be performed. When the consequences of a failure are serious, it is essential to protect life and property
against such a failure with redundant backup systems or safety de ices. It is agreed between the purchaser and
EOS Research Ltd. that protection against and the consequences of any such failure are entirely the purchaser's
responsibility.
This device is not approved for use in life support or medical systems.
As installed, this product may be part of a system which is required to meet various electrical, fire, safety or other
codes and regulations. Compliance with these code is the purchaser's responsibility.
Specifications subject to change without notice.
{ 1996-8 EOS Research Ltd.
EOS Research Ltd.
2,0 West Road
Portsmouth, NH 0380 1
603,.43 .2371
Fix: o0.43 .2562
\backup,81 00\0074.doc
ProControl User's Manual v2.X
TABLE OF CONTENTS
1.0 SYSTEM OVERVIEW
1.1 General
1.2 Key Concepts
1.3 Control Basics
3
2.0 ON-SITE OPERATION
7
2.1 LCD Display
72.2 Keypad
92.3 Password
102.4 Operations Screen 102.5 L O Keys
112.6 Digital Input Menu 112.7 Digital Output Menu 112.8 Analog Input Menu 122.9 Analog Output Menu 132.10 Menu Key 142.11 LED Indicators
17
3.0 REPORTING FEATURES 18
3.1 Fax Report
183.2 Page Alerts
23
APPENDIX A - Typical ProControl Wiring
Please see the ProView manual for operation of the remote access software which is
supplied with the ProControl Series 2"'.
\backup\8 100'
ProControl User's Manual v2.X
1.0 SYSTEM OVERVIEW
1.1 General The ProControl Series 2pl"s is a small but powerful microprocessor based control,
telemonitoring system. By combining a control panel and remote monitor in one
unit, the Series 2p'"5 can act as a central suoerv'isorv and data management tool for
any stand-alone operation. The ProControl Series can perform multiple tasks:
- Stand-Alone Control: The ProConrrol Series 2pl"" is a sophisticated
programmable logic controller that will efficiently supervise and control your
operation. It can interface with up to 70 electrical devices (float switches,
pressure transducers. pH transmitters. flow meters, pumps, blowers, etc.), and
execute numerous control functions simultaneously. Automatic shutdown
routines can be programmed in to protect you operation during alarm
conditions. It is extremely versatile in terms of the control algorithms it can
execute.
. Remote Control and Monitoring: The ProControl Series 2 "" gives you a
window into your operation from any remote location. using the easy-to-use
Windows-based software supplied with the system. You communicate with the
ProControl over a modem link, which allows you to view all of your system's
operating conditions, while also providing the same access to control functions
that you would have if you were at the site (e.g.. turning pumps on and off.
adjusting alarm setpoints. etc.). No other telemonitoring device gives you the
ProControl s level of remote control capability.
. Reporting: The ProControl Series 2"" will keen vou informed. It will send
you periodic fax status reports of your project operations on a schedule
specified by you, and will alert you immediately either by fax or by numeric or
alpha-numeric pager if an alarm condition warrants attention. No longer do you
have to assume what's happening at your remote operation.....the ProControl
will tell you exactly.
* Datalogging: The ProControl Series 21"y is your information manager, It is a
powerful datalogger that autoratically records all operating conditions in its
battery-backed memory. You can access your logged data remotely at any time.
and download it to your office computer for further processing. The
datalogging capability is an invaluable tool for reporting purposes.
troubleshooting, and trend graphing.
One or more of these features can be used in your installation: they are standard in
everv ProControl unit.
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ProControl User's Manual v2.X
1.2 Key The following are the building blocks of any Series 2's
Concepts system.
Inputs and
Outputs (I/O's)
Digital Inputs
Analog Inputs
Digital Outputs
monitoring and control
No system can be effective in the real world without communication and one of the
principal ways the ProControl communicates is by responding to information
collected by sensors and by issuing "commands" to other electronic or electrical
devices. Sensor information constitutes an Input while a "command" to another
device constitutes an Output. The Series 2pIu" works with all of the more important
types of LO devices in general use. Appendix A demonstrates how a variety of 1/0
devices are connected to the ProControl.
These inputs are designed to detect the closure of switch contacts such as those
found on float switches or overpressure sensors. They can respond to any normally
open or normally closed dry contact. The Series 2"'s provides its own wetting
(supply) voltage of 5 volts DC for each digital input circuit. The Series 2p'*" can
respond to changes in state as fast as 4 Hz or 3 Hz (cycles per second) depending on
the model purchased. Digital inputs are "debounced" for 125 or 150 milliseconds,
respectively. This means that a switch or other input that changes state (becomes
open or closed) must stay in that state for 125 or 150 milliseconds before the Series
2 "will respond to the change.
Eight high-speed digital inputs can also be used for traditional digital (pulse-output)
flow meters. These inputs can detect signal changes at up to a 200/500 Hz rate. All
high-speed digital inputs are "debounced" for 1250/500 microseconds. The faster
rate applies only to those systems containing the 18.432 MHz processor.
These inputs are compatible with sensors which send out a 4 - 20 milliamp (mA)
signal. Most analog sensors are available with this type of signal, examples being
pressure transducers, pH transmitters, and many flow meters. These inputs allow
the operator to read the actual "value" of a parameter, such as pressure, instead of
an on off signal.
Digital outputs turn things like pumps, solenoid valves. and alarm lights on and off.
The Series 2 ''"" digital outputs are relay outputs designed to switch small loads
directly, such as motor starters, lamps, and solenoid valves.
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ProControl User's Manual v2.X
Analog Outputs
Tagnames
1.3 Control
Basics
Analog outputs are typically used in process control schemes where a controlled
piece of equipment can accept a signal which is variable over a range. This output
is expressed as a percentage (0 - 100%) and is used to control pump speeds,
chemical dosing rates, etc., instead of conventional on/off operation. The
equipment that the ProControl sends the analog output to must accept a 4 - 20 mA
signal. Often, an analog output is used in conjunction with an analog input such as
a pH transmitter to form a control scheme known asfeedback control. In essence.
the input and output will work together to maintain a user set input level. This
concept is described firther in the next section under Analog Output Processes.
Each input and output is given a descriptive Tagname by the user that uniquely
identifies it to the system operator. For instance, a digital input could be called
"TANKHI", an analog input could be called "AIRFLO" and a digital output could
be called "PUMP_ l". This tagname is used by the local LCD display, the FAX
report and by the ProView software. The analog inputs are also given a Units
Tagnane which identifies the unit of measure associated with the input sensor.
Each tagname can be up to six characters long and each units tagname can be up to
three characters long ("PSI", for instance). The tagnames can include the uppercase
letters A-Z. the numbers 0-9. a blank space, and the underscore (_) character.
The status of all inputs or outputs can easily be monitored both locally and
remotely. What gives the Series 2"" its real power, however, is the ability to
automatically initiate actions based on the status of the inputs and your preprogrammed instructions (this is often called Process Control). These actions can
include switching certain outputs, faxing back a report, sending an alphanumeric or
numeric page. shutting down the entire system or sounding the local alarm. Process
control functions are programmed into your ProControl by EOS Research or one of
our technology partners according to your specifications.
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ProControl User's Manual v2.X
A ctive State Central to the use of control on the Series 2pl"" is the concept of Active State. Each
input on the ProControl receives certain signals from a sensor which constitute
"normal" operation and other signals which constitute an exception to normal
operation.
A digital input can monitor only two states. ON or OFF (alternatively, CLOSED or
OPEN). The Active State would be the state in which the controller would respond
to the digital input, and perform certain actions or generate an alarm. For example.
if a high level float switch in a tank is tripped (turned ON) by rising fluid level, we
can say that its Active State correlates to a situation in which the fluid level is high.
The active state of the float switch could cause the Series 2" to trigger an alarm,
turn off a pump, or initiate some other action. The Series 2 " can be set up so that
either ON or OFF is the active state.
An analog input sensor can take on many states (or values) between the minimum
and maximum of its measurement range. The ProControl operator, however, can
set two threshold values which divide the total input span into two functional
regions. These threshold values are more commonly called the Low Alarm Limit
and the High Alarm Limit, although on the Series 2'" these thresholds are
somewhat more flexible in use than those names imply. An analog input which has
transcended either its Low Alarm Limit or Hiah Alarm Limit is said to be in its
active state.
10 psi _ For instance, consider an analog input sensor which measures
pressure from 0 to 10 PSI. The system operator could set the low
limit to 4 PSI and the high limit to 6 PSI. In this case the Active6 - - High State would usually be considered as the input state greater than 6
PSI or less than 4 PSI. This interpretation is called Endpoint Active
State (EAS) on the Series 2 "lus because the endpoints of the range
Low are the areas which need to trigger action or generate alarms. The
opposite interpretation is also possible and is called Window Active
... 0 psi _ State (WAS). Any input values between 4 PSI and 6 PSI would
EAS WAS trigger action or generate alarms.
Figure 1. Active State
If the ProControl has Alarms Set. when any input enters its active state, a local
beeper will sound on the ProControl. The word Alarm here applies only to the
sounding of a local beeper and is not associated with any process control. The
active state condition is indicated on the LCD display and can be acknowledged by
the operator. The beeper is silenced when it has been acknowledged or after 30
seconds have elapsed. The beeper only operates when the system is operating in
Manual mode.
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ProControl User's Manual v2.X
Startup The Startup Sequence is a series of control algorithms or steps which run in
Sequence succession and which are designed to place the system in its normal operating
mode. It can be as simple as turning all the outputs on simultaneously, or as
complex as a multi-stage delay with many conditions. Up to 8 or 16 individual
startup steps can be declared depending on the model of the controller. The
ProControl can be configured to automatically run this sequence when the unit is
powered up.
Process Tasks A Process Task is an ongoing control algorithm which runs continuously. Think of
each process task as an IF-THEN statement, in which an action is initiated if a
certain condition or combination of conditions exists. Some examples are:
. IF Tank Level Sensor 2 is on. THEN turn Pump 2 off
- IF Air Flow Rate < 10 cfm AND Reactor Temperature > 2500, THEN open Bleed
Valve 2
Up to 16 or 64 separate process tasks can be run simultaneously depending on the
model of the controller. Process tasks can trigger FAX reports, pager alerts, and
system shutdowns.
Shutdown The Shutdoitn Sequence is a series of control steps which run in succession and
Sequence which are designed to shut your system down in a manner which is best for the
equipment or treatment processes involved. The shutdown sequence can be
activated manually or automatically due to an alarm condition. Here is a typical
shutdown sequence:
* Turn off Well Pumps I and 2
- Wait s minutes. then turn off Stripper Blower
- Open Bleed Valve 2
- When Oxidizer Temperature < 1500. turn off SVE Blower
Automatic The use of the startup sequence. process tasks, and the shutdown sequence
Operation constitutes Automatic Operation of your system with the ProControl Series 2
(otherwise known as Auto tfode). The Series 2pl"s will be placed into auto mode
(automatically) when your system has been started up using the programmed startup
sequence. If one condition of the programmed startup sequence is not met during
the startup process, your system will be completely shut down by the ProControl as
a safety measure. Once the startup sequence has been successfully completed. the
ProControl begins running the process tasks continuously. PROCESS TASKS WILL
RUN ONLY WHEN IN ALTO mODE. Please note that the audible beeper will not
sound even if the ProControl has Alarms Set when it is in Auto Mode, since the
process tasks will control these situations as the user has specified.
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ProControl User's Manual v2.X
Manual
Operation
Analog Output
Processes
PID Loops
Proportional
Outputs
You can override the Series 2ps"" programmed control functions by operating in
Manual Mode. In manual mode, your process will respond only to operator input
from the keypad of the ProControl, or to commands issued from the ProView
software. PLEASE NOTE THAT PROCESS TASKS AND THEIR ERROR-CHECKING
MECHANISMS DO NOT RUN DURING MANUAL MODE! Manual mode is useful when
you wish to troubleshoot your system, but none of the system safeguards built into
auto mode are available. You can place your operation into auto mode any time by
issuing the command from the keypad.
In some cases, you may want to use an analog output to control equipment that
maintains an analog input at a certain constant level. For example, you may wish to
automatically maintain a pH of 8.5 in a reaction tank by varying the dosing rate of a
chemical feed pump. The pH you wish to maintain (8.5) is called the SetPoint of
the analog output process. An analog input to the ProControl (in this case, a pH
transmitter) is said to provide feedback to the unit, and combined with an analog
output, constitutefeedback control.
A reliable type of feedback controi can be obtained through a PID Loop. PID
stands for Proportional-fntegral-Derivauive. and is a commonly-used process
control technique. We'll skip the details of the mathematics involved, but suffice it
to say that a PID loop is the favored control technique for most analog output
processes. With only a Proportional term applied in the equation, the analog
output is controlled based on an error signal generated from the difference between
the SetPoint and the actual analog input. The PID loop can also improve its
performance as it continues to run if an Integral term is used and can respond to
quick changes in the controlling analog input if a Derivative term is used. EOS
Research will configure your PID loops for you and can provide further information
if necessarv.
In some cases, it may be desirable to base an analog output signal on an analog
input value. In this situation. no specific SetPoint is used because there is a direct
relationship between the output and input values. For example, if you wanted to
base the output of a metering pump on some flow rate, you might use a proportional
output to relate the amount of chemical metered to the flow rate.
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ProControl User's Manual v2.X
12.0 ON-SITE OPERATION
2.1LCD
Dispiay
Systen Tagname
Tagname Value
Dimensional
Units or I/O
Status
Menu Selection
If your unit did not come with an LCD display, the following sections do not
apply.
The 2 line x 20 character LCD display is used to display and control system
operations. The display is divided into separate areas or fields, as outlined below.
System Tagname
AIRFLO
REP7 RT_
Menu Selection
Tagname Value
or Output Designation
/
Dimensional Units
or UO Status
343.65 CFM
OFFSAUT 12
Communications
Status
System Status
Figure 2. Display Fields
This six-character field is used to identit'y the LO point displayed. Descriptive
names such as WELL I or BLOWER are used.
For analog inputs, this field displays the value of the input, the high alarm limit.
or the low alarm limit. For digital outputs. OUTPUT is displayed. For digital
inputs, this field is unused. For analog outputs. this field displays the output
percentage, the output level, or the associated input setpoint.
For analog inputs, this three-character field displays the dimensional units
associated with the input sensor. such as GPM\I or PSI. For digital inputs and
outputs. this field displays either ON or OFF. For analog outputs, this field
abbreviates percent with PCT. In the case of digital outputs, if the particular
output displayed has been designated a lamp output (see Pro View manual), and a
lamp test is currently running. an asterisk (*) will appear before ON or OFF to
indicate the lamp is illuminated despite the indicated output status (the output
will return to this indicated status once the lamp test has been completed).
This field displays the current menu selection.
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.o ProControl User's Manual v2.X
Communications
Status
System Status
This field displays one of five different descriptors which indicate any of several
special functions of the ProControl. If no communications action is being taken,">" will appear. Communications messages include: SP (Sending Page) -indicates that the unit is attempting to send either an alphanumeric or numeric
page: EF (Encoding Fax) - indicates that the unit is presently encoding afacsimile report as a result of a request by either the operator or the unit itself; SF
(Sending Fax) - indicates that the unit is attempting to send a fax report; and DC(Data Communications) - indicates that the unit is presently interfaced with
ProView.
This area displays the current system status: AUTO, MANUAL, START, or
SHUTD and an associated process task number indicating the last successfully
completed Auto process, current Startup process, or current Shutdown process.
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22 Keypad The Series 2''"s keypad contains 12 buttons which are
Display to control the operations of the system.
S
1W
0
3
Up Auto
Mode
S
used along with the LCD
Z Dow Man Auto Enter
Figure 3. Series 2Y Keypad
This key is used to scroll through a series of options which are displayed on the
LCD screen, and which allow the user to configure various aspects of system
behavior.
These keys are used to display information about particular L10 points on the LCD
Screen. The keys allow the user to scroll through all of the system UO points either
forward or backward.
The Acknowledge key is used to silence the audible beeper or to acknowledge a
memo sent from a remote ProView user.
IThe Set Hi Lc key allows the user to change the high and low alarm limits for
analog inputs or to toggle the display in the [0 Summary.
The Emergency Shutdown key is used to turn off all outputs and return the system
to manual mode.
key.
The programmed shutdown sequence is not executed using this
The Field key is used to select a character position to be edited. It is used in
conjunction with any direct alphanumeric entry.
These keys are used to toggle system variables from one state to the next or to scroll
through possible character entries when used in conjunction with the Field key.
This key is used to place the system in manual mode.
This key is used to place the system in auto mode.
The Enter key is used to initiate certain actions selected bv other keys or to confirm
alphanumeric ediring done using other keys.
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ProControl User's Manual vZX
2.3 Password When the system is first turned on the password screen is displayed and the user is
prompted to enter the password to gain access to the system. "EOS" is the default
password. The password on the Series 2 was designed as a low-level security
feature. It is not sufficient in and of itself to withstand a determined effort at
system entry. The ProControl unit can be configured to bypass the password screen
when the unit is powered up.
CUSTCMER ID TAGNAME
ENTER PASSWORD: BAA
CUSTOMER ID TAGNAME
ENTER PASSWORD: BAA
CUSTOMER ID TAGNAME
ENTER PASSWORD: EOS
[f the password was entered correctly, the
about a second before the operations screen
Password Accepted
VER 2.XXX : 1
Use the Up and Down keys to change
the character displayed above the
cursor.
The Field key
cursor to the
edited.
The enter key
for approval.
following screen
is displayed:
is used to move the
next character to be
submits the password
will be displayed for
User Setup Version #
Otherwise, the following message will
be returned to the password menu:
Incorrect Password
I
be displayed for a second and the user will
2A4
Operations
Screen
After the password has been entered correctly, the operations screen is displayed.
The operations screen allows the user to set system parameters and to review the
status of all system inputs and outputs.
WELLl OFF
ALARMS SET >MANUAL
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2.5 110 Keys
G
G
2.6 Digital
Input Menu
U 't
L ield j
BWWB
L~9W ~
(jyji
Auto 89
WELL2 ON
ALARMS SET >KMANJAL
WELL3 OFF
ProControl User's Manual v2.X
Pressing the UO Up or I/O Down keys
will scroll through the operational IO
points in the system. Data relevant to
a particular I/0 point will be displayed
to right of the point's Tagname.
Forward scroll through /O points
Forward scroll through LO points
ALARMS SET >MAUTUAL
WELL2 ON
ALARMS SET >MANUAL
Input Tagname Input Status
WELL2 ON
ALARMS SET >?UTUAL
Output Tagname Output Status
/ a p S ta tus-- -/ -- - ---- -PUMP1 OUTPUT *OFF
ALARMS SET >MA NTUAL
PUMP1 OUTPUT ON
ALARMS SET >MANUAL
PUMP1 OUTPUT ON
ALARMS SET >MANUAL
Backward scroll through [/0 points
A digital input
operations screen
shown. When the
State -ON" will
Input Status area.
will be displayed.
displayed in the
will be displayed as
input is in its Activ e
be displayed in the
Otherwise, "OFF"
A digital output displayed in the
operations screen will appear as
shown. When the output has been
turned on, "ON" will be displayed in
the Output Status area. Otherwise.
"OFF" will be displayed. The cursor
is displayed under the first character in
the status field to indicate that it can
be changed. The Lamp Status
character (*) will be shown for a lamp
output if a lamp test is running
regardless of the output's true state.
Pressing the Up or Down key will
toggle the digital output state and turn
the corresponding relay OFF or ON.
Pressing the Field key will move the
cursor to the Menu selection field.
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2.8 Analog
Input Menu
Hi Lo
et GADownUp
n ProControl User's Manual v2.X
Analog Tagname
/- --
H2OFLO
Units
Analog Value
4-
54 .6 GPM
ALARMS SET >MANUAL
H2OFLO 20.0 GPM
LOW ALARM > MANUAL
H2OFLO 80.0 GPM
HIGH ALARM >MANUAL
H20FLO 120817 GAL
TOTAL FLOW >MANUA:
H20FLO 30.0 GPM
LOW ALARM >DCUAL
H20FLO 30.0 GPM
LOW ALARM >M&ANTUAL
H2OFLO 30.0 GPM
LOW ALARM >MANUAL
An analog input displayed in the
operations screen will be displayed as
shown to the left. The value of the
analog input will be shown along with
the dimensional units. In the case of a
pulse accumulator (totalizer only), you
will see only TOT where units is
normally displayed.
Use the Set Hi Lo key to set the low
alarm limit.
Press the Set Hi Lo key again to set
the high alarm limit.
Press the Set Hi Lo key again to see
the total flow on a flow type input, and
once more to return.
The Up and Down keys are used to
change the value of the current
character, as denoted by the cursor.
The Field key is used to move to the
next character to be edited.
To save the low alarm
press the enter key.
limit changes,
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Analog Tagname
Percentage
F - --- -- -
VRPUMP 25.0 PCT
ALARMS SET >MANUAL
VRPUMP 25.0 PCT
OUTPUT LVL >MANUAL
2.9 Analog
Output
Menu
set)
Hi Lo
AmDownl VRPUMP 35.0 PCT
OUTPUT LVL >MANUZAL
VRPUMP 35.0 PCT
OUTPUT LVL >MAbmAL
VRPUMP 35.0 PCT
OUTPUT LVL >MANUAL
ProControl User's Manual v.X
An analog output displayed in the
operations screen will be displayed as
shown to the left. The percentage of
full scale output will be displayed as
wveil.
The Set Hi Lo key can be used to set
the output percentage.
Press the Set Hi Lo key again to
declare the SetPoint of an associated
analog input. The SetPoint is used
only if a PID control loop is in use as
an analog output process.
Pressing Set Hi Lo again returns to the
original menu.
The Up and
change the
character, as
Down keys are used to
value of the current
denoted by the cursor.
The Field key is used to move to
next character to be edited.
the
To save the output level changes, press
the enter key.
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ProControl User's Manual v2.X
§r m Hico
Meu YlLJY:90
When pressed, the Menu key will
scroll through a series of items which
allow the user to configure various
aspects of system behavior. A
description of these items appear in a
10 character field at the bottom left of
the display. Either the Up and Down
keys or the Enter key is used to
change the item.
ALARMS I Use the Up and Down keys to enable or disable Alarms.
TAGNAM DIM
ALARMS OFF >MANUAL
TASNAM DIM
ALARMS SET >MANTUAL
1j9Down
Up REPORT Use the Up and Down keys to enable or disable the unit's reporting capabilities
(fax or page).
AGNAM DIM
REPORT OFF >MANUAL
TAGNAM DIM
REPORT ON >MANUAL
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FAX NO V Use the Enter key to send a FAX report immediately.
-AGNAM
FAX NOW
DIM
> MANUAL
Use the Enter key to run the Startup Sequence.
TAGNAM
STARTUP
DIM
>MANTUAL
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ProControl User's Manual v2.X
SHUTDOWV j Use the Enter key to run the Shutdown Sequence.
TAGNAM
SHUTDOWN
DIM
>,?LU TAL
LAST
SHUTDOWV
LOG OFF
S
LASTA.IEA1O
This display item shows what input or output caused the last shutdown.
TAGNAM4 DIM
SDN TAGNAM > LTUAL
Use the Enter key to Log Off the system and return to the password menu.
T NAM DIM
LOGOFF >M A LEnter
Use the Enter key to see the last memo sent from the remote ProVikew user.
Up and Down are used to scroll through the message. and Ack is used to return to
the ProControl menus. If you hit any other key you will see an informative
message telling you which keys are valid. The message will be displayed for 3
seconds if no keys are pressed, but can be acknowledged before the 3-second
period by pressing either the Ack or Enter keys.
DIM
LAST MEMO >MA FJLZ
HEY BULLWINKLE,
REMEMBER TO SHUT THE
LIGHTS OFF!
PUSH TO RETURN
UP & DOWN TO SCROLL
OR NOWLEDGE
LIGHTS OFF!
PUSH TO RETURN
TAGNAM DI1!
LAST MEMO >MAN2UAL
Enter
D
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10SULIARY Use the Enter key to enter the I/O summary. The analog input values 0-10
represent a percentage of full scale (i.e. 0 = 4 mA, 5 - 12 mA). Set HiLo is used
to toggle between input/output summaries. An underscore represents an open
input or an unswitched output. A block indicates a closed input or a switched
output. An x or X is displayed when an output is not enabled and is unswitched or
switched. respectively. An asterisk (*) will be displayed if an output is declared as
a lamp and a lamp test is currently being performed. The Field key can be used to
move the blinking cursor through the outputs. The Up/Down keys can be used to
toggle the state of the output whose position is covered by the blinking cursor.
The Enter key will return the ProControl back to its standard menus. If you press
any other keys you will see an informative message telling you which keys are
valid. The message will be displayed for 3 seconds if no keys are pressed, but can
be interrupted before the 3-second period by pressing the Enter key.
CAZNAM DIM
IO SUMMARY >MANUAL
-DIN
0123456789l01234 AIN
xxx DO
xxxxxxxxxxxxxxxx EXT
xxx DO
xxxxxxxxxxxxxxxx EXT
xxx DO
xxxxxxxxxxxxxxxx EXT
HILO, FIELD, UP/DOWN
CHANGE IO,ENTER EXIT
xxx DO
xxxxxxxxxxxxxxxx EXT
NA24 DIM
10 SUMMARY >MLANUAL
Enter
S
ADown
Up y
Enter
Ene
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ProControl User's Manual v2.X
Use the Up and Down keys to toggle an Analog Output from Manual control
PID control or Proportional control, depending on which analog output process
being used. This selection will only appear if an analog output tagname
displayed and the analog output is part of an analog output process.
TAGINAM
MODE MAN
100 .O PCT
>MANTUAL
A Down
Up to is is WODES
S
GROUP
S
2.11 LED
Indicators
TAGNAM OUTPUT DIM
GROUP 1 >MANUAL
TAGNAM OUTPUT DIM
GROUP 2 >M7TUAL
rnDown
Your ProControl unit has three status LEDs to the left of the keypad. which are
used to indicate the following:
System Status:
Connect:
Network:
Normally ON when unit is powered.
One blink - The system has internally reset.
Two blinks - An internal error has occurred.
ON if user is remotely or locally connected.
ON if system is faxing or paging.
Slow blink - last fax or page failed, press ACK to clear.
Fast blink - local connect cable inadvertantly left plugged
in, press ACK to clear.
Rapid blinking indicates an active network connection.
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TAGNAM! ^+S.3 PCT
MODE PID >ANUAL
TAGNAM 25.0 PCT
MODE PRO >MANUrJA:
The ProControl allows outputs to be assigned to different Groups to allow greater
process control flexibility. In some cases. you may wish to be able to specify
alternate process tasks for a given output. For instance. you can have the operation
of a pump be controlled by a series of level switches in a tank, or alternately, the
pump can be run on a timed cycle. By selecting the appropriate process Group,
you can change the control strategy for that piece of equipment. EOS Research
will configure the groups for you according to your specifications
Use the Up and Down keys to select a Group for the displayed output. This menu
item is displayed only for outputs that have been configured by EOS to have
alternate process Groups.
17
3.0 REPORTING FEATURES
3.1 Fax Report] The ProControl unit wAill keep you informed of your system's
operations with
facsimile status reports. With the supplied ProView software you can configure
the unit to send fax reports to up to two different numbers. You can also have
these reports sent on a daily basis, at regular intervals during the day, or when
triggered by specific process tasks. You can send one at any time by using the Fax
Vow option either from the menu on the ProControl's display, or through the
ProView software.
The tax report you receive will contain several fields, each denoted by a shadow
box. The number of fields will depend on the configuration of your system. For
instance. you would not see a field indicating Analog Outputs if your system does
not contain any of these.
The nelds as ycu wi ll see them are shown below. All information enclosed in
brackets is variable and depends on your particular system configuration.
will indicate the :ntended fax recipient's name.
Front
THE
SETUP VERS-:N x
SYSTEM IN
ROM VERSION 2.x
AT
MODEL 31

will indicate the name and location of your system, the date and time at which the
fax report was
board softwCare
initiated. your current ProView setup version, and the current onversion 2X.
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-CE>*Px.' LAS -SHUTDOWN AT ON BY FAX REPORT INITIATED BY
will indicate the current of the controller and associated process. Forexample, if the controller is running the startup or shutdown sequence, you wouldsee either START or SHUTD followed by the current algorithm. Similarly, in automode, you would see ATO followed by the last successfully completed processtask.
The LAST SHUTDOWN indicates when the system last initiated the shutdownsequence and what caused it to happen. For example, if the shutdown sequencewere initiated by a key press, the cause you would see would be KEYPAD.Similarly, if the shutdown sequence were caused by a process task such as a highpressure sensor whose tagname was HIPRES, you would see HIPRES as the. If multiple inputs or outputs caused the shutdown (i.e. aprocess task was dependent on more than one input being in the active state andormultiple outputs being ON), the most recent one which changed will appear as thecause.
Similarly, the FAX REPORT INITIATED BY line will indicate the tagname ofthe I/O point which caused the fax to be sent, provided there was only one IOpoint responsible. If multiple .O points were responsible, the process itself will beindicated. Consider, for example, a process task where a shutdown was caused byHIPRES and BLOWER, and a fax was also generated. The would be PRcCESS XX, where XY is the number from 1 - 64 of this process task.In the case where Fax Now was selected from the menu option on the LCD, the would be KEYPAD. The from a ProViewgenerated Fax Now command would be REMOTE. This line will not appear ondaily or interval scheduled fax reports.
-I
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ill indicate-the status of all of the digtal inputs in four columns. Inputs which
are in the acti'e state will appear as ON and those which are in their normal state
will appear as
Discrete Outpids:
S>.-A:E> CTAC JAME, SAE
wkI indicate the status of all of the digital outputs in four columns.
And og Intput
-X_-7 a <2-e! LT :C L-L=X> 2 tI> H: 2
%ill indicate the current value, dimensional units, low alarm limit, and high alarm
imit for al! analog inputs which are not flow-type inputs. The precision of the
values displayed can be selected through ProView. Any flow-type analog input
w hich is retponsible for maintaining a total flow will display that flow in place ot'
the alarm Imirs. Any pulse-type digital input used for a digital flow meter will
appear here since the information being obtained by that type of flow meter is
analog in nature. in addition, pulse accumulators (volume totalizers) will appear
here.
'Andiog &dpzt:
ill indicate the output percentage and mode of operation of all analog outputs.
The precision is fixed to one decimal place and will range from 0.0 to [00.0.
expressed as a percentage. The of operation will be PD if the analog
output is currently being used in a PID loop, or PRO if the analog output is
currently being used in a Proportional scheme. otherwisc it will be >LM indicating
that the analog output is under manual control.
The next two pages contain examples of scheduled and alarm fax reports.
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3.2 Page Alerts The ProControl unit can alert you to important conditions at your site via a pagealert. Any system that is not in manual mode, that is, executing process tasks or
the startup or shutdown sequences, can send a message up to eighty characters in
length to an alphanumeric pager or up to nineteen digits in length to a numeric
pager. If you are out of the office and away from a fax machine, you will still be
alerted to any trouble at your site. With ProView you can select up to two pager
numbers to be called. Each process task or startup/shutdown algorithm is capable
of sending a message to either or both of these pagers. The pager messages are
configured by EOS Research according to your specifications.
An example message for an alphanumeric pager would be:
ANYTOWN SITE
High water level EQ Tank
System shut down!
Call Fred to fix: 555-6789
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S:\BACKUP\8 10\0074.DOCA-1
ProViewI
for Series II
User's Guide
ProView for Series I
EOS Research Ltd.
Version 1.70
e 1995-96 EOS Research Ltd.
Version 1.70
EOS Research Ltd.
Pro View 1.70 User's Guide
LICENSE: E10S Riese arch Ltd. grants you the ig to use :he enciosed program i the "Software' You w il not use. copy, modify ret, 'eilor Trater the Softtw are or aln portion hereo \CCep( as prou Ided :or :n th is agreem ent
You ra,
. se the software on uip O (0 Computers ,
-opy the oftware solIl tor backup or archival urposes
REST RICTIONS: You ill nor
c the sotware or cause the Soitware to be used on more than no comuters at the same Time.
- ub-icense the Soitware.
erse engmeer. decompile or disassemble the Sothware
4 Copy the Soitware except as provideu in :his agreement
ermit imultancous use of the Soware by more than two users.
TRA SFER: You may transter ownership of this license to another party ifhe receiting party agrees to the terms of this AgrcemTtent andou reain 1o copies of the Softuare and accompanyig documentation.
Traner of:he iccnse terminates -our right to use :he Software.
O\kNERSHIP AND COPYRIGHT OF SOFTWARE: Title to -he Software and all copies thereof remain with EOS Research Ltd. or is'e:nce The Software , cooTighted and is protected by United States copyrt lt laws and ntcmrational treaty provisions You wil netremo e 'he coprnght ntcte from the Sofware You agree to preven any unauthored copying of the Software.
X A RRANTY : EOS Research Lid warrants that it has the right to license you to ase the Sonware.
EOS ? esearch Lo d.warrants that the media on xhich :he Software is irnisned wll be tree from defects in materials and workmanship undernormai use for a period of one year :rom the dite of purchase. ECS Research Lid., enire liablity and your exclusive remedy shall he thereplac.ment of the Software C the media on which the Software is furnished pro'es :o be defective. This warranty is void if the media defec:has resulted from accident, abuse or misapplication Any replacement of media shall be warranted for the remainder of the original warranirperiod 'r Q0 days, wchets er is loncer
DISCLIlMER: Except as proided abote. the Sontware :s provided AS IS" without warrant' ofany kind.
LIMII IA ON OF LIABILITY: THE ABOE WARRANTIES ARE THE ONLY WARRANTIES OF ANY KIND. EITHEREXPRESSED OR IMPLIED. INCLUDING WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICUL \RP1 RPOSE NEITHER EOS RESEARCH LTD OR ITS VENDORS SHALL BE LIABLE FOR ANY LOSS OF PROFITS, LOSS OF USE.INTERRUPTION OF BLSINESS. NOR FOR INDIRECT. SPEC[AL. INCIDENTAL. OR CONSEQUENTIAL DAMtAGES OF ANY KINDkHETIER UNDER THIS AGREEMENT OR OTHERW\ISE
%LDIT: LOS Research Ltd rescres the right to eonduct or ha'e conducted audits to ' TERNH1NAT[ION OF THIS LICENSE: EOS Research Ltd. may terminate this license at any time it you are in breach of any em, orconditi is 'pon termination. xou will ummediatey destroy the Software or-e'ar all oies of the Softare to LOS Research Ltd. aionstilt aim copies you ha'e made.
L.S. GOERNIENT RESTRICTED RIGHTS: T ie Software and documenaion are pro' ided with "RESTRICTED RIGHTS." Lse.dupm EXPORT LA\X S: You agree that neither the Sonuare nor the direct product thercor is intended to shipped either directly or :ndirec:ly 'otoreitn- -ountres unless a alidated export license is ebtained from :he U.S Departmem of Commerce.
PPL IC ABLE LA\S: This Aegrement is govened by the laws of the State of New Hampshire and The United States, including paten andcopr:I-t ia"s Any clati an sti out of this Agreemen will be brought in Rockinghatm Coun, Newv Hampsh ire.
ps -'0nun
Pro View 1.70 User's Guide
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EOS RESEARCH LTD.
SOFTWARE LICENSE AGREEMENT I
IBy using this Software you are agreeing to be bound by the terms of this Agreement. Do not use theSoftware until you have carefully read and agreed to the preceding terms and conditions. If you do
not agree to the terms of this agreement. promptly return this document and any accompanying
items.
Information in this document is subject to change without notice and does not represent a commitment on
the part of EOS Research Ltd. No part of this manual may be reproduced or transmitted in any form or by
any means, electronic or mechanical, including photocopying and recording, for any purpose without the
express written consent of EOS Research Ltd.
O 1995-97 EOS Research Ltd. All rights reserved. Printed in the United States of America.
ProView and ProControl are trademarks of EOS Research Ltd.
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EOS Research Ltd.
210 West Road
Portsmouth, NH 03801
Voice: 603.431.2371
FAX: 603.431.2562
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Pro View 1. 70 User's Guide
TABLE OF CONTENTS
CHAPTER 1: INTRODUCTION AND INSTALLATION ......................................... 6
Introduction to PRO VIEW ............................................
6.... . ....
System Requirem ents...................................... ....
How to Install from the Windows Program Manager....
R lunning Prov iew ............................................
8
C hanging Inform ation ...... .9............................ 9
CHAPTER 2: GETTING STARTED .................................... 10
Opening a Site File .................. ............ 10
Entering the Password
Examining the Main Screen........
Printing the Setup to File .. 14
Examining the Setup File.... Is
Input and Output Configuration
1~
P rocess T asks...................................
18
Process C apability ...............................
19
CHAPTER 3: ESTABLISHING COMMUNICATION ........................ 21
Local C onnection ...............................
21
Rem ote Connection..............................
23
Ending a C onnection...........................
4
Sending a M em o ............................ . 5
CHAPTER 4: MANAGING YOUR SITE ................................. 27
Switching Between System Modes ....................System Operations ................ 28Date & Time ....... . . .......
28Alarm s . . ............. .. .... ...
9Remote Reporting.... ..... . .. . 29Log Off Remote User ...... .. ..
initiate FAX NOW. .
Initiate New FAX NO\W ....... .. 30
Trend G raphing............... I
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Pro View 1.70 User's Guide
CHAPTER 5: CHANGING SYSTEM PARAMETERS ............................................. 33
S w itching an O utput S tate ................................................................................. ............ 33Process Groups. ................ ............ 4
Output Cycle.... . . .... ......... 3Output Options . ....... .......... .... 34
H our M eters ....... ................. .5
N o te s ..............................................
3 6
Analog A larm Levels......................... 3~
T o ta liz ers ........................................... ..... 3 9
PID and PRO O ptions ........................ . ................ 0
S ite In fo rm atio n ...................................... C................................... 4 2
F A X R eport S etu p ................................................................ 2........ 4 2
P a g in g S e tu p .................................................................................. 4 4
D ata lo gg in g S etu p .......................................................................... 6
C haniin g the P assw ord.................................................................. 4 Process and Instrum entation D iagram ............................................ ... . ............ 48
CHAPTER 6: DOWNLOADING LOGGED DATA............................................. 50
G etting L ogged D ata.. .............................................................................................................. 5
Lookirw at Discrete Data
L oo k in gz at D isce t e D ata ......... .... .................. ........ .. ................................. i5Looking at Event Data,............................. 54
Looking at Analog Data ........ . ... 55
Graphiu Options ..................
Saving Datalogging to File ... 60
Opening a Datalogging File ..... 61
Exporting Datalogging Information 62
CHAPTER 7: OTHER OPERATIONS ................................... 63
Saving the Site Setup to File ........... .................... .............. ....... 63
Printing the C urrent D ata to File 64.......................................... .
E x itin g P roie w .................................................................................................. 6 6
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Pro View 1. 70 User's Guide
CHAPTER 1: INTRODUCTION AND INSTALLATION
T his chapter pro% ides a brief introduction to ProView features, the system requirements for running the
program, and instructions for installing it.
Introduction to PROVIEW
Proview is used in conjunction with the ProControl Series II unit. The ProControl is a teiemonitoring and
control system designed to reduce your operation's O&M toperations and maintenance) costs, while
ensuring that performance is maximized. With ProView you can:
* Monitor system sensors
e Control system inputs and outputs
* Change the way the system operates
* View and change system setups
- Extract datalogged system information
Some system parameters can be set with the ProControl's LCD display (if included). Many others can only
be set using ProView.
In order for ProView to function, it must be connected to the ProControl unit. It can be connected in one of
two ways. The first w.ay is with a cable that connects your PC's serial port with the ProControl unit. This
method of connection is most often used at the system site using a laptop PC. The second method is ia
dial-up modem from your oftice or from anywhere that a connection to the telephone system can be
established.
You should be Jumiliar with te operation of the ProControl u1nit and have read the ProControl manua
before running ProVilew
System Requirements
COMPUTER: You will need an IBM PC or compatible with a 386 (minimum) or greater microproccssor
with 4MB RAM and Microsoft Windows version 3.1 or later. A minimum of 4MB of Hard Disk space
needs to be available. A mouse or similar pointing device is also required.
Se, eruz! /tnctions in ProViewt require the use oIthe right nmouse button. Make ste the right mouse 'uuon
is not assigned to some other function such as double-click. See xour mouse driver sotvare fr details.
MODEM: You need a Hayes Compatible (AT) Modem which supports a data rate of 2400 baud. The
modem can be external or internal. It must be connected to COM Port 1, 2, 3 or 4.
6
Pro View 1. 70 User's Guide
How to Install from the Windows Program Manaer
l. Run Windows as you normally would.
. From the Windows Program Manager, pull down the File menu and click on Run. You will see the
Run dialog box.
3. Place the diskette labeled ProView Installation Disk =1 in the a: drive or the b: drive
4. Type the following:
a:\setup
if you put your diskette into drive b: in the last step then type:
b:\setup
Click on OK.
You will see a screen informing you that ProView is loading the install program. After the appropriate
files from disk =1 have been copied. you will be asked to insert Installation Disk #2. The installation
program will begin and you will be required to select a target drive. In the dialog box, type the drive and
path where you wish to install ProView. The default is C:\PROVIEW.
ProView will then be installed on your hard drive.
You will also need a site description File for every ProControl unit you need to access. This file has a
tpvs" extension and is normally supplied pre-configured for you on a separate diskette. Using Windows
File Manager, transfer all such site files to the directory in which your ProView files were placed. The
default is C: PROVIEW Depending on your site configuration, you may also have several other files
included along with your site description file. The files will have the extensions of *.not. *.pid, *cus or
*.bmp. You should transfer these files to the default ProView directory as well.
When the installation is complete, you will see the ProView program group and icon.
You may nee i to close sone or all of your currently running applications befbre installing ProVieu.
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File Options Window Help
ProView
EDS Research
ProView
R -1 __________________
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Pro I ew i. -0 Cser's Guide
Running ProViewN
ter linstai !n PmOieu as desert bed aboe, doLbe-click on the Pro'e c.t con After an introductionScrien. c oi 'Ali cec the Prot\ny %ain screen
-pPiieeorSrisi
File
Discrete Inputs Discrete or Analog Inputs Discrete or Analog Inputs Discrete Outputs
iL The main screen Contains pull-down mens sImilar to those found On other WA indows applications as we!las a Toolbar wthich proides an alternativ way' to na'i acte throIgh Prov iew Placing the cursor over aToolbar button and ieun i there for a shor. wilie produces a "ballocn A baioon is a small pop-upmessage which describe the action to be taken if the Toolbar button i "pushec
Riht since no sy' ste: ille has been Oaded. the mam creenis blank aind t:he toolbar is disabled. Allmenus eer< the File menu haxe 'een "Ahmcd -lectan :s 2hosted A hen tie operation representedby the selec:Ion is ana' at labeIc.
Bclow the Toolbar are four informniion ares thich are iled cin based on :he %steirn setup and on thecuIrrent system tatus. The Discrete Inputs area contains information about the ON OFF switches or sensorsconnected to input> I through tn on the ProControl Lnit. The Discrete or Analog Inputs area containsintormnaton about >ensois or swi tchec connected :o the ProControl analo- expansion board. These are
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Pro View 1.70 User's Guide
inputs 17 through 32. The inputs can represent 4-20ma transducers or simple ON/OFF switches dependinc
on your site contiguration. The Analog Outputs area, behind the rightmost group of Discrete or AnalogInputs, contains information about any 4-20ma output control schemes that may be included in your
system. The Discrete Outputs area contains information regarding the output relays connected to the
ProControl. The Extended Outputs area, behind the Discrete Outputs, contains information regarding anyrelays or run lights beyond the first 14.
Your particular 'site file" will determine which of these groups you may view. For example, if you useProView 1.70 to open a site file which was originally shipped with version 1.1, 1.5. or [.6, there will be no
extended outputs available. You may also notice that certain menu choices are grayed out and unselectable
depending on your site file version.
At the bottom of the screen are a series of information boxes. These show the status of certain important
system parameters when ProView is connected to a remote ProControl unit.
Chan2ing Information
ProView has been designed to make it easy to view and change the information which governs the way
your system works. However, ProView must always be connecred to the ProControl unit in order to
actually change information. It is important to remember that ProView itself is only a window into the
operation of the ProControl unit. It does not provide any control function by itself Chapter 3 discusses
how to connect to the ProControl.
Most of the information in ProView that can be changed can only be changed while connected. If ProView
is not connected, this setup information is visible but disabled. When ProView is connected to the
ProControl unit, this information becomes accessible. When information is changed in ProView, a -" is
appended to the description or title of the information to indicate that the new data has been sent to the
ProControl. When the "?" disappears, the data has been received by the ProControl and confirmed by
ProView.
While many of the controls that change information in ProView are graphical, much of the information is
displayed in text form. To edit text based information, click on it and make your changes as you would in
any Windowvs application. When you click on the text. it is highlighted to show that it has the current
focus. After completing your text editing you can save the changes by first pressing the ENTER key while
the cursor is still within the text box being edited, and then clicking on the "OK" button for the current
form.
9p Pro View 1. 70 User's Guide
CHAPTER 2: GETTING STARTED
T his chapter explains how to open a site le and examine the information contained within it. Alsocovered is the procedure to print the systern conFiguration to a nile.
Opening a Site File
Everv ProControl unit has a "system confieuration" file which 'elis the unit which inputs or outputs are
enabled. what their descriprive "Tagnames' are and how they should respond :o changes in input status.
This same ile is used by Proview to provide a window into what is going on within the remote ProControl
unit and, by extension, with the site operation. To open a site Lie proceed through the following steps.
I. Pull down the File menu. Click on Open Site. You will see the Open Site dialog box. You can
also use the ALT-Key combination represented by the first underlined character in the menu name.
In this case use ALT-F.
You can also use rhe Toolbar :ulo at he p :he~p of ,17 main ic)reen tO o'pel a su file. The first time you run
the program. however. the toolbar ;s di.sabled. To open a sosIauent file ;ous can click on the Open Filc
Toolbar button .
-n Open Site
Directory:
cAproview
Drives:
I-Dc: [MS-DOS_622J WI
LIkE
In the Dri'es area of the dialog box click once on the down arrow to pull down the Drives list, then
click on the drive that contains the file yout wish to open.
3. In the Directories area of the dialog box. click on the sub directory that contains the file. Notice
that the current director. is shown under the word Directory. To move "up" in the directory tree.
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File Name:
control.pvs
demo.pys
monitor.pvs
sample.pyt
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Pro View 1.70 User's Guide
double-click on the level to which you want to move. To move "down" in the directory structure,
double-click on the sub directory.
4. [n the File area you will see all files in the selected drive and directory that have the extension
.pys. Only files with this extension can be opened. Select the file you wish to open by clicking on
the file name in the file list box. When you click on a file the file name appears in the File Name
box to confirm your selection.
SClick on the OK button to open the selected file.
The title of the main screen will change to include the file name and version number. The file name and
version number are enclosed within brackets.
Proviewfor Series I1 [sample.pvs II [
Enterin2 the Password
No system information is displayed at this point because the password has not been entered. To enter the
password:
!. Pull down the Password menu. You will see the Password dialog box.
site file the Password dialog box will appear automatically.
Enter Password:
Change Ps word
Ce 6|
If you havejust opened a
A4 word about passwords:
The password used in Pro view can be different than the one used to
access the ProControl unit through the LCD display. Jn either case the
ialid characters are 0-9 and A-Z tipper case only. Up to three
characters are permitted. The password was designed as a low-level
securi. feature sufficient to prevent inadvertent operation and to deter
tampering. It is NOT sufJicient in and of itself to withstand a
determined effort at system entry. To disable the password on the
ProControl unit, contact us to configure your unit to by'pass the
password screen, or simply set the password to .A A. The passwordbr
Pro View cannot be disabled.
1 Move your cursor to the text box and enter the password. The default password is EOS. Then
click on the OK button or hit the Enter key.
3. If the password is incorrect, the dialog box will disappear and a beep will sound. No system
configuration information will be shown.
4. If the password is correct, the Password dialog box will disappear and the system configuration
information will be shown on the main screen.
.4 Viev-Only Mode password. "VOX!, may be entered to allow a connection to the remote system for observing
the sistei status, however, no changes to any ProControl information (jax, etc.) may be made when in this mode.
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F.."
Preie fo Seie 11,apep II
ieEnable Communications System Datalogging Password Help
Discrete Inputs Discrete or Analog Inputs Analog Outputs Discrete OutputsHlWEL1 Q H20FLO sw VARPMP
LOWEL100
GPm_ Manual 0.0 % Output ockedNOISTR H2OLVL 40 SEQ_MP
SUMPHI Q 0 .'..'.'''ir Manual 0.0 % '0' WPUMP1 PRSALMA!RPRS Q PHTRNS 14
DOR0 . ,ri . .c)...DOOR
WPUMP2 SMPALMSTPRHI
I:R PSTPRLO
STRIPR PHALMLMPTST
RESET Q
TFPUMP MSTALM
MPPWR
Examining the Main Screen
This particular site has eight discrete inputs. three analog inputs, eleven discrete outputs, and two analogOutputs. Tw.o of the discrete outputs are behind the discrete outputs panel in the Extended Outputs area.
Discrete Inputs
HIWELl C HIWEL1 Q HIWEL1
On :he left side of the screen belowk the heiding 'Discrete inputs" arc shon :he names of enabled discreteor digital inputs. These names (called "Taunanmes'' identify the input. To the right of the Tagname is avirtal 'LED". This LED's color or shape w ill change based on the status of the input. if discrete input =1i --OFF'. the LED next to the letters HI%EL! isravn color. If HIWEL I is"ON" then the LED is green.I HiWYEL ! is "ON" and has been set up as an alarm input the LED becomes a red "Alarm Bell". Thepmls below the 10th discrete input (RESET) are blank because those inputs have not been enabled in thisparticular iite contiguration.
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Pro View 1. 70 User's Guide
Analog Inputs
H20FLO I . ' ' " 'so
00 .OOC
In the middle of the screen below the heading "Analog or Discrete Inputs" are shown the enabled analog
inputs. Analog inputs can also be configured as simple discrete inputs. Below the Tagname is another
LED. For analog inputs, this LED is either gray when the H2OFLO is not in the alarm state or red when it
is in the alarm state. To the right of the Tagname is a small bar graph which gives a visual indication of the
value of the analog input. The bar graph indicator itself can be green or red. It is not shown here because.
at this point, there is no analog input data available (ProView is not connected to the ProControl unit). To
the left and right of the bar graph are numbers that represent the lower and upper bounds, respectively, of
the analog input values. In this case H2OFLO has been set up with a range of 0 to 50. Below the bar graph
is a numerical representation of the value of H2OFLO. (0.00) It changes along with the bar graph when
updates are received from the ProControl unit. Finally, in the lower right corner are the dimension units of
the analog input, in this case GPM.
Discrete Outputs
WPUMP1 WPUMP1,
On the right side of the screen below the heading "Discrete Outputs" are shown the names of enabled
discrete outputs. In this site configuration there are six such outputs. Below the Tagname of the output is a
virtual "Toggle Switch". By its position and its color it shows the state of discrete output and also allows
the user to change that state. If the switch is on the left hand side and gray then the output is "OFF". If the
sw itch is on the right hand side and green then the output is "ON".
|PRSALM PRSALM
Discrete outputs can also be configured with virtual "Alarm Lights" or "Run Lights" instead of switches.
Outputs are configured in this way when an alarm or run light more nearly approximates the function of
this output than a toggle switch would. If the light appears gray then the output is "OFF". If an alarm light
appears red or a run light appears green then the output is "ON".
Your system may also have "Extended Outputs" which are located on a panel behind the Discrete Outputs.
To access these outputs, point your mouse at the title Discrete Outputs. When a balloon appears, indicating
that you may toggle the foreground, click the left mouse button.
Dcrete Outputs Extended Outputs (
e xtended O utputs
Outputilocked iNTRDR
WPUMP1 PRSALM NORMAL
13 po I0man
Pro View 1. 70 User's Guide
Analog Outputs
VARPMP -
Manual 0 0.0 % t00
To the right of the first column of the Discrete or Analog Inputs is the Analog Outputs area. It may be
concealed by the second column of Discrete or Analog Inputs. To pull the Analog Outputs to the front.
point your mouse at the title Discrete or Analog Inputs in the second column. When a balloon appears.
indicating that you may toggle the foreground. click the left mouse button.
To the right of the Tagname there is a slide-scale which indicates the current percentage of full-scale
output (0% to 100%) both graphically and with text. Below the Tagname is the current mode of the output.
This mode can be changed from Manual, which indicates the output is under user control, to PID or PRO,
which would indicate that the output is involved in an output control scheme and is under automatic
control. These output control schemes are described in chapter S under PID and PRO options.
Printin2 the Setup to File
A more detailed analysis of the site configuration can be made by printing the setup data to a file and then
examining the file. To print the setup proceed through the foliow ing steps.
1. Pull down the File menu. Click on Print Setup. You can also use the ALT-F combination to pull
down the file menu.
Or Click on the Print Setup button
2. You w ilI see the Print Setup to File dialog box.
File Name:
sample.cfg
Directory:
cApioview
-re:
Drive:
.Z c: [MS-DOS_622] wOK
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a- Print Setup to File
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Pro View 1. 70 User's Guide
3. In the Drives area of the dialog box click once on the down arrow to pull down the Drives list then
click on the drive where you wish to place the printed setup file. The default is the drive on which
Pro'view has been installed.
4. In [he Directory area of the dialog box. click on the subdirectory where you wish to place the
printed setup File. Notice that the current directory is shown under the word Directory. To move
"up" in the directory tree. double-click on the level to which you want to move. To move "down"
in the directory structure, double-click on the sub directory. The default is the directory in which
Proview has been installed.
i [n the File Name area you will see the name of the suggested print file. The default extension for
the print file is .cfg. To change the filename click on the File Name text box and alter the name to
suit your needs. You can also select an existing .cfg file name by clicking on the file name in the
fie list box. When you click on a file the File name appears in the File Name box to confirm your
selection.
6. Click on the OK button to print the setup to the selected file.
If you are overwriting an existing file, a message box pops up to make sure than this is in fact-what you
want to do.
Prview for Series | .A word about Files:
Do not conjuse the site configuration file (.pvs) which
is a binary file with the printed setupfile (.cfg) which is
Overwrite Existing File? a text file. A text file can be viewed with a Iord
processing program while a binary file tpically
cannot.
Yes No Cancel
Examining the Setup File
To examine your site configuration more thoroughly, use an editor or word processor such as Windows
Write or Notepad to view the file you have just created. See the documentation that pertains to the editor
or word processor you are using to open the .cfg text file.
The file produced by our sample site is shown below. The first section consists of identifying information
about the ProControl unit and setup information about the site in which it is installed.
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Pro View 1. 70 User's Guide
Procentrol. 2eries 0:
PoView Oonfiguratin File :nformation
*Cctipe:: MIYRON R CMP'TR ----.
*ustomer: ECS RESEARCHq TES7 **.
* tate Lcaeion: SUPERFUND USA .*
* ...................,....,.. ... ,,,,..,,,,,,,,.
*.cption: 0-.
The: 3 -+
Sertal :urber:*
ate :5 :23/96
* Ime: 11:39:08
* pr ew: Version 1.70 ....*
7- N7-73 N T SYSTM ARE
CAGNAME :ESCRPT?:N
h eve.
We Level
ureSensor
Kiyn Air Pressure Sensor
cig2r 7.i.sure sw tch
A;ir stripper SUmP Higzh laves trPer Surp law evel
-amp 7esr 3ut-on
Rese: Sntde
We =- -*ZG Flo:w
WeI Pressure Transdu--er
7 ' 7ransmit-ter
SE7UP' ANGE
No, T7
D.NC,AL
I. OAL
A NC.AZ
AC,ST
2.NO,STA?
2. NC,ST,.3LTRT
0.N, ,Th 5-5?GP
A,PS 0-43 2T
A, Ep AL0-14
C h InpSt As .tDscrete) or CT/C?? :neut.
- i Ip S a nalogo or Tariable Inpuc.
- a Pu.se .C'eter : pu.
7 n: -Pu is a 'Normally Cnem) Jiscrete Inpu:.
-=3 i .: is a (Noray Closet tiscrete Input.
-ad it This input is "Active' when Its value is Curie the icw to high alarm levels.
N:- v Thas input as "Active" when its value as between. the low and high alarm levels.
3- ls' his i npu zshows a green LED in Preview when a is in its Active State.
A aar Ts input shows a red alarm bell in PrView when it is in its Active State.
-. his impu; performs an Emergency Shutdown.
SThas utPerforms a system Startup.
-7.s -7,ut puts the system IL Manual moce,
s iput puta the systen ia Auto mode.
-. ur performs a tame Test.
NCWZ-ED :N TH:S SYSTE ARE:
TAGNAME DESUPT:21 SEUP.
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - --- -- - - - -
- .-. U-Tp RPecovery Well Purp .2
? 32-p A Or stripper &o'wer
4 7. P'7M1 ri~nszer Pump
5 APY Xeeriag Pump Power
.PR ~ ... .igh Air Pressure Alarm 17,
SMPAm Hga sup Aar-, LT
- _XALM p Alarm A a A%wINMis ure A LArL7
:,dIncruder Aer 1,A
Nema pea o -ndicaror L A:'n= E=PNCTES
.- -- --
- -
s u
we -- : _ -n- os~~tWI'- . Cr Lo re5=trd -c eozesses l7-3Z
to pv I TOman
- .AG X'
q l lzMP
5 ArPH=
Ha:2 C '
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Pro View 1. 70 User's Guide
Gt- (rop Z- This outtut wi1 not respond to processes 21-6.
- 7m Test) - This outut has teen eclared as an alarmn i-t.
Al-(Alternate -mage; - This outtut ts displaved as an Icon cther than the detault switch.
THE AIAtcG OUTPUTs NcLUED :IN TH:S SYSTEM ARE:
4 TAGNAIE TAGNME :ESCR:PT:CN sETUP INPU-------------- --------- ---- - - -- - - IVARPMP We!l Puo =V -ariacle seed Drive P:D,REV HCLVL
2 SEQ MP Sequestering Agent Metering Pump Rate PROOR H20FLO
PI -h: outt e n a PD :Propcrttnal, ntecra, ter:.e) control loot.
PRO -Th:s output is - d an =pen 0cooc Prtooro-Ma control scheme.
PcR -The ?:; or PRC rop : n -n1the Forwara) direction.
REV -The ?D or PRO c - . run in the Reverse direction.
INPUT--Ths Tagname ser-e as toe onpt to the cntrol ^.cc.
Input and Output Configuration
The Inputs section identifies all enabled system inputs from I to 32 and describes how they are configured.
The bracketed section of each input's notes is used as its Tagname description. The notes feature will be
described later in this document. In addition. a Setup section further identifies each input in terms of its
signal nature, analog (A) or discrete (D), its configuration if discrete as Normally Open (NO) or Normally
Closed (NC), and its alarm displaying nature, Alarm (AL) or Status (ST). Discrete Inputs can also be
configured as functions such as Startup (STRT) or Emergency Shutdown (EMRG), and can be used as a
lamp tester (LAMP) which will illuminate any Discrete Outputs which are configured as lamps. A Range
is specified for all Analog Inputs as well as the Active State region, denoted Endpoint (EP) or Window
(W D).
See the ProControl manuai jbr a description of]Endpoinr and Window Active States.
Other configurations which are not displayed on the printed configuration but are available in system setup
include:
* Zero-clamped display - display will read zero instead of a negative number if less than 4 mA are
received at the input.
* Totalization - whether or not a quantity (GAL) is accumulated from a rate measurement (GPI).
Totalizer slope refers to the ratio of how often the totalizer is updated (fixed at I second) to the time
value implicit in the input's dimensional units. In this case H2OFLO is recorded in GPM (gallons per
minute). Since there are 60 seconds in one minute. the totalizer slope is set at 60.
* Pulse flow meter frequencies - the minimum and maximum pulse frequencies which correspond with
the minimum and maximum flow rate capabilities of the meter.
The Discrete Outputs section is similar except that there are some different Setup codes. Some outputs
may be assigned to groups (Gl,G2) which affect the way they are viewed by the process tasks. Outputs
which display an Alternate Image (lamp image) than the standard switch image are designated Al.
Outputs which behave as lamps are designated LT to indicate that they will be illuminated as a result of a
lamp test input entering its active state.
For ajurrher explanation of'Normally Open, Normally Closed. Groups and related terminology please see
the relevant section of the ProControl Series 11 manual
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Pro View 1.70 User's Guide
The Analog Outputs section details the setup of any enabled 4-20 mA output loops. There are two outputs
in this section: VARPMP and SEQMP. The Setup codes PID and PRO indicate whether or not the outputis involved in one of two analog output control schemes known as PID loops or open loop Proportional
control. The direction of the analog output control scheme is indicated by forward (FWD) or reverse
tREV. The input which provides the reference signal upon which the analog output scheme is based isdesignated under the INPUT heading.
For a further explanation ofPID or open loop ProDorrional control please see the PID and PRO Options
section of this manul.
in this particular seup. H2OLVL is the INPUT which indicates that in this PID loop, the vanable speed
pump VARPIP is using the water level H2OLVL to determine at what rate it should be pumping to
maintain a "set point" water level. The setup section indicates REV for a reverse action PID loop, In other
words. the analog output should respond in a sense opposite the corresponding analog input. In order to
decrease the input (water level over the transducer), it is necessary to increase the pump rate.
The other analog output. SEQ_MP represents a metering pump output whose rate should depend on the
system flow rate. H2OFLO, but in a proportional sense (PRO). Instead of using feedback to achieve a set
point as in the PID loop, this control scheme is not feedback oriented but simply bases the analog output
directly on the input with some proportionalty constant.
Process Tasks
The next section of the file pertains to what are called process tasks. These determine how the ProControl
unit responds to input changes while in Auto. Star.up or Shutdown modes. It is important to note that the
ProView software does not take any independent action itself. All control decisions are made by the
ProControl unit.
-cezs . LOWE-l -N
S.9:r W> ZP FF
7rzcers ; I' f M0:SCR :a ON THEN
celay for 5 Jeconds, Send Repor::?XC tl;FAC I;Page lPage #2), Ini:ace Shutdown, Switch MSTAIM ON 1CNCRM- -Fpage aesse A- r: AirPreuee HA h
Proces T: : 2 is N THEN5endtea '-AX ;A Re; -r-fl :FPaXg Shutd;agn, Swtch SwPALY ON RR
race Miessage: ' Prcsorol Alert: Ir sue AlarmPCroces = 2R sO
qend Rer::FAX a-;FAX -:;Pace 42;Page #0] Swica ONChMA ON
P Mess-ce: ' ?rcCn:rcl Aler: Orrudar Alet
-.-- ---. A ? P h2 is 7 THEN
3 e zCr#tF*A2( 4lA ; Pa.e ;l;Pare #z ....... [A CF
Pace Mlessace:Pontc Alert : Low Flw n #el ,
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Pro View 1.70 User's Guide
Process 8. 2f PHTRIS is 01 THEN
Delay for 5 Seconas, Send Recot FAy a';AX ;;Page 41;Pace :, :notiaze Shutdown, Switch PH ALM ON AOD
NCRMAL OFF
Page Message. 'Procontrol A.ero. PH AlarmProcess 9: IMolST? scF AND SUMPH: :s OFF AND A:RPRS is CFF AND H20FLO is OFF AND PHTRNS is OFF THEN
Switch NCRMA N I
Process 13: :f STPRHi Is ON THEN
Delay -or s Seconds, Swirc TFPUMP ON
Process -1: Ic S=PROC a ON THEN
Switch 7TPMP 'FF
Startup 2:
Switch STRIPR ON
StartuP n:
Celay for 10 Seconds Jwi-sh WPAP2 ON AND MP_PWR ON
StartuP 3.
Switch PRSALM F? AZD SMPALM OFF AD PHALM 'F? AND MSTALM OF? AND 2iTRDR OFF
Shutdown 1:
Switch WPUMPI OFF AND NP'71I2 'O) AND TFPUMP OF? AND MP_PWR o??
Shutdown 2:
Delay for I Minute, Swiozh ST P 0F?
This samole site has a fairly straight-forward process flow. On startup. some of the system outputs are
switched on sequentially and all alarm indicators are switched off. On shutdown, all outputs are turned off
and a FAX message is generated. The process tasks are mostly self-explanatory. It is important to
remember how and when the process tasks are run:
* Process tasks are run continuously while the ProControl unit is in AUTO mode. No automatic
action is taken in MANUAL mode.
* Startup and shutdown processes are run in sequence. When the Startup sequence is finished the
unit is placed in AUTO mode and the Process Tasks are run. If any Startup process in the
sequence fails, then all the non-lamp outputs are turned "OFF" and the unit reverts to MANUAL
mode. A Startup process fails when any IF condition is not satisfiod for 60 seconds after the
Startup process begins. The Startup sequence begins when the ProControl or ProView operator
initiates it. The Startup sequence can also begin when power is first applied to the ProControl unit
if the "Auto Startup" option has been enabled.
* The Shutdown sequence works in a similar manner. When the Shutdown sequence is finished, the
ProControl unit reverts to MANUAL mode. If any Shutdown process in the sequence fails (is not
run after 60 seconds), then all the non-lamp outputs are immediately turned "OFF" and the unit
reverts immediately to MANUAL mode. The Shutdown sequence can be initiated either by the
ProControl or ProView operator or by a process task (Processes 3, 4, 5, and 8 do this in our
example).
Process Capability
The ProControl runs process tasks which are based on Boolean "AND" logic. There are 64 available
processes. 16 of which can be used as part of a startup sequence. and 16 of which can be used as part ofa
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Pro View 1. 70 User's Guide
shutdown sequence. There is no Boolean "OR" command in ProControl logic. If alternate conditionsshould perform the same task, more than one process will be necessary. Each process has the followingcapability:
" Can be based on manysimultaneously existing L1O conditions
* Include short or long delays for de-bouncing or simple time delay
* Use memory variables for linking processes
* Cycle outputs with timers or during certain specific times of the day
e Perform system shutdowns
* Send reports to fax and/or pagers
If you wish to modify the ProControl programming, please contact us br assistance.
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Pro View 1. 70 User's Guide
CHAPTER 3: ESTABLISHING COMMUNICATION
T his chapter explains how to connect ProView to the ProControl unit by local serial cable and byremote modem.
By itself, ProView does not reveal %erv much about youir site. It must be connected to the ProControl unitin order to yield any data.
Local Connection
To establish a local connection, run through the following steps:
1. Use the local serial cable supplied with ProView to connect the computer which you are using to aProControl unit. One end of the cable :erminates with a female 9-pin connector. Use this end toplug into the serial port on your computer. If the CONI port on your computer is a 25-pinconnector, you need a >5-pin (DB25) to 9-pin (DB9) adapter. This is not supplied with ProView.The other end of the serial cable is terminated with a 6 pin RJ-I l "telephone" connector. Use thisconnector to plug into the right hand side of the ProControl unit. You must first remove the cabewhich connects the ProControl's modem to the ProControl unit itself.
Warning: Be sure ani reconnect the modem cable to the ProControl unit after you arefinished. if
you do not. no remote communications ill be possible.
Krning: If/ he ProCcnirol unit or modem is powered OFF jbr any reason, make sure they remamnconnected /or the jirst 45 seconds after poter I beobre unplugging the cable to attempt a localconnection. Otherwise the modem may not be properly configured.
2. Pull down the Communications menu. Click on Local. You can also use ALT-C.
Or Click on the Local Connect Toolbar button.
You will see the Local Communications dialog box.
Select Port
C COMl C COM3
(aCOM2 C COM4
Port Status
Connect to ProControl
D isConnect from ProControl
icE EK
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Select the CONI nor to hich the ProControl is connected by clieking on the -radio button" next
to the C()\l ort ou nxant to usc. CONl ports I through -I are sup'por:cu
4. lick on the Connect to ProControl button.
You kll ee tatus nessaecs in both the Port Status area of the Local Communication dialog box
and in the lcfnmost information box on the main screen. Lsually you xwill see Trying Local...
6iiooned b LOt AL CO NECT if the attempt is successfil. If the attempt is unsuccessful you
iil see message oxas outhIlining the suspected problem.
0. A tIer connect in, click on the OK button to get rid of the Local Communications dialogt box.
A er estabiish ing a ocal connection. ProViewx %ill perform an initial scan of site conditions. This will
take a tew. moments durnu xx hich tirne the mouse pointer wx ill turn into an hourilass. After the initial scan,
updates udli occur exery I seconds or so.
Below is a v ie" of the main screen after a local connection has been established.
File Enable Communications System Datalogging Eassword Help
Discrete Inputs Discrete or Analog Inputs Analog Outputs Discrete Outputs |
HIWEL1 Q H20FLO 50 VARPMP OP
LOWELi 0 PM PlO 74.5 % Output: Locked
MUISTR Q H20LVL I F 40 SEQ MP
_0 20.0 F PRO 0 18.9 % 00WPUMP1 PR
AIRPRS Q PHTRNS 14
DOOR 68 WPUMP2 SMPAIM
STPRHI ] -n
STPRLO Q STRIPR PHALM
LMPTST Q
RESET 0 TFPUMP MSTALM
MPPWR
No Previous Shutdown Reported
LOCAL CNNECT Alarms OFF
Auto S ill 1)Report ON
Notice that the screen has been updated to reflect the current operating conditions at the site.
bottom of the screen. the message boxes haxe been filled in as well
At the
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Remote Connection
For a remote connection, the procedure H a !t:-c different Foilow these steps:
. Make sure that your modem s connw :Wd properly. :o
manufacturer's instrucrions. Don 'rge: to pluu :he
must be Hayes compaible and capay: 'iteratcn at
- our computer's serial port by following the
phone line into your modem. Your modem
'400 baud.
2. Pull down the Communicatnons menu Chek on Remote You can also use ALT-C.
Or Click on the Remote Connect Toolbar nutton.
You will see the Remote Conrnuniai:ons diog box
Select Port
F COM1
(a CO42
C COM3
(7 COM4
Call Status
Site Phone Number
1 [603]555-1212
Initalization String
M1V1NDS37=6
Set Default String
Dial Remote Site
Hangup Phone Line
Canel'
3. Select the COM port to which your modem is connected by clicking on the "radio button" next to
the COM port you want to use. C 0\1 ports I through - are supported.
4. Check to see if the Site Phone Number K the one you want to dial. If not, click on the phone
number text and chang' i'
5 Examine the Initial ization Stinn to 'ee if it is correct for your type of modem. An "AT" is
automatically sent before :he initias:ion strinu. If yout are unfamiliar with "AT" commands. the
default of MlV lN0S3-=o ill usuall a ork just tine if you have a 9600 or 14400 baud modem. If
not, enter the AT commands which tu force your modem to connect at 2400 baud. Higher speeds
are fine but unnecessar and may- make communication less reliable over noisy phone lines. If you
are using a strictly hi baud mel m then you w ill probably get an error if you use the
M'1VINOS37=6 string. Use l IV stead. You may want to consult your modem's manual for
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Pro View 1.70 User's Guide
further details on which "AT" commands it supports. If you need to change the initialization string
then click on the initialization string text and edit it.
6. Click on the Dial Remote Site button.
7. You will see status messages in both the Call Status area of the Remote Communication dialog box
and in the leftmost information box on the main screen. Usually you will see the following
messages:
Trying Remote...
OK
Setup...
Dialing...
CONNECT 2400
REMOTE CONNECT
ProView is attempting to contact the modem
ProView has successfully connected to the modem
ProView is sending the Initialization string to the modem
ProView is dialing the site phone number
Connection has been established with the remote modem
Connection has been established with the remote ProControl
unit
S. If the attempt is unsuccessful you will see message boxes outlining the suspected problem.
9. After connecting, click on the OK button to get rid of the Local Communications dialog box.
The simplest way to end a connection, to hang up in essence, is to click on the Disconnect button on the
Toolbar. This works for either a local or remote connection.
Alternatively. you can re-open the Local or Remote Communications dialog box and click on either the
Disconnect button (Local) or the Hangup button (Remote). After ending the connection, you should see
NOT CONNECTED
NOT CONNECTED in the lower center message box.
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Ending a Connection
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Sending a Memo
A useful feature of the ProControi Series I is the abtityx to :ransmit hort memos to a site operator. From
ProView, you can send a '0) character meosae : he L CD of the ProControl unit. The site operator must
acknowledge your memo before returning to h:, normal display The goal of:his feature is to aid in
communicating with a person at the site hile he phoie ine is Im ise tor a connection to the ProControl.
To send a memo, follow these ;teps
L Pull down the Communications menu and select the menu item Send Memo
Send a memo to the remote ProControl operator
Mvrcr[, raernmb e t.
Send New Memo to ProControl e l
2. Ty ie your memo onto the screen of the MemoPad. which is a %isual representation of the
ProControl Unit. It will appear on the ProControl LCD exactly as it appears to you on the
NemoPad. two lines at a me. Words wviII autormaticaly w rap around to the next line, but yoi
may enter Carriace Retun) i characters to immediately jump to the next line if it is
necessary. HowNeer. the fewx er charac:ers you use, the longer the text message you can
type. since each represents 20 character. The \Mesace Length counter will keep track
of the number of text and decrease to let you know how many more characters can be entered.
3. You can vi Cour memo at a macIgniFed scale Itf ouA wish 3y clicking the right mouse button
when the pointer s ox er the text % indaowk. the text w ndon w ill become significantly wider for
you to edit larger memo> without ha7n 0 o Neml ap and doxn. To toggle back to the demagnified ; iew, repeat this procedure.
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Pro View 1. 70 Users Guidek
MemoPad
Send a memo to the remote ProControl operator
Myron, remenber to shut out the lights.
Call me when you get back to the office.
IE II I a I kno I
-k4,
Field Up Down Mar M la Enter* rekipjflwn I ode IModes re
I Message Length s 81 CA = 0 Max Length is 20
Send New Memo to ProControl
4. Once completed, you may click the Send New Memo to ProControl button to display the memo
on the ProControl LCD, OK to save the memo but not transmit it, or Cancel to abort the entire
procedure.
5. The Ack button on the MemoPad will flash red to indicate when the ProControl operator has
acknowledged your memo. Your computer's speaker will also beep to accompany this visual
indication.
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Pro View 1. 70 User's Guide
CHAPTER 4: MANAGING YOUR SITE
T his chapter explains how to change the way your ProControl system operates by switching betweenMIanual and Automatic nfodes. initiating a startup or shutdown sequence and changing other key
sy stem parameters.
Switchin2 Between System Modes
There are four modes of operation for the ProControl Series 11: Manual. Automatic, Startup and Shutdown.
To initiate a switch to a different mode, simply click on the appropriate Toolbar button
or click on the Systems menu and then on the Process Operations sub menu.
AUTOMATIC Mode: Click on the AUTO Mode button on the Toolbar (The Coffee Cup).
Alternatively, Click on the Systems menu, then on the Process Operations sub menu and finally on the
Auto Mode sub-sub menu.
MANUAL Mode: Click on the MANUAL Mode button on the Toolbar cThe Hammer). Alternatively,
Click on the Systems menu, then on the Process Operations sub menu and finally on the Manual Mode subsub menu.
STARTUP Mode: Click on the STARTUP button on the Toolbar (The Green Traffic Light.
Alternatively. Click on the Systems menu, then on the Process Operations sub menu and finally on the
Startup S\stem sub-sub menu.
SHUTDOWN Mlode: Click on the SHUTDOWN Mode button on the Toolbar (The Red Traffic
Lighu. Alternatively. Click on the Systems menu, then on the Process Operations sub menu and finally on
Shutdow n System sub-sub menu.
EMERGENCY SHUTDOWN: I Click on the Emerg OFF button on the Toolbar (The Red Hand).
Alternatively. Click on the Systems menu, then on the Emergency OFF! sub menu.
You can monitor the current system mode by examining the message box at the bottom of the main screen.
Manual The system is currently in Manual mode.
Auto 1 The sy stem is currently in Auto mode, the last process task run was process task #1.
Start 1 The system is currently in Startup mode, the last startup task run was startup task #1.
Shut 1 The system is currently in Shutdown mode, the last shutdown task run was shutdown task =l
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In addition you can monitor the last action to initiate the Shutdown mode by examining the lower righthand message box.
Last Shutdown 15:18:19,5/23/96, MOISTR
No Previous Shutdown Reported
System Operations
There are several other important system parameters which can be set by ProView.
Date & Time
The ProControl unit keeps a Date and Time clock which it uses to time stamp datalogging information
and other important system events.
To set the Date & Time:
1. Pull down the Systems menu. Click on System Operations. Then click on System Time. You can
also use ALT-S.
Or Click on the System Time Toolbar button. You will see the Date & Time dialog box.
System ProControl
03/11/95 3/11/95
15:20:32 15:20:27
ProControl_= System
2. On the left side of the dialog box in the System panel is the current date and time according to your
PC. On the right side of the dialog box in the ProControl panel is the date and time according to
the ProControl unit. The two clocks should not varv by more than a few minutes. Follow the
procedure outlined below if you need to change the time.
3. To set the ProControl's clock equal to the PC's clock click on the ProControl = System button.
4. To set the ProControl's clock to a specific time use the time spinners 41 to change the
ProControl's clock. The upper spinner changes the date and lower set of three spinners change the
hour, minute and second (left to right respectively).
5. To set your PC's time (System :ime) use the Program Manager in Windows.
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Pro View 1.70 User's Guide
If you are not connected to the remote unit then the ProControl panel in the Date & Time dialog box is
disabled.
Note: Dailight Savings Time is not supported You will need to make any necessary changes manuall
Wri-ning: Changing the time by a large amount can lead to discontinuities in the datalogging histor o
iour ProControl unit.
Alarms
An alarm is an audible indication to the operator that an input signal is in its "active state".
On the ProControl unit, the beeper sounds if the "Alarms" are "Set", the unit is in manual mode and an
input :s in the active state. The Alarm continues to sound until it either is acknowledged by the operator or
times out by itself.
In ProView, a "Beep" sounds from the PC speaker if the 'Alarms" are "Set", and an input that has been
confkured as an "Alarm Input" enters the active state. No acknowledgment is necessary.
The current state of the alarms can be monitored by the message box at the bottom right of the main screen.
Alarms OFF
To change the current Alarm state:
Pull down the Enable menu. Click on the Alarms sub menu choice. The sub menu reads 'Set
Alarms' if the alarms are OFF and Turn Alarms OFF' if the alarms are Set. You can also use
ALT-E to reach the Enable menu.
Or Click on the Alarms Toolbar button. If the Alarms are Set then they will be turned off. If they
are off. then clicking the burton will set them.
If you trv to change the Alarm state and ProView is not connected to the remote ProControl unit then a
message box appears.
Remote Reporting
A report is a FAX or a page message sent by the ProControl unit. In order for any reporting to occur.
Remote Reporting must be enabled. The current status of Remote Reporting is indicated at the bottom
right of the main screen. Report OFF !
To enable or disable remote reporting:
1. Pull down the Enable menu from the menu bar.
1 If Remote Reporting has a check mark next to it then Remote Reporting is enabled. To disable
Remote Reporting click on the word Remote Reporting.
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Pro View 1.70 User's Guide
3. If Remote Reporting does not have a check mark next to it then Remote Reporting is disabled. To
enable Remote Reporting click on the word Remote Reporting.
Log Off Remote User
This function is used occasionally to reset the remote ProControl s LCD screen to the password menu. [t is
used to ensure that password protection remains in effect for the ProControl unit.
To Log Off the remote user:
Pull down the Systems menu. Click on System Operations. Then click on the Log Off Remote User
sub-sub menu. You can also use ALT-S to reach the Systems menu.
Initiate FAX NOW!
This function is the equivalent of pressing FAX NOW on the ProControl unit. It is used to generate and
send an immediate FAX report to the currently enabled FAX numbers. FAX reports must be enabled in the
System FAX Report dialog box and ProView must be connected via modem (remotely) for this command
to proceed.
Since both the modem and FAX system of the ProControl use the same telephone line, ProView will
disconnect from the ProControl unit (hangup) after issuing this command to free the remote phone line for
FAX use. Normal FAX back operations and times will not be affected.
To initiate an immediate ProControl FAX back:
1. Pull down the Systems menu. Click on System Operations. Then click on Initiate FAX NOW! sub
sub menu. You can also use ALT-S to reach the Systems menu.
2. ProView will disconnect from the ProControl unit after issuing this command.
Initiate New FAX NOW!
This function is identical to Initiate FAX NOW! except that you can specify a number which is not
currently part of the ProControl's configuration. This feature is useful for sending an immediate fax report
to someone who does not receive regular fax reports but would like an occasional update.
To initiate a New FAX NOW:
1. Pull down the Systems menu. Click on System Operations. Then click on Initiate New FAX
NOW!
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Pro View 1.70 User's Guide
Proview for Series I1
Enter the FAX number to which the FAX report will be 'l
sent.
2. ProView will alert you first that you will be disconnected from the system in order for the fax to
proceed. Then you may enter the FA.X number to which the fax report will be sent. Enter the
number and click OK to proceed. or Cancel to abort. Don't forget to use "I" and the area code or
other appropriate prefix if it is a long distance call from the remote site.
Trend Graphing
ProView can also perform real-time trend graphing while you are connected either locally or remotely to
the ProControl. A 5-minute trend can be displayed in the lower left hand side of the ProView window.
To start trend graphing:
I. Position the mouse at an analog input or analog output tagname.
Click the right mouse button until the Balloon that appears contains the word "Trend". Then click
the left mouse button to select Trend.
H2 L ' ' ' ' so
__ We tt2 H20 Fiow : T rend J
3. The trend will be updated as long as you are connected to the ProControl. If you wish to observe
another trend, repeat this procedure and the new trend will replace the old trend.
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Discrete Inputs Discrete or Analog Inputs Analog Outputs Discrete Outpuis*f I
HIWELl Q H20FLO so VARPMP , 7
LOWELl Q CPm PID _ 74.5 % Outputfocked
MOISTR O H2LVL I 40 SEQMP
SUMPHI 020 20.0 . T . PRO 0 14.1 % WPUMP1 PRSALM
AIRPRS QTPHTRNS I 'I' I
DOOR 6.9 WPUMP2 SMPALM
STPRHI
STPRLO
LMPTST Q
RESET
STRIPR PHALM
TFPUMP MSTALM
C-P
___ ___ _ ___ ___ __ MP.PWR _ _ _ _
so Trend for H20FLO in GPMT f F nNo Previous Shutdown Reported
LOCAL CONNECT Alarms OFF
Auto 9
fill i I Report ON
4. To stop trending and return the panel to its original empty state. click on the word "Trend" in the
trend panel.
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Fie Enable Commuincations iystem UataIoqqinq Password Hel
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CHAPTER 5: CHANGING SYSTEM PARAMETERS
This chapter explains how; to alter operational data such as the state of a discrete output, analog alarmlevels and FAX and Datalogging serups. Almost all of these changes must be attempted whileProView is connected to the remote ProControl unit. [f you are not connected you will see a messace
like the one below reminding you to connect before attempting a change.
This command is unavailable because ProView
* is not connected to a Remote ProControl unit.
Swirchin2 an Output State
The state of a discrete output can be changed manually by clckinu on the virtual "switch" associated with
its Tagname. If the switch is on the left hand side and gray then the output is "OFF". If the switch is on
the right hand side and green then the output is "ON". You must also have the outputs "Unlocked" in order
to make any output changes. The outputs can be locked and unlocked by clicking on the virtual "slide
switch" at the top of the discrete output section of the main screen.
Outputs Locked Outputs Unlocked
The Output Lock feature is included to prevent inadvertent output changes. You should leave the slide
switch in the Locked position whenever possible.
Keep in mind that if the ProControl unit is in Auto mode any discrete output change you make may be"overridden" by a process control task in effect. Atake sure that you are familiar with such possibilities or
switch to Manual mode before changing the state of a discrete output.
MP1 To change the state of a discrete output click on the virtual toggle switch.
2.WPUMP1 The toggle switch will change positions and append a "?" after the Tagname. This
indicates that the command was sent to the remote unit but that confirmation of the state change
has not yet been received. You w ill not be able to make any other changes to this output until the
confirmation has been received.
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Pro View 1. 70 User's Guide
3. WPUMP1 The "" will disappear after confirmation of the state change has been received from
the ProControl unit.
Depending on your site configiration. you may be able to change options that affect how the discrete
outputs in your system operate in Automatic mode.
Process Groups
If your site has been configured for Process Groups. then you can switch between Group I and Group 2
Process Groups are a way to allow a particular discrete output to respond only to a certain group of process
tasks. This is usually used when, for instance, you have a pump that sometimes pumps water to one
treatment unit and at other times pumps to a second treatment unit. If something should cause a shutdown
of the first treatment unit you may want only those pumps currently pumping to the first treatment unit to
be shutdown. Process Groups give you the ability to make that distinction.
Output Cycle
As part of your site configuration. a discrete output may have been set up as a "Switched" output. This
option gives your site the ability to cycle an output on and off continuously at a duty cycle specified in the
output options dialog box. It can also give "our site the capability to restrict a process task's control over
particular discrete output to certain times of the day.
Output Options
To change an output option proceed through these steps:
1. Place your mouse pointer over the output's Tagname until a balloon appears. Click the right
mouse button until "Output Options" balloon appears.
ca I ITRIPR
0utput Options|
2. Click the leji mouse button.
3. You will see the Set Output Options dialog box. The Set Process or Set Output Cycle panels may
not be visible if those options do not apply to your site. Both panels will be disabled if ProView is
not connected to a ProControl unit.
Set Proces Set Output Cycle
r~ Enable (e Group 1 Time ON 00:30
C Group 2 Time OFF 02:00
Canc O
To change Process Groups click on either the Group I or Group 2 radio buttons in the Set Process panel.
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I. To change the Output Cycle times click on the time you want to change and enter the new time in
an hours:minutes format. Alternatici. click on the up or down spin buttons to increase or
decrease the time you want to change.
2. Click on the OK button to confirm the changes and send the to the ProControl unit. Click on
Cancel to get rid of anv changes.
3. If you click on the OK button and are not connected to the remote ProControl unit then a message
box appears warning you of that condition. Your changes are not saved.
Hour Meters
Hour meters give you the ability to know exactly how long an input or output has been ON as well as how
long it has been OFF. For analog inputs, these hour meters indicare the time the input has been in and out
of its Active Stare (for an explanation of Active State, see the accompanying ProControl Series II manual).
This information is useful for monitoring electrical consumption or for projecting equipment replacement
time. These Hour Meters are updated everv second on the ProControl unit. The displayed time resolution
will be tenths of minutes.
To read the Hour Meters. follow these sters:
I. Position the mouse pointer over the 1,O point's Tagname until a balloon appears.
Hour Meter
2. Click the right mouse button until the balloon reads "Hour Meter".
0. Once the appropriate balloon appears. click the left mouse button. The Hour Meter dialog box
appears.
4. The Hour Meter box contains information in the form of Hours:Minutes.10th Minutes for both
ON time and OFF time. The "Duty Cycle" or ratio of ON time to total time is also displayed. It
may take a few seconds for the display to be updated once the dialog box appears.
Total Time ON Total Time OFF Duty Cycle
000,105 : 00.0 000,026 : 15.0 80.00 %
5. To edit the Total "ON" time or the Total "OFF" time click on the total time text and make the
required changes. The time text will become highlighted when you click on it and must remain
highlighted for you to edit it.
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Pro View 1.70 User's Guide
6. When you have finished editing either the Total Time "ON" or "OFF" hit the enter key to confirm
the changes and send the new value to the ProControl unit.
7. Move the cursor away from the text areas so that it again becomes a pointer shape to enable new
hour meter updates from the ProControl unit.
Notes
Each 1/0 point can have its own set of associated notes. You can attach
purpose of the [/O point or define the L 0 point in more derail. This can
results from the limitation of six characters in each point's tauname.
notes which explain the functional
eliminate some confusion which
To edit an 1/0 point's notes follow this orocedure:
1. Position the mouse pointer over the L O point's Tagnarne until a balloon appears.
SUPii)
AU H =Sump LeveI: Notes
2. Click the rigzht mouse button until the tag-descriptive balloon also contains the word "Notes".
3. Click the left mouse button to enter the "Notes" feature. The Notepad dialog box appears.
4. Click in the Notes window to edit any notes. The notes enclosed in angle-brackets (i.e. )
will also appear at the top of the main screen when the cursor is placed over the tagname of an L O
point.
High Sump Level
5. Press Save to save your notes and or definitions or press Cancel to exit without saving. You must
also save the site file before exiting ProView to retain any changes made in Notes.
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Analog Alarm Levels
The analog alarm levels define %%hat parts Ot an analoU inputs ranue are considered "active" and which arenot. This affects not only the color of L E D", and bar graph on the main screen but also can affect process
operations if the analog input is used in a process task.
To set an analog alarm le'el followk the procedur: outlined below.
1. Position the mouse pointer oer :ne anaoc C points Tagname until a balloon appears.
H20 S0 so
2. Click the right mouse but:on ntiii the balloon reads larm Levels".
3. The Alarm Levels dialog box arears.
AanmEeBls forH
Low Alarm
5.00 GPM
High Alarm
:40.00 GPM
Cance1 EK
4. The present alarm le els are show'n in text as wvell as in the position of the sliders. The low alarm
level is shown in the upper half of the dialog box w hile the high alarm level is shown in the lower
half of the dialog box.
i To change the current alarm letel click., and hold on the red pointer part of the slider and move your
mouse to the left or right. \Io' e the nouse to the left to decrease the alarm level or to the right to
increase the alarm level As you mox the slider the text display is updated with the new current
value of the alarm lcvel. I yOu tr and moe the low alarm level higher than the high alarm level
the slider -snaps back to a letel equal or just below that of the high level after you release the
mouse button. If you ix and Iox e :he high alarm lexel lower than the low alarm level the slider"snaps back" to a let el equal or just artOe that of the low level after you release the mouse button.
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Pro View 1. 70 User's Guide
larm Levels for H20FLO I
6. Another way to change an alarm level is to click on the alarm level text and then type in a
value for the new alarm level. If you press the enter key after entering the new alarm level then
the alarm level is updated and the new value is sent to the ProControl unit if ProView is
connected to it.
If Pro View receives an updated alarm level from the ProControl unit, it will update the A larm Levels
dialog box with the new information. If you are in the middle of changing an alarm level your changes
mayv be overtritten b the newv received alarm level. This can happen if someone is changing the alarm
levels on the ProControl unit through its LCD display and keypad at the same time you are viewing the
alarm levels with ProView. It also happens even 30 to 40 seconds when ProView initiates a newfidl scan
of ProControI data.
7. Click on the OK button to confirm the changes and send them to the ProControl unit. Click on
Cancel to get rid of any changes.
8. If you click on the OK button and are not connected to the remote ProControl unit then a
message box appears warning you of that condition. Your changes are not saved.
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Totalizers
If your site configuration includes an analog input to w hich a tlow meter is connected, it may also include a
totalizer. Totalizers give you the ability to view the cumrulative total of a flow-based analog input.
To view the totalizer for a flow-based analog input:
I. Position the mouse pointer over the analog input's Tagname until a balloon appears.
2OFLO ''''''''50
ficed 24.88 CPM
2. Click the right mouse button until the balloon reads 'Alarm Levels". If this balloon never appears
then this input is not configured to pro% ide totals.
3. Press the left mouse button to see the Totalizer dialog box.
- Tta=zer for H20FLO
Total Flow
5.784 GAL
4. The Total Flow for this input since the totalizer was last reset is displayed. It is updated evexry
second while the dialog box is visible and " hile ProView is connected to the ProControl unit.
. If you would like to set the totalizer to a different value then click on the value displayed in the
dialog box. Enter the new value for the totalizer and press the enter key.
6. Click on the OK button to close the Totalizer dialog box.
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Pro View 1.70 User's Guide
PID and PRO Options
Analog outputs can be involved in one of two different control schemes. The first is known as a PID loop
and is a common control strategy which employs feedback to achieve a stable, desired input set point by
continuously modifying an associated variable output. The second control scheme is known as an open
loop proportional (PRO) output. In this scheme, there is no feedback and no setpoint. However, the analog
output is related to an input signal by some proportionality constant.
You can modify the PID parameters of a PID controlled analog output (the Proportional, Integral, and
Derivative gains) if your analog output is not responding smoothly or quickly enough to changes in its
associated input. The Proportional gain specifies the output level based on the error signal produced
between the Set Point (desired input level) and the actual input level. Integral gain smoothes the output
level based on the tracking history of the input to the Set Point and provides a means of good steady state
control. Derivative gain will allow the output to respond to quick changes in the input and provides a
means of establishing good transient or instantaneous control.
In the case of a PRO output, you can modifv the constant of proportionality to change the amount the
output depends on its controlling input. A value of 100 indicates that the output should be 100%.when the
input is at full scale.
The Max Change parameter allows you to regulate how much the analog output can change in one control
cycle (one control cycle is about 1/4 of a second).
To change the PRO or PID parameters, Set Point, or Max Change parameters:
1. First make sure that the analog output is in Manual mode. If the text beneath the Tagname reads
'NManual" then proceed. If not, click the word PID (or PRO) and wait a second for it to change to
Manual.
Note: I/'the analog output is still engaged in a P[D or PRO algorithm when you make changes to its
gains, whatever piece of'equipment is connected to it may be damaged from large output swings. Be
sure to place the output in Manual mode first!
1 Position the mouse pointer over the analog output's Tagname until a balloon appears.
VAR IP %
Manual PID OPtions 50.0 %
3. If the balloon reads "PID Options" then proceed to the next step. If not, click the right mouse button
until the correct balloon appears.
4. Press the leN mouse button to enter the PID Parameters dialog box.
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Pro View 1.70 User's Guide
P Gain 13ain D Gain MAX Chae'
1o 2 2- 10
P Gain MAX Change
0I 0
7.5 1.0 1 0 5.0 %o
Set Point for H2OLVL
25 5.0 % . 48
dance OK
20.0 Fr
. To change any of these parameters you can either click and drag the sliding scale or click the text area
and enter the value through the keyboard. You can also change the upper limit on all of the gain scales.
If you change the upper limits, the slider's position will change accordingly so that its position
correctly relates to the lower and upper limits displayed.
If you wish to saxe your changes, click the OK button. If not. click the Cancel button.
3. To restart your PID loop. click the word Nlanual underneath the Tagname and wait a second for it to
change to PID. Your new parameters are now being used.
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Pro View 1.70 User's Guide
Site Information
Site Information is site identification data used in the FAX report and in
ProView.
To view or change the Site Information proceed through the following steps:
1. Pull down the File menu. Click on Site Information. You can
Information dialog box appears.
the various files printed by
also use ALT-F. The Site
Customer Name
ABC ENVIRONMENTAL
Site Location
SUPERFUND USA
FAX Iecipient
MYRON R COMPUTER
iCacel
2. To change the Customer Name, Site Location or FAX Recipient click on the text you want to
change and enter the new text. Only uppercase letters, numbers and blank spaces are allowed.
3. Click on the OK button to confirm the changes and send them to the ProControl unit. Click on
Cancel to get rid of any changes.
4. If you click on the OK button and are not connected to the remote ProControl unit then a message
box appears warning you of that condition. Your changes are not saved.
FAX Report Setup
This setup screen is used to change when and where the ProControl's FAX report is sent. You can also
disable the FAX report entirely.
To view or change the FAX Report Setup proceed through the following steps.
1. Pull down the Communications menu. Click on FAX Report Setup. You can also use ALT-C.
Or Click on the FAX Report Setup Toolbar button. You will see the FAX Report Setup dialog
box.
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2. If Remote Reporting is not enabled, the contents of the dialog box will appeardisabled. .grayed out" or
3 The first and second FAX number panels determine where and what kinds of FAX reports are sentby the ProControl unit. There are two kinds of FAX reports generated by the Series I. Ascheduled FAX report occurs on a regular basis while an Alarm FAX Report can only occur whena Process Task or shutdown is completed. Whether a Process Task does in fact send a FAX reportdepends on your site confinuration. To enable either kind of FAX report click on the Alarm orScheduled check box and make sure it contains an -X". To disable FAX reports click on theappropriate check box and make sure it does not contain an -X". If you enable Scheduled FAXreports the Alarm FAX reports for that same number are automatically enabled for you. You cannot enable only Scheduled FAX reports.
4. To change the phone number to which the ProControl will FAX reports click on the phone numbertext and enter any required changes. You can use delimiters like parentheses and dashes to makethe phone number easier to read. The ProControl can FAX to two different phone numbers. It willmake up to three attempts to send the FAX. If the first try is unsuccessful. the second try shall beinitiated 5 minutes later, If the second rv is unsuccessful the third tr; will be 10 minutes after thefirst. If the third try is unsuccessful the faxback attempt shall be abandoned. The ProControl wtry both phone numbers (if they are both enabled) on the first try before moving on to a secondattempt.
The Scheduled FAX panel determines what kind of FAX report schedule is maintained. To selecta daily FAX report click on the Everv Day d button. Then click on the text just to the right of thebutton and enter the time you would like the FAX report to be sent. The time is in 24 hour formatso enter 17:00 for instance for 5 p.m. or 00:30 for 12:30 a.m. To select a shorter periodic intervalfor FAX reports click on the At [nterals of button. Then click on the text just to the right of theAt Intervals of button and enter the time between FAX reports. To establish a FAX report everyhour you would enter 01:00 The smallest interval you can enter is 30 minutes or 00:30.
6. The Next Scheduled FAX variable is set by the system
completed to show you when the next FAX will be sent.
instance, the ProControl is set to FAX every hour but you
every time a scheduled FAX report is
You can also change it yourself if, for
wx ould like it to skip a few hours before
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FA RFeprt Se l tip
1st FAX Number 2nd FAX Number
1 (800) 555-5555 555-5555
fi Alarm FAX fi Alarm FAX
1i Scheduled FAX F Scheduled FAX
Scheduled FAX 6 Every Day @6: 04:00
C At interval: of: 00:30
Next Scheduled FAX @ 04:00
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Pro View 1. 70 User's G,
resuming the FAX reports. To set the Next Scheduled FAX time click on the time text in that
panel and enter the new time in 24 hour format. Warning: / iyou enter a Vext Scheduled FAX time
that is earlier than the current nime as dtcermined by the ProConrol's clock vou will prevent any
scheduled Jxes ,,roi occurring until the next das at that tine.
7. Click on the OK button to confirm the changes and send them to the ProControl unit. Click on
Cancel to get rid of any changes.
8. If you click on the OK button and are not connected to the remote ProControl unit then a message
box appears warning you of that condition. Your changes are not saved.
Pagin2 Setup
This setup screen is used to change the information pertaining to the two hand-held pagers which
can be
alerted by the ProControl if a specific event occurs (i.e. system shutdown). You will probably
need to
contact your paging service directly to obtain some of this information.
To view or change the Paging Setup proceed through the following steps:
1. Pull down the Communications menu. Click on Paging Setup. You can also use ALT-C.
Or Click on the Paging Setup Toolbar button. You will see the Paging Setup dialog box.
I~s Pae Seu
Pager Service Number 1
1 (800) 555-5554
1i Enable Page
$h Numeric Pager
C Alpha Pager
Pager Service Number 2
555-1234
LW Enable Page
C Numeric Pager
@I Alpha Pager
1st Pager Identification # 2nd Pager Identification i
5960104 8125375
There are no Pages in the queue
Baud Rate for Paging
C 8aul C 1200 Baud C 2400 Baud
Pager Message for Process 3 : Pager #1.#2
ProControl Alert Moisture Level High
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i The Paging Setup dialog box contains a panel for the Paging Service Number. This number is a
modern dial-up which dispatches the page regardless of whether your pager is alphanumeric or
numeric. Most paging service customers with numeric pagers do not know this number. You wilI
need to contact your paging service directly to obtain it.
3. To change the paging service number click on the phone number that appears in the panel. You
may then edit it as you would in any text editor. You may use parentheses or hyphens if you so
choose.
4. In order to enable your paging service number. you need to make sure the Enable Page checkbox is
checked. To change the page enable status, simply click on the box next to the words Enable Page.
If there is an X in the box. the pager is enabled.
5 Next you must specify whether your pager is alphanumeric or numeric only. Click on the
appropriate radio button.
6. The Pager Identification Number (P[N is a code which identities your pager and may be up to
eight digits in length. If your pager is numeric. the PIN 's typically the -digit phone number you
.ould dial to manually enter the page. if your pager is aiphanumeric it will have a PIN as well but
it will not be associated with any manual page entry phone number like the numeric pagers. You
should probably contact your paging service directly to confirm this information if you do not
already have it or have any doubts. To change the PIN click on the number that appears in the
panel. You may edit it just as you edited the pacina service number before. Do not use any
parentheses or hyphens in this PIN.
~. The next panel indicates whether or not there are queued pages. In other words, if a page has not
yet been successfully completed and you have called up the ProControl w ith ProView, you may be
interfering with the ProControl's attempts to send a page. If you disconnect from the ProControl,
the page will go through on the next attempt. If you remain connected for several minutes. the
page may be canceled and will be logged in the datalogiging event log as a Page Fail.
Next Page is Scheduled to occur at 15:56
S. The Baud Rate panel can be used to select the speed at which the page information is sent to your
paging company. You will need to contact your paging service directly to know what speed they
can accommodate. It is recommended that you use 300 baud since it is the most reliable.
However. if your paging service number is a toll call. .ou may wish to take advantage of a higher
speed to save phone charges. To change the baud rate, simply click on the appropriate radio
button.
9. The Page Messages Field allows you to monitor and or change the information which will be
transmitted to your pager from specific events. If you are using a numeric pager, this message
cannot exceed nineteen digits in length and may contain only hyphens as non-digit characters. If
you are using an alphanumeric pager. this message cannot exceed eighty characters in length. The
messages that appear are those associated with process tasks which have been set up to tngger a
page. You may wish to consult your site configuration printout to verify this information.
Warning: lf ou are using a nuneric pager and exceed nincteen digits only the first nineteen will
be Uansmitted to 1our; page;. Ifyou attempt to enter non-digit characters such as letters for the
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Pro View 1. 70 User's Guide
Page Vessage intended Tor a numeric pager. only the digits ip to the first non-digit occurrencewill be transmiued.
To change the pager message simply click on it and edit it as you would with any normal texteditor. To see the pager messages associated with other control processes, click on the up or downarrow icons beside the pager message box.
Pager Message for Process 7: Pager 31.#2
: ProControl Alert: Break-in at Site. Door is oper
10. Once you have finished making your changes click OK to accept changes or Cancel to abort.
Datalogging Setup
There are three different types of datalogging on the Series I. Discrete Input and Discrete Output changesare logged as they happen. Events are also logged as they happen. An Event is generated each time aProcess Task runs and everv time an emergency shutdown or other such system action happens. AnalogInputs, on the other hand, are logged at specific time intervals determined by the user. The DataloggingSetup dialog box is used to determine how dataloqcing is carried out in the ProControl unit.
To view or change the Datalogging Setup proceed through these steps:
1. Pull down the Datalogging menu. Click on Datalogging Setup. You can also use ALT-D.
Or Click on the Datalogging Setup Toolbar button. You will see the Datalogging Setup dialogbox.
Datalog Enable Analog Logging
i Discrete Logging Interval 00:01
F Analog
fx Events Next Point @ 13:21
2. To enable a type of datalogging click on the Discrete, Analog or Event check box located in the
Datalog Enable panel and make sure it contains an "X". To disable a type of datalogging click on
the check box and make sure it does not contain an "X".
3. To change the logging interval for analog inputs click on the time next to Logging Interval. Enter
the interval you want in 24 hour time format. The range is I minute to 24 hours.
4. The Next Point ii variable is set by the system every time a data point is logged to show you when
the next point wvil be logged. You can also change it yourself if, for instance, the ProControl is se
to log everv hour but you would like to skip a few hours before resuming datalogging. To set t
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next datalogzing time click on the time text associated with Next Point @ and enter the new time
in 24 hour format.
W'arning: lI u enter a .ex: Point a tie that is earlier than the current time as determined i
the ProControl's clock you itll previent any analog datalogging from occurring until the next day
at that time.
5. Click on the OK button to contirm the changes and send them to the ProControl unit. Click on
Cancel to get rid of any changes.
b. If you click on the OK button and are not connected to the remote ProControl unit then a message
box appears warning you of that condition. Your changes are not saved.
Chan2ing the Password
You can change the password for ProView or for access to the ProControl unit. The passwords do not
have to be the same. If you change the password while ProView is connected to a ProControl unit then the
new password is effective for both Pro\'iew and the ProControl unit. If you change the password while not
connected to a ProControl unit the new password is effective only for ProView.
To change the password follow these steps:
1. Pull down the Password menu. You can also use ALT-P.
Or Click on the Password Toolbar button. You will see the Security dialog box.
Enter Password:
ChangePassword
2. Click on the Change Password button. You will prompted to enter the Old Password. Enter the
old password in the text box provided. Then click on the OK button or hit the enter key. If you do
not enter the password correctly. a beep sounds and the security dialog box disappears.
Old Pansword:
Change Password
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Pro View 1. 70 User's Guide
3. If you enter the old password correctly vou are prompted to then enter the new password. Enter the
new password in the text box provided. Recall that the password can be up to three characters
consisting of the numbers 0-9 and the letters A-Z. Then click on the OK button or hit the enter
key.
New Passwordt
4. Now you will be prompted to check the new password. Once again enter the new password in the
text box provided. Then click on the OK button or hit the enter key.
Check Password
Change Password
5. If both new password attempts were identical, the new password will be accepted and the security
dialog box will disappear. If ProView is connected to the remote system then the new password
will be effective for both ProView and the ProControl unit.
6. If you click on the Cancel button it any time during the dialog box session, any password changes
do not take effect.
Process and Instrumentation Diagram
One option that can be purchased with the ProControl system is the Process and Instrumentation Diagram
(P & ID). If this option has been included in your system configuration, you can view this diagram by
clicking on the P & ID icon
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Process and ustrumentation Diagram
The P & ID contains a craphic representation of your s. stem. The craphic rile w hich displayed is a bitmap(BNIP) tie wxhich can be edited wit h Palnzbrush or other graphi c airTs tool. The appropriate ile'sextension wkill be .pid".
On top of the bitmap background are boxes which contain some of the 1 0 %alues as they pertain to thesystem. Digital h0 are displayed as a tagname which changes color wxhen the 1.O point is activated.Analog 1. 0 are displayed as a xalue with analog outputs also containina the "' symbol to distinguish themfrom analog inputs. You can move or remoxe these boxes as you choose Remember to save the site filebefore vou exit Proiewx to store these chances.
To chance the appearance of the P & ID
I To moxe a decriptie box comatning either a tagname or vailie, hold the shift key and click the leftmoise button when pos itcined orn the arropriate box. This n ill enable you to drag and re-positionthe box wxhereter you choose.
. To remove a descriptixe box. double-click on the box. Once you hate removed a box, it will nolonger be axailable to you unless you restore all boxes.
3. To restore all descriptixe boxe>. position the mouse at the bottom oft'he P & ID window in the grayarea. Then hold dowxxn the control and shift keyS wx :le simLltaneoLsly clicking the left mousebutton.
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CHAPTER 6: DOWNLOADING LOGGED DATA
h is chapter explains how :o gathcr and anal'e logged data that nas becn stored in the ProControluni's batrer-bac kd memory
Datalo2Cd information can be down loaded tram a ProControl un i anl time ProView is connected. Toecgin. pul dow n the Daraloucinc menu and cuck on Get Logged Data.A:lcr a few moments the ExtractDaralouced InIormnation dnaio box appears.
Discrete Anaiog Events I 0sipae6aa
Log Start Time
09/13/96 $$
00:00:00 $$
Update Start Time
Data Type
(a Discrete
C Analog
C Events
Extracted Record:
Move Data
Extract Datalog Info From ProControl System
Save Datalog Into to File Open Datalog File
Export Datalog Info to Text File
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Gettin2 Louged Data
To extract datalogging information from the remote ProControl unit follow these steps:
I. Make sure that you are connected to a ProControl unit.
2. In the Log Start Time panel select the start time. ProView will
occurred after this time. Change the start time by clicking on
decrease the Month, Day. Hour, Minute or Second. Click on the
the start time to the current time.
Log Start Tiie
09/13/96
00:00:00
Update Start Time
extract all datalogged data that
the spin buttons to increase or
Update Start Time button to set
3. Select the type of data you wish to extract. Click on the Discrete, Analog or Event
radio button.
Data Type
Co Discrete
C Analog
SCEvents
4. Click on the Extract Datalog Info From ProControl System button.
Extract Datalog Info From ProControl System I1
5. Monitor the progress of the data extraction.
Extracted Records
24
6. Wait until the data extraction is complete. A message box will pop up to inform
you.
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Datalog Extraction Complete!
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Looking at Discrete Data
To examine the discrete datalouing record that you have extracted click on the Discrete tab.
The Discrete Tab appears. On the left , in the Select LO list box is a list of all enabled inputs and outputs.In the middle is the Discrete Data record. it is empty; at the moment since no discrete input or output isselected. On the righi the earliest record extracted is shown as i 123:47 on ) 13 96. The latest record is14:05:16 on Q 1496. 24 records were extracted.
flicet Analog Events Get LoggedData
Select 1/0 Discrete Data Earliest Record 1All +.
1:HlWEL1
2:LOWEL1
9/13/96 11:23:473: MOIST R
Latest Record 24-'
4:SUMPHI
I
8:DOOR
9/14196 14:05:16
Click on the All n the Select L0 list box to examine the entire discrete record. To see other parts of thediscrete data record scroll up and dowxn in the Discrete Data list box.
Discrete Analog Events Get Logged Data
Select 1/O Discrete Data Earliest Record 1
1:HIWEL1 9/13/96,11:23:57 > MP PWR ON2:LWEL1 9/13/96.11:23:57 >WPUMP2: ON 9/13/96 11:23:473:MOISTR 9/13/96.11:23:57 > NORMAL: ON Latest Record 24
4:SUMPHI 9/13196:11:24:48 > LMPTST : ON5:AIRPRS 9/13/96.11:24:49 > LMPTST : OFFS:DOOR 9/13/96,13:50:21 > PRSALM: ON + 9/14/96 14:05:16
24 Points
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r Pro View 1. 70 User's Guide
The Select 10 list box is used to filter the data record to include just one discrete input or output. Below.
the record rbr LIPTST is shown. Whenever a single input or output is selected. statistics are generated
regarding the selected input or output. 6 points out of the total of 24 were associated with LMPTST. The
total time ON was only 3 seconds while the total time OFF was 26 hours, 40 minutes. and IS seconds.
Discrete Analog Events Get Logged Data A&
Select 1/0 Discrete Data Earliest Record
4:SUMPHI + . ..i ... i., i.. . 1
5:AIRPRS 9/13/96,11:24:49 OFF
6:DOOR 9/14/96,14:05:07: ON
7:STPRHI
8:S L
9/14/96,14:05:09
9/14/96,14:05:09
9/14/96,14:05:09
OFF
ON
OFF
Latest Record 24
|10:RESET + 9/14/96 14:05:16
Time ON 00:00:03 Time OFF 26:40:18 6 Points
The Earliest Record and Latest Record sliders and spin buttons are used to filter the total record with
respect to time. To change this time window click and hold on a slider and move the mouse to the left or
right. You can also click on the spin buttons to change the time wxindow. When you are finished click
again on the input you wish to examine in the Select L0 list box to see the results of your changes. Below.
the total record has been limited to points 5 to 20. Within this time interval. 3 state changes for LMPTST
occurred.
Discrete Analog Events GetLoggedData
Select I/0
4:SUMPHI |+
5:AIRPRS
6:DOOR
7:STPRHI1
8:STPRLO
10:RESET +
Discrete Data
9/13/96,11:24:49 : OFF
9/14/96.14:05:07 : ON
Earliest Record
1 , 1 .... , I . :II.'L j k
9/13/96 11:24:48 -
Latest Record 201
9/14/96 14:05.07 "
Time ON 00:00:01 Time OFF 26:40:18
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Looking at Event Data
To examine the event datalogging record that vou have extracted click on the Event tab.
Events L
The Event Tab appears. On the left. in the Select Eent list box is a list of all enabled processes. In the
middle is the Event Data record. On the right the earliest record extrac:ed is shown as 09:08.2 on
9 12 %6. The latest record is !4.5:16 on 9 4 6 15 records were extrac:ed.
Discrete Analog Events GetLoggedData
Select Event Event Data Earliest Record
+ 9113/96.09:08:32 > Power Up +. .T. .. I . A.i.I. i1: Process 1 9/13/96.09:08:33) Manual Mode
2: Process 2 9/13/96.09:09:20 > Local Connect /1 69:3
Process 3 9/13/36.03:09:24 > Emerg Shut Latest Record 15-4: Proces 4 9/13/96.09:09:24 > Manual Mode
Process 5 9/13/96.11:23:46 > Reset
6: Process 6 + 9/13/96.11:23:47 > Startup 01 9/14/96 14:05:16
\tanipulating the event data follows the same procedure as is described for the discrete data earlier in this
chapter.
The foliow ing s a table describing the list of all datalogged events for the major ProControl versions:
Points / Version 1.7 1.6 1.5 1.1
Processes S-32 Yes Yes Yes Yes
Processes 31-64 Yes N N A A NA
Startup 1-16 Yes Yes Yes Yes
Shutdownr I-6 Ys Ye Ys Ys
Emergencv Shui"down Yec es Ys e
Startuo, Failur Ys Yes Ye Yes
Shutdowxn Failure Yes Yes Yes Yes
Fax Failure Yes ' Page Failure Yes Yes I Yes A
Connect i N A Yes Yes Yes
Local Connect Ye s No No No
Remote Connect Yes No No No
Power Lp Y es No No No
Reset 7es No No No
Manual Nede Ys No No o
Auto \lode Yes No No No
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Lookin2 at Analog Data
To examine the analoc datalougingz record that you have extracted click on the .\nalog tab.
Analog 1
The .\nalog Tab appears. On the lett in the Select Input list box is a list ot'all analog inputs. In the middle
is the Analog Data record. it is emptv at the moment since no input is selected. On the right the earliest
record extracted is shown as 1-1:4-:00 on 9 13 96. The latest record is 1 04:0)0 on 9/13 96. 18 records
were extracted.
ExlrctDtll e Informaion
Discrete _na Events Get Logged Data
Select Input Analog Data Earliest Record 1
17:H20FLO _ _ ._ ._ _...r _i.. _
18H2SLVL 9/13/96 14:47:00
19: PHT1RN S ______
Latest Record 18
9/13/96 15-04:00 ~
Analog Data Granh Qinn
FY Axis Calc
F Grids
F Line Stats
F Thick Lines
r Symbols
F Cursor
F Zero Clamp
OK
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The Select Input list box is used to show and graph data generated by the analog input selected. Below, we
u il ick on an mout to The. the data for H2OFLO. Statisis are generated recarding the Ielected analog
input. In this case there are 1 points wih a Low of 29.2. a High of 3 3 and \[ean of 32.5 A graph of
the data points appears :n the lower half of the tab along with soie graphine otions. As in the digital and
eent tabs the Earliest Recordiand Latest Record sliders and spin bunonIs can he used to filter the total
record wnh respect to time. lf you ilter the data in this w' a o uOt must dick again on the input oLU wish to
examine to se the results of' our chances.
Discrete Analog Events GetLoggedData
Select Input Analog Data Earliest Record 1
9/13/96.14:47:00: 32.0 1E a.' 4I ]18:H20LVL 9/1 3/96.14:48:00: 33.4
19:PHTRNS 9/13/96,14:49:00: 32.8 9/13/96 14:47:00
9/13/96.14:50:00
9/13/96,14:51:00
9/13/96.14:52:00
9/13/96.14-53:00
3 7
33.8
: 37.3
37.3
Latest Record 18
9/13/96 15:04:00
Low: 29.2 High: 37.3 Mean: 32.5 i 18 Points
H20FLO in GPM Graph Options
FY Axis Calc
Grids
Line Stats
Thick Lines
Symbols
Cursor
IZero Cdamp
The Graphing Options are used to change the look
check box so that an "X" appears.
of the analog crap h. To enable an option click on its
Y Axis Cale: One problem apparent in the graph as it stands now is that the total range in the Y axis is
miuch greater than the range of input data in this sample. That's because the default Y axis range is the
range of the analog input itself. Clicking on Y Axis Calc redraws the graph with a calculated N axis range
based on the data in the samnle. Now trends in the data are much easier to spot. There are four different Y
axis calculations which can be performed. Clicking on the Y Axis Cailc box produces the basic Y axis
calculation which tightens the v ertical axis to aid in showing small changes in the sampled data.
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Pro I iew 1.70 User's Guide
H20FLO in GPM
42.0
33.5
25.0
Graph Options
~ Grids
j Line Stats
r Thick Lines,,
Symbols
r Cursor
fi Zero Clamp
o Holding dowkn the Shift, Control, or Alt ke respectively. w hile clicking Y Axis Calc will produce
variation y-axis calculations I through 3. Each has a tighter vertical scale than the last, with "Y Axis Calc
3" drawn from the minimum to the maximum in the sampled data set.
H20FLO in GPM
37 30
33.25
29 20
Graph Optibns
Fl AxisrdalcI
~Grids
~ Line Statt
F Thick Lnes .
F Symbols
~ Cursor
IF Zero Clamp
Grids: The grid option places
calculated based on your data.
a few X and Y axis grids on the graph as shown below. The exact number is
H20FLO in GPM
32.
27 0
57
Graph Options
fY Axis Calc 2
Line Stats
Thick Lines,
r Symbols
F Cursor
1W Zero Clamp
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Line Stats: This option w ill dra Jashed lInes across the graph to vi>LiAIll indicate Low. High and Mean
input IeC\es.
Thick Lines: This option makes the graph data thicker" to show up more clearly on the screen.
[n the graph showxn below we ha; e appiied the Line Stats and Thick Lines options while disabling the
Grids option.
H20FLO in GPM
38.0
32.5
27.0
Graph
[f Y Axi
r Grids
Options
s Calc 2
[1 Line Star
I~Symbols
~ Cursor
|W Zeio Clamp
Sy nbo ls: This option places a small - at each data point instead of a dot.
H20FLO in GPM
38.0
32.5
27.0
Graph Options
I Y Axis Calc 2
F Grids
F Line Stats
F Thick Lines
FW Symbols
F Cursor
Fi Zero Clamp
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Pro It jew 1.70 User's Guide
Cursor: This option plhices a ertical line on the graph at the point selected by
list box. This makes it easier to correlate the list data with the graph.
H20FLO in GPM
38.0
32.5
27.0
clicking in the analog data
ff Y Auis Calc.Z.
r Le Stats
F ThickLines
XY Cursor
1W Zeso Clamp
Zero-Clamp: This option forces the graph to display zero
negative values. Negative values are typically logged when an
at all points where data was logged with
analog transmitter outputs less than 4 mA.
Keep in mind that every time the graph is redrawn it is also placed in the Windows Clipboard. This makes
it easy to use the graph in another application such as a word processor by just -pasting" it in.
ClipSookViewer ril
After you are finished examining the dataloeged information. you may wvant to save it for future reference
within ProView or export to a spreadsheet or word processor.
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Savins Datalogging to File
To save a datalogging record to a ProView-readable rile followv these steps:
1. Click on the Get Logged Data tab. Select the tyne of tile you wish to save by clicking on theappropriate button in the Data Type panel.
2. Click on the Save Datalog Info to File button.
Save Datalog Info to File
3. This opens the Save Data Log As dialog box. The default file nameconfiguration file with the pvd. pva or .pve tile extension depending on
intend to save (discrete, analog, or events. respectiaely .
is the name of the site
the type of data file you
Save Analog Data Log As
File Name:
sample2-pva
Directory:
cAproview
Drives:
5 c: [RKLAPJ 7]
Canc l
5. To change the file name click on the text box in the File Name panel and
on the OK button to save the file
make any changes. Click
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Openin2 a Dataloggin2 File
You may wish to open a datalog tile that you previously saved for use within ProView. To do so follow
these steps.
1. Call up the Extract Datalogged Information dialog box if you are not already there. From the main
screen this is done by pullinu down the Datalogging menu and clicking on Get Logged
Data. Click
on the Get Logged Data tab. Select the type or'tle you wish to open by clicking
on the appropriate
button in the Data Type panel.
2. Click on the Open Datalog File button.
Upen Datalog File I
3. This opens the Open Data Log dialog box. The default file name
is the name of the site
configuration file with the .pyd, pva or pve File extension depending on the type of data
file you
intend to open.
File Name: Directwy:
data pyd cAproview
Drive::
-- ;c: [RKLAPI
4. To select a file click on the text box in the File Name panel and
make any changes or click on the
file name in the file list box. Only flies with the .pyd, .pva and
.pve extensions can be opened.
Click on the OK button to open the tile.
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Exporting Datalogging Information
You can export ProView analog data to a CSV Comma Separated Variable) file suitable for importing intomost spreadsheet programs. You can also export discrete and c, ent data to a text file.
1. Call up the Extract Datalogged Information dialog box if you are not already there. Click on the
Get Logged Data tab. Select the type of file you wish to export by clicking on the appropriate
button in the Data Type panel.
2. Click on the Export Datalog Info to Texr File button.
EIxport Datalog Info to Text File
3. This opens the Save Analog Data Log As CSV File or the Save Discrete
the Save Event Data Log As .TXT File dialog box depending on the type
The default file name is the truncated name of the site confguration
extension.
File Name: Directory:
data-csv c:f actwin
t'bridge
7 cardsoft
ccardview
dc4in+
Drives:
l c: [RKLAP]
Ccl K
Data Log As .TXT File or
of file you wish to export.
file with the .csv or .txt
. To change the file name click on the text box in the
on the OK button to export the file. It ou ha'.e a
this will take a few moments.
File Name panel and make any changes. Click
large number of data points you wish to save.
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CHAPTER 7: OTHER OPERATIONS
T his chapter explains how to save the site setup. print the current data, configure the remote unit,retrieve a configuration and exit the program.
Savin2 the Site Setup to File
While you work in ProView you may very often change system information or defaults as outlined in
previous chapters. This information is part of your site contiguration (or .pvs) file. It should be saved in
your .pvs file before ending the program. If it is not, the changes you have made will be lost and the
configuration of the remote ProControl unit will be different than that of your site file.
To save your site configuration to file pull down the File Menu. Click on Save Site.
To save your site configuration to a net /ile name proceed through these steps:
1. Pull down the File menu. Click on Sa'e Site As.
Or Click on the Save Site As button.
2. You will see the Save Site As dialog box.
File Name:
samplelpyt
Directory:
c:\proview
Drives:
Ac: [RKLAP] ±
Cance!
3. Select the Drive. Directorv and File Name you would like and click on the OK button to save the
file.
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Printing the Current Data to File
You can print the current operational data of the site to a text tile for future reference. This can prove
useful for documentation and report purposes.
To save your current process data to a text file follow these steps.
1. Pull down the File menu. Click on Print Current Data.
2. You will see the Save Current Data As dialog box.
=Save Current Data AsI
File Name:
sample2.dat
Directoiy
cAproview
t 4:1
Drives:
~c: [RKLAP]
Cancel K
3. Select the Drive, Directory and File Name you would like. The default file extension is .dat. Click on
the OK button to save the current data to the file.
4. If you are connected to the ProControl unit. Proview will scan for the latest totalizer and hour
meter values.
You can examine the current data tile with any text editor. An example of the
EOS RESEARCH LTD.
PrcCsatrcl Series :
P=Viaew Curves: Operatior.a- ntra:-.02
file is shown below.
*EAX Recipient: MYRCN R =CMPUTE .- *-Customer: ECS RESEARCH TES- **
***** Site Lccation SUERFND USA ***-***** Type:**'
* Serial Numiher: 11119
***** Date: 9/16/96 .**
*** * i e : 1 32 :3..1*
**** PrcView: Versio '.70 *'
***** Communications Stace: LOCAL CONNECT
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Sstem Mode: Auto 9 *****
last Shutdown: No Previous Shutdown Repcrted ....*
Alarms: Alarms OFF *
FAX: Retort ON .. *
********************** *.PU. S * .*** *****
T"E -URN NPUT STATUS:
4 TAGNME CURRENT VALUE '0 ALARM
- .NE-1lis OFF
2 LWE.l is OFF
2 MCOSTR :s OFF
4 5UMPHA2 is OFF
5 A aPS is OFF
I :CCR isOFF
7 TPRH s 2?F?
9 STPR:, :s CFF
9LMTST is OFF
0 RESET is OFF
i2OFLO 30.6 PM 0.0
S HZCLVL 21.2 FT 5.0
13 THTRS .9 5.0
HI ALARM TOTAL2ZER
50.2
40.0
10. '
HOURS ON
020, J02 00.1
300 , '0.00 .0 00.1
022,000 00.0
00000 00-.3
2223,300 2'0.0
0C2,000 00.0
220,000 00.
300,3020 00 0
00000 00.1
000,300 00.0
135,775 GAL 200,JO 01.4
020,000 01.4
0,230 20.1
TE~.'RRENT OUTPUT STATUS :
=TAGNAM4 E 2URRENT VAL,.E
PUNMP is OFF
2 NMPn'M2 -s ON
' RRis N
4 TEPMP isOFF
S MPWR s ON
8 PRSALM is OFF
9 SMPAL.M is OFF
SA OFF
ASTAM is OFF
I5 NTRD'R is OFF
16 NORMAL is ON
ScURs ON
0:3, DOD0x000520', ill
00.0, 000
000, 200
000,000
000,000
20.2
38.7
32 .9
30 .0Co. 033.714.9
00.0
00.0
00.0
0'0.0
HOURS OFF
000,074 22.3
000,074 22.4
000,074 22.4
000,074 22.4
220,074 22.4
000,074 22.5
000,074 22.5
000,074 22.5
000,074 22.4
000,074 22.5
000,074 21.1
-00,074 21.1
D000,074 22.4
HOURS OFF
200,04 22.5
000,068 43.9
:00,268 43.6
,00,074 22.5
300,068 43.9
000,074 07.6
000,074 22.5
000,074 22.5
'00,074 22.5
000,000 00.0
020,300 00.0
.H U.N' ANALOG OUTPUT STATUS:
TAZNAYE VALUE
VARPYP 48.7
SEQ YP 15.3
PID Mode SETPOINT
ALO 20.0
ALG 20.0
0
0a n
5.0
25
S3a-n 2 Cain
0.5 0.5
ANALCO CUTP" NOTES
VALUE -
AL -
MAO 2MG -
The current output level expressed as a percentage J%-4ma l20%
Manual The P2D or PRO control loop algorithm has been turned
The ?2D or PRO algorithm is running,
he maximum amount the output can cnange in one contrc zvce.
k=2ma.
oft.
THE TUPRENT REPORT-NG SETUP:
...............................................................................*Recort Enable: ON
FAX Number 1: 1 (800) 555-5555 Alarm, Scneduled *+.**
.FAX Number 2: 555-5555 Alarm *****
.*.** Scheduled FAX: Every Day at: 04:03 *.*Next Scheduled FAX: 04:00 .*.**
Pager 41: Enabled, Numeric .****
Per 42: Enabled, Achanumeriz -*+
65
e 1
A 2HG
5.0 4
5.2 %"
Pro View 1.70 User's Guide
Paging: Will occur at 300 baudPage Number 1: 1 (800) 555-5554
*.** Pager ID 1: 5960104
******** Page Number 2: 555-1234* ** Pager ID 2: 8125375
THE cTRRENT DATALOGGNG SETUP:
**Enabled Datalogging: Digita Analog EventDatalogging Interval. 00:01 I**.Next Dacalog Time: 11:36 *****
Exiting ProView
You can exit ProView by double clicking on the large at the top left of the main screen or by pullingdown the File menu and clicking on Exit. In either case you will be prompted to save your siteconfiguration file and to save any datalog information in memory. You should also disconnect from theremote ProControl unit before exiting the program.
66
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4
1.4
a S
A Penta Company
Electric Heaters
Elektrisches Heizgerst
Rschauffeur Elbtrique
E!6ctrico Calentador
CAUTION: SURFACE MAY BE HOT
CATALOG No, D-iMG"tA
VOLTS 11? WATTS2f
000
P N 28359001 87565511Rev. A 102070 2001 Hoffman E-closures inc.
English
INTRODUCTION
1. Before installing the electric heater, read these instructions carefully. Failure
to follow these instructions could damage the product or cause a hazardous
condition.
2. Check the ratings on the heater label to assure the product is
your application.
suitable for
GENERAL SAFETY INFORMATION
1. Protect the lead wires from coming in contact with sharp objects, hot
surfaces, and/or chemicals.
2. If continuous operation of the heater is essential to the safe functioning of
any other equipment, adequate warning devices must be installed to assure
safe operation at all times.
-2- 2001 Hoffman Enclosures Inc. 87565511
To avoid electric shock and equipment damage,
disconnect any power supplies to the enclosure
before installing the electric heater.
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These electric heaters are not designed for use in dusty,
dirty, corrosive, or hazardous locations.
Portions of the heater can get hot. Adequate protection
must be taken to protect people from potential bums, and to
protect other components from this heat.
This heater can only be installed in a totally enclosed metal
enclosure.
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English
LOCATION AND MOUNTING
1. Hoffman electric heaters should be centered as
low as possible in the enclosure for optimum heat
distribution.
2. It is recommended that the heater be installed
on a panel for optimum performance. It may,
however, be mounted on any metal surface.
3. Tie heater should be mounted in a vertical
position with the terminal block at the bottom and
the air outlet openings at the top as shown.
4. Heaters should not be installed on wood or
other combustible surfaces.
5. Heat sensitive components should not be
piaced above the heater discharge area.
6. The recommended clearances shown by the
shacowed area indicate the space that should be
keot free of components for safe operation of the
heater
7. Four 10-32 UNF, self-tapping screws are
included for installation.
-ACAUTION-"-W#*N i
~hermal sensitive devices or materials may need to be
lcated further from the heater than the minimum
recommended distance.
Vertical Surface Mounting
F//T/1R -
172(4)
4=
1 .00
25 mmn
1 .00
25 rri25
Optional Horizontal
Surface Mounting
Temperature Rise Vs Distance Above Heater
60-
108_
50 -
90
40-
72
30-
54
10-
18-
- - - - -
18
0
0 2
50mm
4
102mm
X (Minimum
recommended
distance above
heater)
100 Watt Heater
- - - - - - 200 Watt Heater
--- - 400 Watt Heater
- - 800 Watt Heater
6 8 10 12
152mm 203mm 254mm 559mm
Vertical Distance Above Heater, inches/mm
Temperature measurements reflect unrestricted air flow.
2 2001 Hoffman Enclosures Inc
D--AH1CO1A D-AH1002A
C--AH2001A D-AH2002A
D--AH4001 B D-AH4002B
D-AH80018 D-AH80002B
1 .00
25 Yn
(TYP)
-3 -
8,65511
English
WIRING (Reference Page 14)
1. All wiring must comply with applicable local codes and ordinances.2. Connect the heater leadwires to the proper A.C. power source. Powersource for 800 watt heaters should be continuous.
3. The heater must be properly grounded.
NOTE: Exposed wires should not come in contact with the heater housing.
MAINTENANCE
1. Always disconnect power supply before inspecting or working on the heater.
2. Generally the unit requires no maintenance since the fan bearings arepermanently lubricated and sealed.
Wiring Schematic
2C01 Hoffman Enclosures Inc. 8756
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To avoid electric shock, do not energize any circuits
before all internal and external electrical andmechanical clearances are checked to assure that allassembled equipment functions safely and properly.
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1-4-
HITACHI INVERTER
J300 SERIES
I INSTRUCTION
MANUAL
J300 U USA version
After reading this manual, keep it at hand for future reference.
Hitachi, Ltd.
Tokyo Japan
NB506XC
SAFETY
For the Best Results with J300 Series inverter, read this manual and all of the warning sign attached to
the inverter carefully before installing and operating it, and follow the instructions exactly. Keep this
manual handy for your quick reference.
Definitions and Symbols
A safety instruction (message) is given with a hazard alert symbol and a signal word;
WARNING or CAUTION. Each signal word has the following meaning throughout this manual.
This symbol means hazardous high voltage. It used to call your attention to
items or operations that could be dangerous to your and other persons operating this equipment.
Read these message and follow these instructions carefully.
This is the "Safety Alert Symbol." This symbol is used to call your attention
. s, to items or operations that could be dangerous to your or other persons operating this equipment. Read these messages and follow these instructions
carefully.
WARNING WARNING
Indicates a potentially hazardous situation which, if not avoided, can result in
serious injury or death.
CAUTION CAUTION
Indicates a potentially hazardous situation which, if not avoided, can result in
minor to moderate injury, or serious damage of product.
The matters described under I CAUTION may, if not avoided, lead to
serious results depending on the situation. Important matters are described in
CAUTION (as well as WARNING), so be sure to observe them.
NOTE NOTE: Notes indicate an area or subject of special merit, emphasizing either
the product's capabilities or common errors in operation or maintenance.
A HAZARDOUS HIGH VOLTAGE
Motor control equipment and electronic controllers are connected to hazardous line voltages. When
servicing drives and electronic controllers, there might be exposed components with cases or protrusions
at or above line potential. Extreme care should be taken to protect against shock.
Stand on an insulating pad and make it a habit to use only one hand when checking components. Always
work with another person in case an emergency occurs. Disconnect power before checking controllers
or performing maintenance. Be sure equipment is properly grounded. Wear safety glasses whenever
working on an electronic controllers or rotating electrical equipment.
- I -
PRECAUTIONS
[WARNING: This equipment should be installed, adjusted and serviced by qualified electrical
maintenance personal familiar with the construction and operation of the equipment
and the hazards involved. Failure to observe this precaution could result in bodily injury.
WARNING : The user is responsible for ensuring that all driven machinery, drive train
mechanism not supplied by Hitachi, Ltd., and process line material are capable of safe operation
at an applied frequency of 150% of the maximum selected frequency range to the AC motor.
Failure to do so can result in destruction of equipment and injury to personnel should a single
point failure occur.
WARNING : For protection, install a leak breaker type with a high frequency circuit capable
of large currents to avoid an unnecessary operation. The ground fault protection circuit is not
designed to protect personal injury.
WARNING: HAZARD OF ELECTRICAL SHOCK. DISCONNECT INCOMING
POWER BEFORE WORKING ON THIS CONTROL.
AVERTISSEMENT : RISQUE DE CHOC ELECTRIQUE COUPER L'ALIMENTATION
AVANT LE DEPANNAGE DE CETTE COMMANDE.
CAUTION: These instructions should be read and clearly understood before working on J300
series equipment.
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CAUTION: Proper grounds, disconnecting devices and other safety devices and their location
are the responsibility of the user and are not provided by Hitachi, Ltd.
CAUTION: Be sure to connect a motor thermal switch or overload device to the J300 series
controller to assure that the inverter will shut down in the event of an overload or an overheated
motor.
A CAUTION: DANGEROUS VOLTAGE EXISTS UNTIL CHARGE LIGHT IS OFF.
A ATTENTION: PRESENCE DE TENSIONS DANGEREUSES TANT QUE LE VOYANT
N'EST PAS ETEINT.
CAUTION: Rotating shafts and above ground electrical potentials can be hazardous. Therefore, it is strongly recommended that all electrical work conform to the National Electrical Codes
and local regulations. Installation, alignment and maintenance should be performed only by
qualified personnel. Factory recommended test procedures, included in the instruction manual,
should be followed. Always disconnect electrical power before working on the unit.
- ii A
A
NOTE : POLLUTION DEGREE 2
The inverter must be used in environment of the degree 2.
Typical constructions that reduce the possibility of conductive pollution are;
I) The use of an un-ventilated enclosure
2) The use of a filtered ventilated enclosure when the ventilation is fan forced that is,
ventilation is accomplished by one or more blowers within the enclosure that provide a
positive intake and exhaust.
NOTE : ENCLOSURE SIZE FOR 75 kW TO 110 kW
The inverter, 75kW to I I10kW must be installed into an enclosure with dimmensions no
less than 183cm (72 in) by 183cm (72 in) by 60cm (24 in).
NOTE: ENCLOSURE SIZE FOR 132 kW AND BIGGER
The inverters, 132kW and bigger, are complied as recognizedcomponents.
Therse devices are intended for use in an overall ecciosure with an internal ambient of
40 degree C for variable torque rating or 50 degree C for constant torque rating maximum.
End product temperature testing should be conducted to verify sufficient forced air ventilation
is provided to maintain this ambient in room ambient of 10-40 degree C.
Based upon component level testing, end product temperature testing may be conducted at
any convenient room ambient in the rangeof 20-40 dwgree C, unless the room ambient in the
intended application exceeds 40degree C, in which case testing should be conducted at the
elevated ambient.
Enclosure internal ambient temperature should be measured above the drive on to the upper
left or right side. Temperature measurments on the drive itself should not be necessary.
NOTE: SET OF MOTOR CAPACITY AND POLES (Al, A2)
When data does not match a capacity of connected motor, it may cause unstaible motor
operation. Set proper motor capacity (kW) and motor poles even under V/F control mode.
- iii Revision History Table
No. Revision Contents The Date Operation
of Issue Manual No.
Page iii : Pollution degree
Page 2-1: Description of inverter model
Page4-2 Change of note
Page 5-8, 5-9 : Addition of 750 to 1 100H
Page 5-10: Terminal description
Page I 1-1, 11-2,11-3 : addition of 750 to I lOOH
Page iii : Enclosure size
Page 4-1 : Enclosure size, page 7-5; note 3,
Page 7-11: F8 boost value in VPI to 3
Page 7-15: AO note for boost value
Page 12-13: additio of note I
Page A25-A3 1: addition of line for set value
Page A-33: deletion of A-93 on clause
Page iii: note for 132 kW to 220 kW is added
Page 2-1: added 132 to 220kW
Page 4-1; note for 132 kW to 220 kW is added
page 4-2: notenote I corrected I1OkW->260kW
page 5-8: added 1320 to 2200H in table
Page 5-10: terminal layout corrected
Page7-5: corrected monitor d3 39 to 99
Page7-18: A10, addition of 1320 to 2200H
Page 11-1,2,3: added 1320 to 2200H
2
NB506XA
NB506XB
NB506XC
- iv Aug. 1997
Feb. 1998
Feb. 1999
TABLE OF CONTENTS
SAFETY PRECA UTIO NS ..........................................................................................
INSPECTIO N U PON UN PACKIN G ........................................................................
APPEARANCE AN D NAM ES OF PARTS.............................................................
IN STA LLATION ..........................................................................................................
W IRING ........................................................
O PERATION .................................................................................................................
O PERA TION OF THE D IGITA L O PERATOR ......................................................
PROTECTION FUNCTIONS.....................
TRO UBLESHO OTING ...............................................................................................
M A INTENANCE AND IN SPECTIO N .....................................................................
STANDARD SPECIFICATION S ..............................................................................
12. FUNCTIONS WHEN USING THE OPTIONAL REMOTE OPERATOR.......... 12-1
13. SERVICE
APPENDIX I
APPENDIX 2
APPENDIX 3
APPENDIX 4
APPENDIX 5
APPENDIX 6
APPENDIX 7
APPENDIX 8
I .
2.
3.
4.
5.
6.
7.
8.
.9.
10.
1 1.
Page
1-1
2-1
3-1
4-1
5-1
6-1
7-1
8-1.
9-1
10-1
11-1
13-1
A-1
A-15
A-19
A-20
A-21
A-24
A-25
A-32
.......................................................................................................................
.......................................................................................................................
......................................................................I.................................................
.........................................................I .............................
. ...................................................................................................................
..........I .............................................I...........I...............................................
.......................................................................................................................
. .. ..................................................I ....I..............................
... . ................................................................................................................
1. SAFETY PRECAUTIONS
,CAUTION
- Be sure to install the unit on flame resistant material such as metal.
Otherwise, there is a danger of fire.
* Be sure not to place anything inflammable in the vicinity.
Otherwise, there is a danger of fire.
* Be sure not to let the foreign matter enter such as cut wire refuse, spatter
from welding, iron refuse, wire, dust, etc.
Otherwise, there is a danger of fire.
* Be sure to install it in a place which can bear the weight according to
the specifications in the text (4. Installation).
Otherwise, it may fall and there is a danger of injury.
* Be sure to install the unit on a perpendicular wall which is not subject
to vibration.
Otherwise, it may fall and there is a danger of injury.
* Be sure not to install and operate an inverter which is damaged or parts
of which are missing.
Otherwise, there is a danger of injury.
* Be sure to install it in a room which is not exposed to direct sunlight
and is well ventilated. Avoid environments which tend to be high in
temperature, high in humidity or to have dew condensation, as well as
places with dust, corrosive gas, explosive gas, inflammable gas,
grinding-fluid mist, salt damage, etc.
Otherwise, there is a danger of fire.
* Be sure that the wall surface is a nonflammable material, such as steel
plate.
........... p. 4-1
... .. p. 4-1
...... p. 4-1
4-1
4-1
4-1
........... p .
........... p.
........... p .
........... p. 4-2
2. Wiring
I WARNING
* Be sure to ground the unit.
Otherwise, there is a danger of electric shock and/or fire.
* Wiring work shall be carried out by electrical experts.
Otherwise, there is a danger of electric shock and/or fire.
- Implement wiring after checking that the power supply is off.
It might incur electric shock and/or fire.
* After installing the main body, carry out wiring.
Otherwise, there is a danger of electric shock and/or injury.
* Wait until DC bus voltage is discharged after power supply is turned
off.
Otherwise, there is a danger of electric shock.
............ p. 5- 1
............ p. 5-1
............ p. 5-1
............ p. 5-I
............ p. 5-10
1-1
K
K
1. Installation
)
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11 CAUTION
* Make sure that the input voltage is:
Three phase 200 to 220 V/50 Hz, 200 to 230 V/60 Hz
Three phase 380 to 415 V/50 Hz, 400 to 460 V/60 Hz
+ Be sure not to input a single phase to a 3 phase type.
Otherwise, there is a danger of fire.
* Be sure not to connect AC power supply to the output terminals
[U (Ti), V (T2), W (T3)].
Otherwise, there is a danger of injury and/or fire.
INPUT
........... p
5-2
.....
p. ............ p. 5-2
OUTPUT
Note)
(LI) (L2) (L3) (TI) (T2) (T3)
L R S T
Power supply
U V W
* Fasten the screws with the specified fastening torque. Check so that
there is no loosening of screws.
Otherwise, there is a danger of fire.
+ Be sure to install an earth leakage breaker.
The ground fault protection is designed to detect current flowing to the
ground upon power on. This fuiction is to protect the inverter, not
people. Install the earth leakage breaker to protect against the ground
fault on wires between the inverter and the motor. (Use a breaker that is
very sensitive to high frequency current so as not to cause malfunction.)
* Be sure to set the fuse(s) (the same phase as the main power supply)
in the operation circuit.
Otherwise, there is a danger of fire.
" As for motor leads, earth leakage breakers and electromagnetic
contactors, be sure to use the equivalent ones with the specified
capacity (rated).
Otherwise, there is a danger of fire.
* Connection to wiring terminal must be reliabily fixed with two means
of support.
............ p. 5-2
............ p. 5-2
----- . - P .
--------.... p.
5-2
5-2
--.---------. p. 5-2
1-2
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CAUTION
External or remote over load protection required, if multiple motors to ............ p. 5-4
be connected.
For models J300-450LFU and -550LFU only , connect to branch
circuit protected at maximum 300% of output current rating.
Suitable for use on a circuit capable of delivering not more than 10,000
rms symmetrical amperes,*** volts maximum,
(where *** = input voltage)
Alarm connection may contain harzordous live voltage even when ........ p. 5-11
inverter is disconnected. In case of removing front cover for
maintenance or inspection, confirm that incoming power for alarm
connection is surely disconnected.
CAUTION
Input phase failure protection
(1) J300-U version inverter are provided with the phase failure protection on the power
supply.
(2) When a buzzer, lamp, noise filter or transformer is connected between the input power
terminals (L 1, L2, L3) and input power fuses, input phase failure cannot be protected.
(LI) (L2) (L3)
R S T
(Bad example)
Noise filter
Fuse
L (Good example)
Power supply
1-3
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3. Control and operation
/ WARNING
+ Be sure to turn on the input power supply after mounting the surface
cover, While being energized, be sure not to remove the cover.
Otherwise, there is a danger of electric shock.
* Be sure not to operate the switches with wet hands.
Otherwise, there is a danger of electric shock.
. While the inverter is energized, be sure not to touch the inverter
terminals even during stoppage.
Otherwise, there is a danger of electric shock.
* If the re-try mode is selected, it may suddenly restart during the trip
stop. Be sure not to approach the machine. (Be sure to design the
machine so that personnel safety will be secured even if it restarts.)
Otherwise, there is a danger of injury.
* Even if the power supply is cut for a short period of time, it may restart
operation after the power supply is recovered if the operation command
is given. If it may incur danger to personnel, be sure to make a circuit
so that it will not restart after power recovery.
Otherwise, there is a danger of injury.
- The Stop Key is effective only when the function is set. Be sure to
prepare the Key separately from the emergency stop.
Otherwise, there is a danger of injury.
* After the operation command is given, if the alarm reset is conducted, it
will restart suddenly. Be sure to set the alarm reset after checking the
operation command is off.
Otherwise, there is a danger of injury.
* Be sure not to touch the inside of the energized inverter or to put a bar
into it.
Otherwise, there is a danger of electric shock and/or fire.
* The STOP/RESET key works only when a function is set. Prepare an
emergency switch separately. The use of the STOP/RESET key as an
emergency switch may cause an injury.
............ p. 6-1
............ p. 6- 1
............ p. 6-1
............ p. 6-1
............ p. 6 - 1
............ p. 6-1
p. 6-1
............ p. 6-1
............ p. 7-l
1-4
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CAUTION
- Radiating fin and discharging resistor will have high temperature.
Be sure not to touch them.
Otherwise, there is a danger of getting burned.
* Low to high speed operation of the inverter can be easily set. Be sure
to operate it after checking the tolerance of the motor and machine.
Otherwise, there is a danger of injury.
* If a motor is operated at a frequency higher than 60Hz, be sure to check
the speeds of the motor and the machine with each manufacturer, and
after getting their consent, operate them.
Otherwise, there is a danger of machine breakage.
* Check the following before and during the test run.
Otherwise, there is a danger of machine breakage.
- Was the short-cut bar between +1 and - connected?
- Was the direction of the motor correct?
- Was the inverter tripped during acceleration or deceleration?
- Were the rpm and frequency meter correct?
- Were there any abnormal motor vibrations or noise?
- When overcurrent tripping or overvoltage tripping occurs during the
test run, increase the acceleration time or deceleration time.
4. Maintenance, inspection and part replacement
WARNING
* Be sure to turn off the power supply during maintenance and
inspection.
* After. the power supply has been turned off, you must always wait 10
minutes so that DC bus capacitors can discharge then start maintenance
and inspection after the CHARGE lamp on the printed-circuit board has
gone out. (Immediately after the lamp has gone out, there will be a
residual voltage of about 50 V DC in the DC bus intermediate circuit.)
Perform the work after the CHARGE lamp has stopped flickering.
- Make sure that only qualified persons will perform maintenance,
inspection and part replacement. (Before starting the work, remove
metallic objects from your person (wristwatch, bracelet, etc.)
(Be sure to use tools protected with insulation.)
Otherwise, there is a danger of electric shock and/or injury.
---......... p. 6-2
........-.- p. 6-2
............ p. 6-2
............ p. 6-3
1-5
........... p. 10-1
........... p. 10-1
-------.--- P. 10-1
L! CAUTION
- When removing connectors, never pull the wires. (Wires for cooling ........... p. 10-1
fan and thermal relay)
Otherwise, there is a danger of fire due to wire breakage and/or injury.
5. Appendix
WARNING
- When the inverter stops due to a trip with retry mode selected, the .......... p. A-15
motor restarts suddenly. Stand clear of the machine. Otherwise, you
may be injured. (Design the machine in such a way that persons are
protected against a restart of the machine.)
- If the retry mode is selected, do not approach the inverter unnecessarily. ........... p. A-16
It will be restarted suddenly after it trips/stops. (Design the inverter so
that the safety can be assured even in such a restart.) Otherwise, bodily
injury will result.
1-6
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6. Others
WARNING
- Never modify the unit.
Otherwise, there is a danger of electric shock and/or injury.
I CAUTION
- Withstand voltage tests and insulation resistance tests (megger tests) are executed
before the units are shipped, so that there is no need to conduct these tests before
operation.
When conducting megger tests as a part of daily inspection, be sure that these tests are
only executed between the main circuit and the ground. Do not'execute megger tests
on the control circuit.
(LI) (L2) (L3) (RB) (+) (-) (TI) (T2) (T3)
R S T RB P N U V W
FM P24 PLC FW ...
Megohm-meter Megohm-eter
* Do not attach or remove wiring or connectors (including Digital operator and
Remote operator) when power is applied. Also, do not check signals during
operation. Otherwise, a trip may occur or a failure may be caused. To stop the
operation, be sure to use an operation instruction (FW,REV.) Do not turn
power off within three minutes after it is turned on, or vice versa.
" Do not stop operation by switching off the electromagnetic(Mgo) contactors on
the primary or secondary sides of the inverter.To stop the operation, be sure to
use an operation instruction (FW,REV.) Do not turn power off within three
minutes after it is turned on, or vice versa. (Bad example)
Earth
leakage ONOFF
breaker
Mgo (L1)(L2)(L3) (Tl)(T2)(T3)
Power OS> Motor
FW
ON,0FF P2
Turn ON and OFF
(Good example)
When there has been an instantaneous power failure, and if an operation instruction
has been given, then the unit may restart operation after the power failure has ended. If
there is a possibility that such an occurrence may harm humans, then install an
electromagnetic contactor (Mgo) on the power supply side, so that the circuit does not
allow automatic restarting after the power supply recovers. If the optional remote
operator is used and the retry function has been selected, this will also cause automatic
restarting when an operation instruction has been input, so please be careful.
1-7
f CAUTION
* Do not insert leading power factor capacitors or surge absorbers between the
output terminals of the inverter and the motor.
Earth
leakage Surge absorber
breaker
Power /. RST.-vWFOMoo
supply '>
Leading power factor capacitor
+ Be sure to ground the grounding terminal, (.
+ When inspecting the unit, after turning the power supply off be sure to wait unitl
the CHARGE lamp beside the control terminal is off before opening the cover.
(If the lamp is lit or still flickering, then the internal capacitor's residual voltage is still
dangerous.)
* MOTOR TERMINAL SURGE VOLTAGE SUPPRESSION FILTER
(FOR THE 400 V CLASS)
In a system using an inverter of the voltage control PWM system, a surge voltage
caused by the cable constants such as the cable length (especially when the distance
between the motor and inverter is 10 m or more) and cabling method may occur at the
motorterminal.
A dedicated filter of the 400 V class for suppressing this surge voltage is available,
Please order one.
* PROTECTION AGAINST NOISE INTERFERENCE FROM INVERTER
The inverter uses many semiconductor switching elements such as transistors and
IGBTs. Thus, a radio set or measuring instrument located near the inverter is
susceptible to noise interference.
To protect the instruments from erroneous operation due to noise interference, they
should be installed well apart from the inverter. It is also effective to shield the whole
inverter structure.
Addition of an EMI filter on the input side of the inverter also reduces the effect of
noise from commercial power line on external devices.
Note that external dispersion of noise from the power line can be minimized by
connecting an EMI filter on the primary side of inverter.
1-8
CAUTION
EMI filter Inverter
R R2Motor Power NoiseRI R2 L(LL) U (TI) M Source _ Motor
Power SI SI LZ(L2) V TZ) V
source T1 T L3(L3 i W (T31 W Inverter
Teminal EMI
' for filter Ground the
grounding frame.
- e * ,Pipmng
_u iNoise : (to be grounded)or shielded wire
Completely ground the shield made
of metal screen, enclosed panel, etc.
with as short a wire as possible.
- EFFECTS OF DISTRIBUTOR LINES ON INVERTERS'
In the cases below involving a general-purpose inverter, a large peak current flows on
the power supply side, sometimes destroying the converter module. Where such
situations are foreseen, or the paired equipment must be highly reliable, install an AC
reactor between the power supply and the inverter.
(A) The unbalance factor of the power supply is 3% or higher.
(B) The power supply capacity is at least 10 times greater than the inverter capacity
(and the power supply capacity, 500 kVA or more).
(C) Abrupt power supply changes are expected.
Examples:
(1) Several inverters are interconnected with a short bus.
(2) A thyristor converter and an inverter are interconnected with a short bus.
(3) An installed phase advance capacitor opens and closes.
In cases (A), (B) or (C), we recommend installing an AC reactor of 3% (in a voltage
drop at rated current) with respect to the supply voltage on the power supply side.
* When occurring an EEPROM error ([El7 ), be sure to confirm the setting
value again.
* When setting b contact to the reverse command ([REVI terminal), the inverter
state automatically. Do not set to b contact.
GENERAL CAUTION
In all the illustrations in this manual, covers and safety devices are occasionally
removed to describe the details. When the product is operated, make sure that the
covers and safety devices are placed as they were specified originally and operate it
according to the instruction manual.
1-9
2. INSPECTION UPON UNPACKING
Before installation and wiring, be sure to check the following:
- Make sure that there was no damage during transportation the unit.
- After unpacking the unit, make sure that the package contains one inverter and one operation manual
- Make sure that the product is the one you ordered by checking the specifications label on
the front of the cover.
Model abbreviation
(The example is for the 1300-055HFE2)
INVERTER
HITACHI 3oo 55HFU
INPUT OUTPUT
Input power supply, 380-4_5V 3 Ph 50Hz max:380-460V 3 Ph_ - Output voltagephase, and frequency 4oo-460V 3 Ph 60 Hz Amps (CT) 13 N(VT) 1 A Rated output current
(cT) 5.5kW(VT) 75kW Maximum applicable motor (4P kW)Production year - DATE 1995 MFG NO. |30-55H251L Production number
Hitachi, Ltd. Made in Japan |NE1539 and factory control symbol
Contents of Specifications Label
If you discover any problems, contact your sales agent immediately.
2-1
/
3. APPEARANCE AND NAMES OF PARTS
3.1 Names of Parts
Blind cover
3-1
)
4. INSTALLATION
4-1
)
CAUTION
- Be sure to install the unit on flame resistant material such as metal.
Otherwise. there is a danger of fire.
" Be sure not to place anything inflammable in the vicinity.
Otherwise, there is a danger of fire.
* Be sure not to let the foreign matter enter such as cut wire refuse, spatter from welding,
iron refuse, wire, dust, etc.
Otherwise, there is a danger of fire.
* Be sure to install it in a place which can bear the weight according to the specifications
in the text (4. Installation).
Otherwise, it may fall and there is a danger of injury.
* Be sure to install the unit on a perpendicular wall which is not subject to vibration.
Otherwise, it may fall and there is a danger of injury.
* Be sure not to install and operate an inverter which is damaged or parts of which are
missing.
Otherwise, there is a danger of injury.
- Be sure to install it in a room which is not exposed to direct sunlight and is well
ventilated. Avoid environments which tend to be high in temperature, high in
humidity or to have dew condensation, as well as places with dust, corrosive gas,
explosive gas, inflammable gas, grinding-fluid mist, salt damage, etc.
Otherwise, there is a danger of fire.
NOTE: ENCLOSURE SIZE FOR 75 kW to 110kW
The inverters, 75kW to I10kW must be installed into an enclosure with dimmensions no
less than 183cm (72 in) by 183cm (72 in) by 60cm (24 in).
NOTE: ENCLOSURE SIZE FOR 132 kW AND BIGGER
The inverters, 132kW and bigger, are complied as recognizedcomponents.
Therse devices are intended for use in an overall ecclosure with an internal ambient of
40 degree C for variable torque rating or 50 degree C for constant torque rating maximum.
End product temperature testing should be conducted to verify sufficient forced air ventilation
is provided to maintain this ambient in room ambient of 10-40 degree C.
Based upon component level testing , end product temperature testing may be conducted at
any convenient room ambient in the rangeof 20-40 dwgree C, unless the room ambient in the
intended application exceeds 40degree C, in which case testing should be conducted at the
elevated ambient.
Enclosure internal ambient temperature should be measured above the drive on to the upper
left or right side. Temperature measurments on the drive itself should not be necessary.
For cooling purposes, be sure that the inverter is installed vertically. In addition, be sure that it
is separated from other components and walls. If foreign matter is introduced into the interior
of the inverter, this may cause malfunctions, so make sure that no foreign matter can enter it.
0 cm or more Flow of air
(30cm or more)
5 cm 5 cm
or +-or Wall
mor mor
10 cmor more
(30cm or more'
(a) (b)
NOTE: Install the inverter vertically.
Do not install it on the floor or horizontally.
( ) is for 75 to 260kW
CAUTION
Be sure that the wall surface is a nonflammable
material, such as steel plate.
1_ Be sure to check the ambient temperature.
Place of installation Load characteristics Ambient temperature Applicable model
Within the enclosure Constant torque -10 to 500C All models
(NOTE 1) Variable torque -10 to 400C (NOTE 2)
NOTE 1: The inverter should be installed in a locked enclosure that meets the requirements in
IP4X.
The higher the ambient temperature inside the inverter, the shorter its life will be. If
a heat generating unit is used near the inverter, try to keep it as far away as possible.
Also, when installing the inverter in a box, be sure to carefully consider ventilation
and the dimensions.
NOTE 2: Each of inverters 22 kW to 260 kW must be installed in a locked enclosure.
4-2
IPrecation for installation and wiring_
When executing the wiring work or another work, attach a cover on the vent hole (slit) on the top of the
inverter to prevent wire chips, weld spatters, iron scraps, or dust from falling into the inverter.
y 15 cm or more
Cover (a nonflammable
- _plate such as an iron plate)
I i!
Vent hole
4-3
5. WIRING
. WARNING
* Be sure to ground the unit.
Otherwise, there is a danger of electric shock and/or fire.
* Wiring work shall be carried out by electrical experts.
Otherwise, there is a danger of electric shock and/or fire.
* Implement wiring after checking that the power supply is off.
It might incur electric shock and/or fire.
* After installing the main body, carry out wiring.
Otherwise, there is a danger of electric shock and/or injury.
5-1
AL CAUTION
* Make sure that the input voltage is:
Three phase 200 to 220 V/50 Hz, 200 to 230 V/60 Hz
Three phase 380 to 415 V/50 Hz, 400 to 460 V/60 Hz
* Be sure not to input a single phase to a 3 phase type.
Otherwise, there is a danger of fire.
* Be sure not to connect AC power supply to the output terminals
[U (TI), V (T2), W (T3)].
Otherwise, there is a danger of injury and/or fire.
INPUT OUTPUT
(L) (L2) (L3) (TI) T2) (T3)
R S T U V W
Power supply
* Fasten the screws with the specified fastening torque. Check so that there is no
loosening of screws.
Otherwise, there is a danger of fire.
Be sure to install an earth leakage breaker.
* The ground fault protection is designed to detect current flowing to the ground upon
power on. This function is to protect the inverter,not people. Install the earth leakage
breaker to protect against the ground fault on wires between the inverter and the motor.
(Use a breaker that is very sensitive to high frequency current so as not to cause
malfunction.)
* Be sure to set the fuse(s) (the same phase as the main power supply)
in the operation circuit.
Otherwise, there is a danger of fire.
As for motor leads, earth leakage breakers and electromagnetic contactors, be sure to
use the equivalent ones with the specified capacity (rated).
Otherwise, there is a danger of fire.
5-2
The terminal board will be exposed when the front cover or terminal cover (450L/HF,
550L/HF) is removed. Wire the inverter in this state.
5.1 Wiring the Power Supply and Motor
GG R S T RB P N U V W
(PE) (LI) (L2) (L3) (RB) (+) (-) (TI) (T2) (T3) (PE)
bral
resi
7T {ELB
ong
stor
MOTOR
Braking Units
Power supply
- The inverter will be damaged if the power supply is connected to the motor terminals
U(T I), V(T2) and W(T3), so be sure not to make any mistakes.
- If multiple motors are to be connected, be sure to attach a thermal relay to each motor.
NOTE 1: When changing the power supply of the motor between the inverter and commercial power, be sure to install mechanically interlocked switches MgI and Mg2.
ELB
R{LI) (TI) UPower S (L-2) Inverter (T2) V Motor
supplyT(L3) (T3)W Mg2
NOTE 2: Install an earth leakage breaker at the input of the inverter. (Select an earth leakage breaker whose sensitive current level is raised in high frequency range.)
When the cable length between the inverter and motor is long (more than 10 m),
the thermal relay may malfunction due to higher harmonics. Therefore, install an
AC reactor on the output side of the inverter or use a current sensor in place of the
thermal relay.
5-3
NOTE 3: Be sure that the specified grounding is carried out. Be sure to separate the unit's
grounding pole from those of other heavy electric machinery, and avoid using
common grounding poles.
If multiple inverters are used, make sure that the grounding connections do not
create a loop.
Improper grounding
Inverter
Inverter G)
Inverter
Proper grounding
Inverter
Inverter
Grounding bolt
Inverter (at the site)
5-4
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CAUTION
External or remote over load protection required, if multiple motors to be connected.
For models J300-45OLFU and -550LFU only , connect to branch circuit protected at
maximum 300% of output current rating.
Suitable for use on a circuit capable of delivering not more than 10,000 rms
symmetrical amperes,*** volts maximum,
(where *** = input voltage)
I
5.2 Wiring of Control Circuit Terminals
SINK TYPE wiring
(Factory settings)
FM CMI PLC P24 FW 8 7 6 5 4 3 2 I H OI L CM2 12
0 O0 O 0O O O
YUUUT TT
Input intelligent terminal Frequency setting(500 0 to 2 )
Q
RYf
RY I It
Fault alarm
For output
Current input ntel I gent terminal
27 V 50 mA nDC~to2OmA 5nA max
SOURCE TYPE wiring
FM PLC P24 FW 8 7 6 5 4 3 2 I H O oi L CM2 2 iA
0 0 0 0 O 0
Input intelligent terminal
I-
Frequency setting
(500 Q2 to 2 W )
|RY
RY I
Fault alan
For output
Current input Intel Ig nt terminal
DC 4 to 20 mA 27 VDC 5 mA
10 MA max
NOTE 1: When an output intelligent terminal is used, be sure to install a surge absorbing
diode in parallel with the relay (RY). Otherwise, the surge voltage created when
the relay (RY) goes ON or OFF may damage the output intelligent terminal circuit.
NOTE 2: Use a twisted and shielded wire for the signal line, and cut the shielded covering
as shown in the diagram below. Make sure that the length of the signal line is 20
meters or less.
5-5
Li -7
Frequency meter
9 /
Frequency meter
Insulate
No grounding necessary
Connect FG (frame ground) of the inverter.
NOTE 3: When the frequency setting signal is turned on and off with a contact, use a relay
which will not cause contact malfunctions, even with the extremely weak currents
and voltages, such as crossbar twin contacts, etc.
NOTE 4: Use relays which do not have contact defects at 24 V PC, 3 mA for the other
terminals.
NOTE 5: Separate the main circuit wiring from the relay control circuit wiring. If they must
cross, be sure that they cross at a right angle.
Main circuit power line
(R. S, T. U. V, W, PP. P, RB, N, LI, L2, L3, TI, T2, T3, +, -,etc.)
Right angle
Signal input line
(FM, CM1, PLC. P24, FW, 8, 7, 6, 5, 4, 3, 2, 1,
H, 0, 01, L, CM2, 12, 11, ALO, ALl, AL2)
Separate by 10 cm or more.
NOTE 6: Do not short between the terminals H and L and between the terminals P24 and
CM1 of the control circuit.
NOTE 7: Insulate the common terminal L for frequency analog command input and
the
common terminal (COMMON) of the peripheral equipment such as the sequencer
before starting use.
5-6
5.3 Connection to the Programmable Controller
(1) When the internal interface power source is used
T This is an example when the sink type transistor
output (open collector output) module of the
sequencer is connected
Note: Make sure of the short-circuit bar or wire
between the terminals PLC-and P24.
J300 series
Com
YTR48 type output module Inverter
(by Hitachi)
(2) When the external interface power source is used
10 This is an example when the sink type transistor
output (open collector output) module of the
sequencer is connected
Note: Remove the short-circuit bar or wire between
the terminals CM I and PLC or P24 and PLC.
@ This is an example when the source type
transistor output (open collector output)
module of the sequencer is connected
Note: Make sure of the short-circuit bar or wire
between the terminals CM I and PLC.
1300 series
COM P24
PLC
F ('
YTS48 type output module Inverter
(by Hitachi)
@ This is an example when the source type
transistor output (open collector output)
module of the sequencer is connected
Note: Remove the short-circuit bar or wire between
the terminals CM I and PLC or P24 and PLC.
vrDc J300-sen1es J300 series
SP24P1I
C[C24v 4vDC CMI T24Voc
A PLC - PLC
8-
YTR48 type output module Inverter YTS48 type output module Inverter
(by Hitachi) (by Hitachi)
Note: Be sure to turn the inverter on after the controller and external power source are turned on.
(Otherwise, the data in the inverter may be changed.)
5-7
5.4 Wiring Equipment, Options (EMI filter, etc.)
Standard equipment (200V class)
Wiring (AWG or Kcmil) Applicable equipment
Constant torqe Variable torqe Power Signal Signal Earth leakage EleciroPower supply Inverter lines llines ines breaker (ELB mapetic
model Motor Power Motor Pe Extea CL ".L.O
output lines output lines resistor Fw5,76:543 A L
(kW) RS.LUV (kW) R.S.T,U,V R813, 2.I0OULL
W.P.N W.P.N P,RB CM-.I2.tt
AWG 8 AWG 8 10 AWG 18 AWG 16
J300-55LF 5,5 or more or more or more Shielded ormore20
AWG6 AWG6 10 wire
ELB - 1300-075LF 7,5 or more or more or more EX50C30A) H20
AW U4 -AWG4
1300-IIOLF li or mor 5 or mor whnthe EX50C(50A) H25
AWG 3 AWG3 sberor
1300-1iOLF 15 2ormore 2 EX60B(60A) H35I L or m~~re or MOreM ~ t
AWGI/o AWGl; useis
J300-220LF | G22 30 - re RXIOO(75A) H50
7 Y Magnetic or more 3 or more
4 30-00F AWG3/0 AWG 310 oteach RI0Ic-3 contactor J30-0LF 3 3 7 --- xad X 010Ah6
S30 or more , or more
AWG4O AWG4/0 ihold
J300-370LF 37 45 Aw2 40 RX100(100A H80or more or more A%__ :_
300 -- 300
J300-450LF 45 or more o more RX225(I50A H100
J300-550LF 55 or more or more - RX225(175A H125
(400V class)
Wiring Applicable equipment
Constant torge Variable torqe Power Signal Signal Earth leakage Electro
nerter lines lines lines breaker (ELB magnetic
model Motor Power Motor Power External FM.cMI.PCL 24.AL.ALI contactor
output lines output lines resistor FWsL6.543 AL(kW) R.S.T,UV (kW) R,S,T.U.V RBI 2,3, -,IoYOLL,
W.P,N W.P.N PRB M12.11
J300-55HF 5.5 AWG 8 AWG8 10 AWG IS AW 6i EX50C(30A) H20or more or more or more Shielded or more
1300-075HF 7.5 AW 8 11 AW 8 0 wte EX50C(30A) H20or more or more or more
AWG8 AWG8
J300-110HF 1 8 15 --- EX50C(50A) H25or more orLre Whethe
AWG6 AWG6 ni d
1300-150HF 15 or more 22 orhmore EX60B(60A) H35
AWG4 AWG4 sedsl
1300-220HF 22 30 - ormor RX100(75A) H50or more or more e rn
AWG4 AWG 4 fr.h
1300-3001F 30 37 o e - hmed RX100(100A H65or more Or more
AWG2 AWG2
J300-3701F 37 45 or ore ^* RX100(100A H80
AWGOI AWGOl
J300-450HF 45 55 RX225(150A H100or more or more
AWG 3/0 AG/
3300-550HF 55 75 RX225(175A H125or more or more
J300-750HF 75 300 90 300 RX225(225A H150I or more or more_
J300-9001HF 90 300 110 300 -- RX225(250A H220or more or more
1300-1 100HF 110 350 132 350 RX400(350A H250or more or more
1300-1320HF 132 AWG4 0 160 AWG 40 RX400(400A) H400parallel parallel
1300-1600HF 160 300 2o 300 -- RX600(600A) H600parallel - parallel
J300-2200HF 220 350 260 350 - RX600(600A) H600parallel parallel
5-8
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NOTE 1: The applicable equipment is for Hitachi standard four pole squirrel-cage motor
NOTE 2: Be sure to consider the capacity of the circuit breaker to be used.
NOTE 3: Be sure to use bigger wires for power lines if the distance exceeds 20m.
NOTE 4: Be sure to use an grounding wire same size of power line or similar.
(*) Use AWG 16 wire for the alartm signal wire.
Classify the detective current of the earth leakage breaker depending on the total
distance between the inverter and the motor.
NOTE 5: When using CV wire and metal tube,
the leakage current is around 30 mA/km.
NOTE 6: The leakage current becomes eight times
because IV wires have a high dielectric
constant. Therefore, use an one class
larger earth leakage breaker according
to the left table.
5-9
Part description Function
AC reactor for This part is used when the unbalance voltage ratio is 3%
improving or more and power supply is 500 kVA or more, and there
the power factor is a rapid change in the power supply.
(ALL- C L) It also improves the power factor.
(ALI- ECH)
Radio noise filter Using the nverter may cause noise on the penpheral
(Zero phase equipment through the power lines.
reactor)(ZCL-A) This pan reduces noise.
EMI filter for This part reduces common noise generated between
nverter the power supply and the ground, as well as normal noise.
(FFJ300-E Em ) Put it in the primary side of inverter.
Regenerative This part is used for applications that needs to increase
resistor the brake torque of the inverter or to frequently turn on(RB=CE1 -) and offand to nan high inertia load.
Radio noise filter This part reduces noise generated at the output of
(Zero phase the inverer.
reactor) (ZCL-A) (It is possible to use for both input and output.)
AC reactor for Running motors with the inverter generates vibration
reducing vibration greater than that with commercial power supply.(ACL-L-EE) This part installed between the inverter and motor reduces
(ACL-H-.E:) torque ripple.
When the cable length between the inverter and motor is
long, i countermeasure for a malfunction of the termal
relay is taken.
length Detective current (mA)j
100 m and less 30
300 n and less 100
600 mt and less 200
5.5 Terminal
Width
(I ) Main circuit terminal
Terminal layout Type Screw Widthdiameter (mm)
Ge R S T RB -P N U / V IW T
(PE) (LI) (L2) (L3) (RB) + (D) (T ) (T) ) ( 2E) 2055 075LF M5 23
40, 150LF M6 17.5
GO R S T P N V W G 0W150HF
(PE) (LI) (L2) (L3) (+) (D) TI) (TI) (T) TI) P ) 450o37L0F
M8 23
450, 550LF M10 35 _
---Intemnal short circuit bar 220 to 370HF M6 17.5
G R S T PD P N U V W GO IOH M 40()i (Ll) i ( L (3)| (+1) (+) I(D)
I(Tl) (TI) (T) (PE) 450, 550HF M8 23
----Intemnal short circuit bar71,90F M
3
GO R S T PD P N U V 9 l0HF M10 40
(PE) (LI) (L2) (L3) (+1) (+) ( D) (TI), (TI) (TI) (PE)
1320 to 2200HF Ml6 5I
Main circuit
Terminal
symbol Terminal description Function
R, S, T
B rakin iCL,R,() T Main power Connect the power supply r ara king Units
U, V, W Inverter output Connect the motor ELB
ST l).(T2) (T3) Power supply
Connect a braking resistor (option)
P( RB Extemal braking Only the 055LFRHF and 075LF/HF Ii'lm onr ihsr
(-),(RS) resistor are equipped RB terminals. I.
P, N Dynamic braking unit Connect a dynamic braking unit
) (option) Remove the intermal short circuit bar when
DCL is connected.
G Ground Ground (connect grounding to avoid L WARNING
(PE) electric shock) watil o bus voltage is diseharg after powersupply istumed if
Otherwise, there isa danger orelectnc thock.
PD External choke coil Connect a choke coil (DCL) for
(+1) harmonics current reduction
Ground at case Ground (connect grounding to
avoid
electric shock)
(2) Control circuit terminal
The intelligent 1/0 terminals I to 8 and I I and 12 are initialized as shown below at factory before shipment.
FM CMI PLC P24 FW REV CFi USP CHI FRS JG AT RS H O O L CM2 RUN FAI AL2 ALl ALO
T T T T T T I T T T
FM CMi PLC P24Fw 3 7 6 5 4 3 2 i H 0 O1 L CM2 12 11 AL2 ALI ALO
5-10
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Control circuit
erminal T. Standard setting of
symbol Termmal description and function intelligent terminal Remarks
FM Frequency monitor Dry contact
CMI Common for monitor Close: ON (run)
Open: OFF (stop)
PLC Common terminal for the external power
source of the sequencer (PLC) Min. ON time:
20 ms or more
P24 Internal power source for the frequency
monitor and intelligent input terminal
Input FW Forward operation
monitor I
signal 8 Intelligent input terminal 8 REV Reverse operation
7 Intelligent input terminal 7 CF I Multistage speed
(First stage)
6 Intelligent input terminal 6 USP Prevention function of
restart upon power on.
5 Intelligent input terminal 5 CHI 2 stage acc./dec.
4 Intelligent input terminal 4 FRS Free run input signal Ite power is turned
on when the input
teroinats I to 5 are
kept on, all the data
3 Intelligent input terminal 3 JG Jogging sd in ye nv rer
2 Intelligent input terminal 2 AT Current input selection thepo"n'in rch
I Intelligent input terminal I RS Reset (NOTE 1)
Frequency H Power supply for frequency command 10 VDC
command 0-5 VDC(nominal),0-0VDC
input 0 Voltage frequency command omimtiouimpneduc
of Current frequency command DC 4-20 mA (nominal)
input impedance 2500
L Common for frequency command
Output CM2 Common for intelligent output terminal
signal 12 Intelligent output signal 12 RUN Run signal 27 VDC
l 1 Intelligent output signal I I FAI Frequency arrival signal '
Fault alarm ALO Normal: ALO-AL I close Contact rating
output ALl Abnormal, Power off: 250 VAC 2.5 A (Resistor load) Min 100 VAC
ALO-ALI open 0.2 A (cos =0.4) 10 mA
AL2 |AL2 | ALI ALO 30 VDC 3.0 A (Resistor load) 5 VDC
0.7 A (cost=0. 4 ) 100 mA }
4 CAUTION
Alarm connection may contain hazardous live voltage even when inverter is disconnected.
In case of removing flont cover for maintenance or inspection, confirm that incoming power
for alarm connection is surely disconnected.
NOTEI: Terminal RS can use only contact a (normally open). It cannot use contact b (normally closed).
5-11
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5.6 Control Circuit Terminals
Terminal symbol Terminal name Description
FM Monitor terminal Analog: Output frequency, current, torque
Digital: Output frequency x frequency converted value
(Set in the remote operator monitor mode), max. pulse: 3.6 kHz
CM Common terminal L Common terminal for the monitor terminal
PLC Intemiteraccommon Common terminal for the external power source of the sequencer
P24 Inpusignaboweesource internal power source for the contact input terminal and frequency
monitor terminal, 24 VDC.
Common for the FW terminal and intelligent input terminals
OUTPUT frequency
FW Forwardunistolernmal Forward
Reverse
REV Reverse run/stop SwF
SwR1 swE
Frequency
CFI S Hz) Fourh(FS) (sourcetype)speed
Third
speed1
Second
,ped evlTC. r4F 8 7 6
CF2 Multistage speed SW2 Fid
Swiich Tune
SW le -When seuting frequency,
CW31 ON 0 connect P24 and6Or7
CF3 SW3 sw2 and set with digital
(NOTE 1) SWFE ON operator[Kor .
JG Jogging Jogging run
DB External DC braking DC brakig input signal
STN Initialization Initialization (shipment status at factory) input
SET 2nd function |The output frequency setting, base and maximum frequencies,
control method, motor constant, acceleration or deceleration time,
manual torque boost setting, and electronic thermal setting are
changed in batch.
- CH7 Two-stage acceleration The acceleration or deceleration time or selection of two-stage
or deceleration accration or deceleration is changed by turning the contact ON.
FRS Free run stop The inverter stops and the motor stops free run
FRS functions when the contact is opened. (European version)
EXT External trip External trip input signal (The contact is open.)
USP Power-ON restart Restart prevention when the power is turned on in the RUN
prevention state (The contact is open.)
C Commercial power source Switch signal from the commercial power source to inverter
switching drive (Note: When the terminal is used, a trip is also conceled.)
SF1~ Termmal software lock The data o all funcitons except for output frequency setting is
locked. See 12-9 [F-25].
AT Analog input command Analog input voltage-current switching (When the contact is ON,
current input signal to OI-L is acrive.)
RS Reset | Trip or alarm signal is reset.
UP Remote control function, When the contact is turned ON, the operation is accelerated.
acceleration (Available only when the frequency command is sent
to the operator.)
D 1 Remote control function, When the contact is tumed ON, the operation is decelerated.
deceleration (Available the frequency command is sent to the operator.)
5-12
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Terminal symbol Terminal name Description
H Frequency command power * Initialization of a voltage signal by an external command
terminal is between 0 and 10 VDC. (Switching from 0 to 5V is executed
by A48.) When inputting 4 - 20 mA, turn the input terminal at
_________ON.
Frequency command ON.
terminal (voltage comand) L H I 0 01 L
01 Frequency command -$
terminal (current command) VRO DCO to 10 V DC4 to20 mV
1Frequency command 500 to 2 k) DCO to SV Input impedance 250 kD
input mpedance 30 kO
common tenninal When a current is inputted from between 01 and L and the value is 4 mA,
the output frequency may 0.6 Hz. If this occurs, set a value more than the
frequency which is outputted by [A 4] start frequency setting.
(NOTE 2)
CM2 Common terminal 2 Common terminal for imtelgent output terminal
FAl Frequency arrival signal When each operator is used, and arrival signal can be
outputted at an optional frequency.
RUN Signal during run The transistor output is turned 0N during running.
(Outputted even during DC injection braking)
OTQ Over-torque signal The transistor output is turned ON when the torque is more
than the set value.
The set value can be changed by the remote operator.
Use this function only under the sensor less vector control.
ALO
Normal: ALO-ALI close
Abnormal, Power off:
AL2 |Aul Ato ALO-AL I open
ALl Fault alarm terminal
Contact rating
250 VAC 2.5 A (Resistor load) Min 10OVac
0.2 A (Coso=0.4) 10 mA
AL2 30 VDC 3.0 A (Resistor load) 5 VDC
0.7 A (cos0=0.4) 100 mA
NOTE'1: To set four or more multispeeds, use the CF3 terminal.
NOTE 2: When an inconvernience occurs in the above characteristics, adjust it using
Ra 80and R B A. The sum of both analog input signals is outputted
When selecting one of analog input current and voltage, make sure that the other
is not inputted.
5-13
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5.7 Terminal Connection Diagram
Power supply -ELB
Three phase _
power supply
Frequency setter
5000 to 2 kO
Current input
4 to 2\0 nA Dynamic braking resistor
055, 075LF: RBI,RB2 or RB3
055, 075HF: RB2, two each in series.
Fault alarm signal
(Normal: ALO-ALI ON)
RY
RY
24 VDC
Follow the timing shown as below
upon power on.
- Grounding
NOTE 1: Common terminal for each terminal is different.
Terminal FM FW, 8 to I H, 0, 01 11, 12
Command CMI CMI (P24)* L CM2
*: P24 is for source type wiring.
NOTE 2: The regenerative resistor has a temperature sensor.
When it works, turn off power supply to the inverter
o set the deceleration time longer.
Main circuit
power supply (NOTE 4) 1 0.6 or more seconds
Operation
command
Output
frequency
Number of
revolutions
ofmotor
NOTE 3: When the operation command is input first
and the main circuit power is turned ON,
and direct start results and a trip occurs.
NOTE 4: Do not input the operation command
simultaneously when the main circuit
is turned on.
5-14
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6. OPERATION
6.1 Before Starting Operation
Prior to the test run, check the following.
I WARNING
" Be sure to turn on the input power supply after mounting the surface cover. While
being energized, be sure not to remove the cover.
Otherwise, there is a danger of electric shock.
- Be sure not to operate the switches with wet hands.
Otherwise, there is a danger of electric shock.
* While the inverter is energized, be sure not to touch the inverter terminals even during
stoppage.
Otherwise, there is a danger of electric shock.
* If the re-try mode is selected, it may suddenly restart during the trip stop. Be sure not
to approach the machine. (Be sure to design the machine so that personnel safety will
be secured even if it restarts.)
Otherwise, there is a danger of injury.
" Even if the power supply is cut for a short period of time, it may restart operation after
the power supply is recovered if the operation command is given. If it may incur
danger to personnel, be sure to make a circuit so that it will not restart after power
recovery.
Otherwise, there is a danger of injury.
* The Stop Key is effective only when the function is set. Be sure to prepare the Key
separately from the emergency stop.
Otherwise, there is a danger of injury.
* After the operation command is given, if the alarm reset is conducted, it will restart
suddenly. Be sure to set the alarm reset after checking the operation command is off.
Otherwise, there is a danger of injury.
- Be sure not to touch the inside of the energized inverter or to put a bar into it.
Otherwise, there is a danger of electric shock and/or fire.
6-1
I CAUTION
" Radiating fin and discharging resistor will have high temperature. Be sure not to touch
them.
Otherwise, there is a danger of getting burned.
- Low to high speed operation of the inverter can be easily set. Be sure to operate it
after checking the tolerance of the motor and machine.
Otherwise, there is a danger of injury.
- If a motor is operated at a frequency higher than 60Hz, be sure to check the speeds of
the motor and the machine with each manufacturer, and after getting their consent,
operate them.
Otherwise, there is a danger of machine breakage.
Note:
(1) Make sure that the power lines (input power supply R(LI), S(L2) and T(L3), and output
terminals, U(T 1), V(T2) and W(T3) are connected correctly.
(2) Make sure that there are no mistakes in the signal line connections.
(3) Make sure that the inverter case ( ) is grounded.
(4) Make sure that terminals other than those specified are not grounded.
(5) Make sure that the inverter is installed vertically on a wall, and a nonflammable material
such as a steel plate is used as a mounting surface.
(6) Make sure that there are no short-circuits caused by stray pieces of wire, solderless terminals or other objects left from wiring work. Also, make sure that no tools have been left
behind.
(7) Make sure that the output wires are not short-circuited or grounded.
(8) Make sure that there are no loose screws or terminals.
(9) Make sure that the maximum frequency setting matches the machine specifications.
Be sure to refer to page 10-2 when conducting insulation resistance and withstand
voltage tests. Never test terminals other than those which are indicated.
6-2 I
6.2 Test Run
An example of a general connection diagram is shown below.
Operating with digital operator:
When setting frequency, run and stop
with digital operator.
(The same way as remote operator
(DOP) or copy with (DRW).)
ELB Inverter
Three LIl R(LI) (TI)Uphase L2- A S(L2) (T2)V
power L3 T(L3) (T3)wsupply
Running from external command:
When setting frequency, run and stop
from external command (FW,RV Terminal.)
The following shows run from
the operation box (OPE-4MJ2,OPE-8MJ2)
Three
phase
power
supply
ELB
Motor
Fault alarm signal
(Normal
ALQ -A LI: ON
Abnormal
Power offT
ALO-ALI: OFF) |
Fault alarm
signal
seet
Operator
(OPE-4MJ12\
SOPE-8M12)
*: For sink type wiring.
CAUTION
Check the following before and during the test run.
Otherwise, there is a danger of machine breakage.
- Was the direction of the motor correct?
- Was the inverter tripped during acceleration or deceleration?
* Were the SPEED (rpm) and frequency meter correct?
- Were there any abnormal motor vibrations or noise?
When overcurrent tripping or overvoltage tripping occurs during the test run, increase
the acceleration time or deceleration time.
Factory settings
Maximum frequency: 60 Hz
Forward operation
6-3
Ground
Operating with digital operator:
Proc
(1)
(2)
(3)
Runnign from external command:
edure
Turn on ELB to supply power to the inverter. Make sure that the POWERLED on the digital
opera tor turns ON.
Press the FUNC key once to display 0 .
Press 7 of the digital operator four times to display F 9.
(4) Press the FUNc key and then press the
key to set 00. Press the FUNC key to
establish the data.
(5) Press the F key four times to display
(6) Press 7 of the digital operatort five times
to dispaly F 2.
(7) Press the FUNc key and then the ey
so as to increase to frequency or the
key so as to decrease the frequency.
(When the For key is pressed continuously, the frequency is changed continuously.)
When the FUNc key is pressed, F 7 is
displayed.
(8) Check the output frequerncy and rotation
direction. When the or F key is
pressed to display F 9 and then the
FUNc key is pressed, the rotation direction
can be checked. F| indicates forward
rotation and r indicates reverse
rotation. When the rotation direction is
checked, press the FUNC key. When the
rotation direction cannotbe found, operate
the equipment at a low frequency to check
the rotation direction.
(9) Presst the RUN key. The equipment
starts running.
(10) Press the STOPRESET key. The equipment
decelerates and stops.
(4) Press the FUNc key and then press the A
key to set Q 3 . Press the RUNG key to
establish the data.
(5) Press the [ key four times to display
(6) Short the terminals FW and P24 (CMl*)
of the control terminal block.
(7) Apply a voltage between the terminals 0
and L to start running.
(8) Open the terminals FW and P24 (CM1*)
of the control terminal block to stop deceleration.
*: Symbols are indicated for Sink type wiring.
Refer to page 5-5.
6-4
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- The failure alarm signal is generated from the terminal ALO and ALL when a failure happens. At this time the contents of the failure are displayed on the digital operator.
- Whether the alarm terminal output is to be turned on or off during normal run can be
selected by the extension function
The alarm output terminals at initial setting are as follows (1).
The alarm output terminals are valiable as follows (2) by setting W ~U.
(1) Contact b (2) Contact a
During norrnal operation At occurrence ofan During normal operation At occurrence of an alarm
alarn or power off or al power off
AL2 ILALI AI Lo ALl ALO AL2 ALI ALD
Contact Power Operation ALO-ALI ALO-AL2 Contact Power Operation ALO-ALI ALO-AL2
Status IStatus
b ON Normal Closed Open ON Nonal Open Closed
(initial ON Abnormal | Open Closed a ON Abnormal Closed Open
seling) OFF N Open Closed OFF 9 Open Closed
- Contact specification
Maximum Minimum
250 VAC 2.5 A (Resistor load) 0.2 A (cost=0.4) 100 VAC 10 mA
30 VDC 3.0 A (Resistor load) 0.7 A (cost=0.4) 5 VDC 100 mA
Working voltage: Max. 50 V
- Saving the alarm signal
When an alarm signal is outputted, the alarm signal data is stored even if the input power is
turned off and the contents can be checked by turning the power on once again. However,
when the input power is turned off, the inverter control power is also turned off. As a
result, when the power is turned on next, the alarm contact output is reset (deleted). Therefore, when saving the alarm contact output, let the external sequence receive and save it
and then turn off the inverter input power.
- When the alarm contact output is set ON during normal run, a time delay occurs until the
contact is closed when the power is turned on. Therefore, when using the alarm contact
output, set a time delay of about 2 seconds when the power is turned on.
6-5
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Resetting (Any one of A, B and C is possible)
CMI PLC P24
When the internal interface power source
P24-CM I is used (Source type wiring)
CMI PLC P24
When the internal interface power source
P24-CM I is used (Sink type wiring)
A) Turn control terminal I on. (In the
initialization at factory before shipment, intelligent input terminal 1 is
allocated to the reset RS terminal.)
B) Press STOP on the digital
operator. (This is effective only when
an alarm occurs.)
C). Open the power receiving breaker of
the inverter, and make sure that the
Charge lamp on the control board
goes out. (See page 3-1.) Then, close
the power receiving breaker.
NOTE: When the control circuit terminal RS is used, never short-circuit RS-P24 (CM1*)
for four seconds or more. Otherwise, a communication error
R-ERROR COMM<2> may occur (Although the digital operator display is
, the inverter is normal). When the above error occurs, open the RS terminal and press the operator key.
*: For sink type wiring
How to return to the initialization (state before shipment)
When returning the equipment to the initial state set at factory before shipment for some
reason, see page 7-14.
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I6-6
7. OPERATION OF THE DIGITAL OPERATOR
The standard type digital operator is modified so as to be used easily by minimizing key operations. Data can be set simply.
POWER
=TOP/RESET
D
7.1 Names of Parts
Monitor (LED display)
This display shows frequency, motor
current, motor revolution speed, and
Trip history
FUNC (Function) key
This key is used for changing
commands. When pressing
key after setting data and
parameter, they are automatically memorized.
RUN key
This key is used for starting. (When
terminal run is selected, this key does
not work.)
POWER Lamp
Power lamp of control
circuit
Up key, Down key
These keys are used to
change data and increase
or decrease the frequency.
STOP/RESET key
This key is used for stopping the motor or
resetting errors.
(When either operator or terminal is selected, this key works. If the extension
function is used, this function is void.)
I WARNING
D The STOP/RESET key works only when a function is set. Prepare an emergency switch separately.
The use of the STOP/RESET key as an emergency switch may cause an injury.
7.2 Operation Procedure
(Example that the frequency is set and the equipment starts running)
f|i iO id C : 2 flOf lfl.
Display after
power is turned Press the FUNC Press the Press the key once
on key once. key five times. and set the frequency by using
the Fand keys.
(Frequency
monitor) ~ Press the FN
key once, m
to hen selecting the monitor
ode, press FA and
display dE0I.
7-1
Start , c -- _ |
run I- L | The frequency which is
Press RUN set by the FUNC key is
stored.
7.3 Key Description
Data display The key are used to select the code and change the data. When
Code display the [ key is pressed once, the monitor mode I 0 is displayed
UP/DOWN key, first and thendl ll, d D, F = , --- are one by one. If the A
key is pressed once again when F I L/ is displayed, the display is
returned to [ OJ .
If an optional code is selected when F / 19 is displayed and the
FUNC key is pressed, the extension function mode can be selected.
FUNC] [Function key].
|MB
This key allows the selection of commands and memorizes parameters.
When this key is pressed once in the state of F |, F / I , the
data state is set. When the key is pressed once in the state of F / ,
the extension function code selection state is set.
S Fe :0l|I2
5|7.9|
ld| L /|screen transition [
RUN [RUN key] . . .This key starts the run.
The set value of F4 det
sRESET
FUNC F N C
F9| F o Fi-99- 7 :
Select the extension A setting method which
function code. is the smame as that for
|d| Qto || |is
used for the subsequent
screen transition.
FF|1 / 9|screen transition
ermines a forward run or a reverse run.
[STOP/RESET key] . . .This key stops the run.
When a trip occurs, this key becomes the reset key.
7-2
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7.4 Explanation of Screen Display
- When the inverter is turned on, the latest display appears. However, when the display
unit for data of the commands F2 to F14 is turned off, the commands (F2 to F14) are
displayed. (d10 and dl I excluded)
- Data during running in any function mode or extension function mode can be displayed.
Even if data cannot be changed during running, data can be monitored.
- In each of the function modes|F| F, F1 F , and=F Q, data
can be changed even during running. In other function modes and extension function
modes, data cannot be set during running.
d=D toll |2 i +d Uto C- 2/
The display is left unchanged.Or data display
Running start
FW 2 F77||Fl| |F 1 1 i|F | - |1|1.0|
Code which can change data during running
FUN Data can be canged]even during running
7-3
7.5 Transition of Each Code
j Li Output frequencymonitor
,Motor revolution
d1 speed monitor
j JOutput current
- monitor
Frequency converted
4 s value monitor
u/I-) Trip monitor
Trip history
I monitor

C D Output frequency
setting
Running direction
setting
r Acceleration time
/ setting
,C j Deceleration time
setting
)C - Manual torque boost
setting
Run command,
C frequency command
1 Analog meter
-J adjustment
t Motor receiving
voltage
c i y Extension function
setting :
When theFUNC key is pressed onc
to set the extension function, the
screen is changed to the extension
function code selection screen.
When a code is selected from the
codes to M and the
FUNC key is pressed, the screen is
changed to the relevant extension
function settig screen.
To extension function code setting
y
R jRT- P 15P13
RH
RI-JPF- q-M3
|[' RL1
_-I T?79
Control method setting
Motor capacity setting
Motor poles setting
Speed control response
constant setting
Start frequency adjustment
Maximum frequency
limiter setting
Minimum frequency
limiter setting
Jump frequency setting I
Jump frequency setting 2
Jump frequency setting 3
Carrier frequency setting
Frequency command sampling
frequency setting
Multispeed first
speed setting
Multispeed second
speed setting
Multispeed third
speed setting
Electronic thermal level
adjustment
Electronic thermal
characteristic selection
Motor pole number setting
for motor speed monitor
External frequency setting
start
External frequency setting
end
Instantaneous restart
selection
Dynamic braking usage
ratio
Optional arrival frequency
for acceleration
Optional arrival frequency
for deceleration
Monitor signal selection
Frequency converted
value setting
Analog input selection
Frequency arrival signal
output method
Restarting after FRS
signal selection
7-4

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1 7 9 51
IE- _
IT
P3 S/
c e- I
/1 -5
I IRI /
- -PR-)-9 9
ILI I
r L/
Reduced voltage soft
start setting
Running mode
selection
Jogging frequency
setting
Base frequency
setting
Maximum frequency
setting
Maximum frequency
selection
Frequency command/
output frequency adjust
(0-L terminal)
Frequency command/
output frequency adjust
(O-L terminal)
Selection of reset
termal performance
P gain setting of PID
funciton
1 gain setting of PID
function
D gain setting of PID
funciton
Selection of PID
funciton
Setting method of PID
reference value
Setting of PID
reference value
Auto tuning setting
Motor data selection
Ro-To option selection
Input terminal setting I
Input terminal setting 2
Input terminal setting 3
Input termianl setting 4
Input terminal setting 5
Input terminal setting 6
Input terminal setting 7
Input terminal setting 8
Output terminal setting
Output terminal setting
Input terminal a and b
contact setting
I1
12
=F7 Output terminal a and b
-- J contact setting
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7.6 Digital Operator Initialization List
(1) Monitor mode, function mode
* The standard set value of each code number is displayed.
- The extension functions shown on page 7-6 can be set by the Fl/ 9 extension
function setting funetion.
iScreen display I setable
order Function name Type Code Settable alue function value
display during Monitor/set valuerunning
I Output frequency monitor Monitor d 0 - 0.00-9.99/10.0-99.9/100-400 - 2 Motor revolution speed Monitor d I - 0.00-9.99/10.0-99.9/100-600 - monitor
3 Output current monitor Monitor d2 - 0.0-999 - 4 Frequency converted value Monitor d 3 - 0.00-9 99/10.0-99.9/100.-999. - monitor 100-999/F0-99
5 Tnp Monitor Monitor dio 6 Trip history monitor Monitor di1 7 Output frequency setting Set value F 2 4 0.00-9.99/10.0-99.9/100-400 0.00
8 Running direction setting Set value F 4 Not possible F/r (forvard run/reverse run) F 9 Acceleration time setting I Set value F 6 4 0.01-9.99/10.0-99.9/100-999 30.0
10 Deceleration time setting I Set value F 7 4 0.01-9.99/10.0-99.9/100-999 30.0
I l Manual torque boost setting set value F 8 00-99 NOTE 3
12 Runn command, frequency Set value F 9 Not possible 00-15 03
command setting
13 Analog meter adjustment Set value Flo 4 00-250 172 14 Motor receiving voltage Set value Fi l Not possible 200-230/380-480 230/460 -NOTE 2
15 Extension function setting Set value F14 Not possible A 0-A99/C 0-C21 A 0 NOTE 1: In the standard configuration, four values from 0 to 3 can be selected. When an
optional PC board is mounted, 16 values from 0 to 15 can be selected. Refer to
F-9.
NOTE 2: For the 200 V class, one of 200, 215, 220, and 230 can be selected.
For the 400 V class, one of 380, 400, 415, 440, 460 and 480 can be selected.
NOTE 3: Set torque boost in 70 to 90 when using VP1, VP2 or VP3 in V/F control mode.
7-5
(2) Extension function mode
- Each function name and settable range to the extension function mode are shown
below.
- Set the extension function code to be changed by|Fl /.
Screendisplay se.a
FErn.siont unctionname Code lsa Remark value
riery d Setting range Initial alue
: n tiehod serim; A) N I 0-5
M ttrcapacity scon A 4 37 1o7 ) IN) NOTE I
letor..poles t erung 2 9 !,4/6 8 4
sieede ontr irosp nsconstant eting N 4.00-999100-99.9/100 2% N
Stan Irequencvadiustment \4 N 010-990 050 N
Maximumfreqiuenc yhlimier setting AS 9 ,- 120 (400) N
intnium firequency Jitter seitilg A 6 1N 0-120 140041 (
u lmp frequency setting-l A
7
' N1 0-400 0 N9 _______ ________
O ump trequencysetting 2 A8 N 0-400 0 N _____
0 Jump frequency setting 3 A N 0-400 0 N
camerfrquenyseimg AlOi NI 20-160 '16.0 N See7- 18
12 FrequencyLomanand sampling frequency Al 9 1-8 8 N
3- Multispeed firsi speed settng A 12 s4 0-120 (400) 0
4 MultisPeed second speedsetting A13 N 0-120400 0 N
ulispeediird speedseting A14 N -120<400) 0 N
6 Eleciro nichermallevel djustmeni -A23 t l 20-120 100
- i-ectronictherma I baracterstic selection A24 N -2 L
8 .Motor Nole number whine for motor speed monnor | A25 N ito 48 i 4 N
1I I temal frequenc ysetng siaN A26 N 0-1 20(4001 ) 9
20 Exreeal frequeny setting end i A27 I 0-120 1400) 0 N
21 Instantaneous restart selection i A34 N 0-3
22 Dynamic braking usage ratio A38 N 0 0-99 9I 100 1 | See 7-1
')ptionil amtval frequente ir acceleration | A39 IN | f-400 1 N
'4 optional armtal frequency for deceleration A40 0-4) 0 9t
.5 Monitor signal election A44 0-3
26 | Frequercy converted value seting A47 0.0-99-9 -.0
27 1 A naomputselection A49 C4 0-1 N
232 Fc y vs ootpur method n o c up., tr l I A49 N 0-2 0 N
29 Resiarting afer FRS signal selection A54 N W-1 V N
0 Rcedcedolagesot start seing A58 N 04 6 N
31 Runngnrode selecton A59 N 0-2 0
32 Jogg g reguency setting A61 N 1 -9.99n Lf in"
33 1 Base trequency setting A62 N 30-120 400) 60
34 Maximum frequency seting A63 N9 30-120 400) 60
35 I Maxinum frqencyse lecton A64 N 120'400 120 A
36 Frequency conmand/ouipuirfrequency adjust 0-L termnnal) ASO N 0-255 N N NOTE 2
37 | Frequency commnoiutui freqtec adjust01-1L tennali A8I N 0-255 N A NOTE 2
8 Selecion reset termal perforance i A86 N 0. 1 0 N
39 P tain seting of PID funcion A90 1-0.5 1 0 9!
41.1 - an etg of PlD funiton A91 N 00-15.0 1 0 N
41.1 D gm setingofPiDnflaction A92 N 00-100 0 N
42 |Selection of PID funciion A94 T N 0-4 0 N
a3 Settiig method of PID reference value A95 N 0.1 0 N
44 I Setomg of Pl reference value A96 N 0.00-200 0.0 N
45 I Auiotuning eitng A97 N 0-2 0 N
46 Motor data selection A98 N 0-2 0
47 Ro-To option selection A99 N -) I N
48 I [nput terminal setting I C oN h-3. 5-9. 11-16. 18-28 I8 N
49 lnputtermmialseiting2 C I 0-3. -9. 11-16. 18-28 16 N
50 Inputtermmalsetting3 C2 F 0-35-9. 11-16, 18-28 1 5
I Inpu terminalscottm 4 C3 1 0-3. 5-9. 11-16. 8-2 11 N
2 Inputtermnal setting5 C4 N 0-3.5-9.11-16. 18-28 9
I Input terminal seting 6 C 5 N 0-3, 5-9. 11-16. 18-28 13 N
54 Input teminal nettrg 7 C 6 N 0-3. 5-9. 11-16, 18-28 N
55 | Input termnal seing C7 0-3. 5-9. 1-16.18-28 N a
S tapu termnal seing C -2 1 0 N
ouputtilsettig12C 0-2 cnauria
I nput ternal a and 6 coniact sertng 1 C20 N I 00-FF 00 N
59 i pst lerinnal a and b coniac seiting C21 N -07 04 N
NOTE 1: The most applicable motor capacity of the inverter is set.
NOTE 2: The initial setting of each inverter is adjusted when shipping from the works.
7-6
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7.7 Explanation of Modes
(L) Monitor mode contents
Monitor
mode
contents
Contents and display
The frequency outputted by the inverter is monitored.
The display is as shown below.
lI l I) l )
till Ii
Display when stopped
(2) 7{77i n t -n - to -1 (2) to - (3) [ to A frequency between 0.01 Hz
and 9.99 Hz is displayed in units
of 0.01 Hz.
A frequency between 10.0 Hz
99.9 Hz is displayed in units
of0.1 Hz.
A frequency between 100 Hz and
400 Hz is displayed in units of
I Hz.
The rotational frequency converted value of the frequency outputted by the inverter
is displayed.
(Note that the value is not the real rotational frequency of the motor.)
The converted value is displayed as shown below using "rotational frequency/100."
I I F) i~)
'I'll'
FUNC
SFN
Display when stopped
(1) 77 ito -q-q
(2) to
(3) 11
- -1 -1 t 1 1
The converted value is displayed
in units of 0.01 (1 rpm).
From I to 999 rpm
The converted value is displayed
in units of 0.1 (10 rpm).
From 1000 to 9990 rpm
The converted value is displayed
in units of 1 (100 rpm).
From 10000 to 60000 rpm
NOTE: Motor pole number can be set by .
The current outputted by the inverter is monitored. The display is as shown below.
I: F) :~)
I'll),
Display
when
stopped
to (2) to - The output display accuracy is about I10%.
Inverter output current: IS
Monitor display current: INc
Rated current of the inverter: Ia
[MC - INS
A current between 0.1 and 99.9 A
is displayed in units of 0.1 A.
A current between 100 A and 999 A
is displayed in units of I A.
7-7
U-J
Output
frequency
monitor
UL11
Motor
rotation
speed
monitor
I i~
Output
current
monitor
FUNC
FUC
F UN C
FUNC
H
Contents and display
The product of the value of frequency converted value setting (A47) and that of output frequency
Monitor
mode
contents
Frequency
converted
value
monitor
to -i 0.0 to 9.99
to - 10.00 to 99
to - -J-5100.00 to 9
to - - - 1000.00 to
to - 10000.00 t
.99
99.99
9999.99
(dO) is displayed on the monitor.
FUC (1)
(2)
(3)
(4)
(5)
When a trip occurs, the cause of the trip is displayed in this code.
the contents of the latest trip are displayed. Whenever the
of each is displayed.
As a general display,
key is pressed, the content
NOTE 1: When there is no trip, is displayed.
NOTE 2: The above example of the voltage between P(+) and N(-) indicates 390 to 399 V.
NOTE 3: When the SOPRESET key is pressed after a trip occurs,
is displayed.
The causes of the last trip and the last trip but one are displayed. When the command is displayed
and the FUNC key is pressed, the trip cause is displayed.
FUNC
NOTE 1: When there is not a trip history, is displayed.
NOTE 2: How to delete trip history data, see page 7-14.
7-8
o39960.00
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Trip
monitor
Trip
history
monitor
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(2) Function mode
Monitor
mode Contents and display
contents
Methods for setting the output frequency are as follows:
I. Digital operator --- ---------------- Refer to this setting.
2. Control circuit terminal ---------------- Refer to this setting.
(multistage speed command)
3. External analog input ----------------- Refer to page 6-2.
(0 to 10 V, 0 to 5 V, 4 to 20 mA)
4. Remote operator ------ Refer to the explanat
(new type, general purpose)
5. Optional PCB ----------------------- Refer to each option
(I) Setting from the digital operator
r n n bII
-I -flflfl
FUNC Initial set value
ion of each remote operator.
al PCB operation.
A frequency between 0.01 Hz and 9.99 Hz is
set in units of 0.0 1 Hz.
A frequency between 10.0 Hz and 99.9 Hz is
set in units of0.1 Hz.
A frequency between 100 Hz and 400 Hz is
set in units of I Hz.
When the or F key is pressed continuously, the value is changed continuously.
(2) Setting from the control circuit terminal (multispeed setting)
The output frequency at the multispeed can be set as specified below. When the running
mode is the process stepping mode, switch it to the multistage speed mode by the remote operator.
( Connect the multispeed terminal for setting the frequency to CM1.
(The relationship between multispeeds I to 7 and the control circuit terminals is as
shown below)I
CF1 : CF3
Example ofterminal connection
for sink type
Refer to page 5-5
*I: By initialization, the multispeed can be
set up to the third stage. When CF3 is set by
terminal allocation (in this case, intelligent
input terminal 5 is allocated), up to the 7th stage
can be set (set by the extension function mode
C4)'
Intelligent input terminal allocation: CO to C7
Set value: 3 (CF3)
@Z) Set an optional output frequency using the For 7key.
@ Press the FUNC key once to store the set output frequency.
NOTE 2: F| 8 is displayed.
@ Press the F key once. (Check whether the output frequency, which is set,
is displayed.)
@ By repeating ( 1) to (4), the output frequency in the multispeed mode can be set.
NOTE 3: Whenever any data is changed, be sure to press the FUNC key before starting
the next setting. Note that when the FUNC key is not pressed, the data will
not be set.
NOTE 4: When setting to over 120 Hz. the changing over maximum frequency is necessary.
Remote operator or copy unit must be used.
(When the value is switched to 400 by F-30, an output frequency of up to 400 Hz
can be set.)
7-9
Output
frequency
setting
Multispeed Control circuit terminal
1I 2 3('1)
Multispeed I ON OFF
Multispeed 2 OFF ON OFF
Multispeed 3 ON ON
Mutispeed 4 ON OFF
Multispeed 5 OFF ON ON
Multispeed 6 ON ON
Multispeed 7 OFF OFF
7-10
I
Monitor
mode Contents and display
contents
Set the motor direction.
Set the motor direction when running by pressing the RUN key.
NOTE: The setting duang run is impossible.
FUNC Initial set value
Running Forward run
direction i ijj ... ' E..Forward run
FUNC Switching can be done by pressing
- Reverse run- the
key.
Monitor
mode Contents and display
contents
-C - These commands set and display Acc. time (F 6) and Dec. time (F1D1).
I C ISetting range Period
Initial value 0.01 to 9.99s Every 0.0ls
Accelera- |F II6|7. 1FI | 10.0 to 99.9s Every 0.Is
tion time 1 100 to 999s Every Isand 2
Deceleration time I r f j
and 2 U U
- Acceleration time 2 and deceleration time 2 are set when CHI is connected with P24.
- When a time of more than 1,000 seconds is set by the remote operator,
is displayed on the digital operator.
Set torque boostC * Motor torque can be adjusted to increase the output voltage when the starting torque
is not sufficient in V/F control. Pay attention not to cause the motor to burnout and
an inverter trip. Set boost value in 70 to 90 when using VPI, VP2 or VP3 in V/F control mode.
Manual - Setting is effective only when V/F control is selected.
torque
boost Output
setting Setting method voltage - - --------A 100%
Initial value
About I1.8
Output
D V .0 frequency
|TC |7 0 5 10 25 50 Hz
6 12 30 60
With the remote operator (DOP, DRW, HOP, or HRW), (V-Boost F 20.0% is setpoint @ in the torque boost graph can be changed within with 20e0%mot e
the range of 0% to 50% with respect to the base frequency. with the remote operator.)
7-11
Monitor
mode Contents and display
contents
Switching the run command and frequency command setting modes
Set the run command and frequency
selection range is from 00 to 03.
command sending destinations. The standard specification
Run
commanding
method
Frequency
commanding
method
Setting method /S
FUNC Initial valueFUNC
|F| 9| | |3 - F|i 9|
NOTEI: The run command and frequency command sending destinations can be set to any
of the terminal, operator, option 1, and option 2. Select the relevant set value.
NOTE2: When option I or option 2 is selected for "Run command to" and "Frequency command
to," the digital operator and terminal block cannot issue commands. Set option I
or option 2 (set values L - ET ) only for operation or frequency commands
from the optional PC board.
7-12
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Set value Run command to Frequency command to
QQ Digital operator Digital operator
Digital operator Terminal block
0 70 Terminal block Digital operator
ZI7 Terminial block Terminal block
o -/ Digital operator Option I
O 5| Option I Digital operator
70 Option I Option I
0 7| Digital operator Option 2
0- Option 2 Digital operator
o 9 Option 2 Option 2
T 10Terminal block Option I
Option I Terminal block
Terminal block Option 2
Option 2 Terminal block
-( Option I Option 2
| 5 Option2 OptionI
Initial value
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Contents and display
Adjust the analog meter connected to the frequency monitor
terminal. (Initial setting of the [FM] terminal: Analog frequency monitor)
When operation starts, t/T output between FM and CM I terminals is
proportional to the outpflt data. Adjust the meter so that it indicates
the maximum point when the output is at the maximum.
'Sink type wiring>K Refer to page 5-3)
n value FUNCOutput = (variation)
Fiia vaue 'utp2 T||
When adjustirig the analog meter furthermore, repeat the same operation.
Maximum level of analog meter
Frequency monitor: CA63 maximum frequency setting)
F252 Current monitor: (200% of inverter rated current)
T i 200% f d
NOTE 1: This function is valid only when the analog monitor is used.
(Freqency monitor, current monitor, torque monitor)
NOTE 2: The adjusted value when the input terminal STN (initialization) is used is
the initial value.
Set the motor receiving voltage. When the FUNC key is pressed once, the current set value
of the motor receiving voltage is displayed.
FU NC 200 V class
initial value
400 V class M
Initial value
Select the item of each extension function. After setting, the display is returned to the code
display.
@After data is changed, be sure to press the FUNC key to store it.
FUNC Code selection FUNC Code selection
FUNC 7 i
Rm When the data is changed,/ I Ithe display blinks.
(Set value storage wait state)
When the FUNC key is pressed, the display stops
blinking and the data is stored.
7-13
Monitor
mode
contents
Analog
meter
adjustment
Motor
receiving
voltage
setting
Extension
function
setting
orque monitor: ( o rate torque)
Returning to the initialization (State set at factory before shipment)
When returning the equipment to the initial state set at factory before shipment for some reason,
follow the following procedure.
1) Allocate STN (set value = -) to one of the input intelligent terminals. (Use C / to C "'
in the extension function mode to set the intelligent terminals.)
(However, C' '~' cannot be used since resetting RS is initially set.)
2) Short-circuit the STN terminal and P24 (CM 1*), then turn power off and on. (When the power is
turned off, do not turn it on again until the CHARGE lamp of the logic PCB goes off.)
3) Keep the STN terminal open for more than 6 seconds. (When keying, resetting, or turning power
off is performed within 6 seconds, the equipment may not be initialized.)
4) Turn the power off after more than 6 seconds. (When the power is turned off within 6 seconds,
the equipment may not be initialized.)
How to Delete Trip History Data (O 1/o, and ci /)
To delete trip history data for some reason, follow the instructions shown below using the remote
operator (DOP or HOP) or copy unit (DRW or HRW).
1. Using the remote operator (DOP-OA) or copy unit (DRW-OA)
(1) Display|[NIT TCNT (trip history count clear) or the function mode initial settingF-38 NIT.
(2) Move the cursor to beneath the initial set values. Select CLR and store it.
1) Turn the power off once and then turn it on. or close the reset terminal RS-P24 (CM I*) for
approx. a second. By this, trip history data is deleted.
2) When trip history is deleted, data of [F-3 8] is set to [CNT]. Trip counting restarts.
2. Using high-performance remote operator (HOP-OJ) or high-performance copy unit
(HRW-OJ)
(1) Display [TCNT 0: CNT] (trip history count clear) or the function mode initial setting
[2-1 [NIT].
(2) Enter a count clearing value [0: CLR] from the 10-key pad.
1) Turn the power off once and then turn it on. or close the reset terminal RS-P24 (CM1*) for
approx. a second. By this, trip history data is deleted.
2) When trip history is deleted, data of [2-1 INIT] is set to [CNT]. Trip counting restarts.
NOTE: Symbols * are indicated for Sink type wiring.
7-14
(3) Extension function mode contents
Extension
function
code
Contents and display
Set the control method. Select one of the following control codes.
FUNC Initial value
RE0 b u ----F UNC
E----
Fv-- -FET71~ ...
V/f control (VC)
Constant torque characteristics
V/f control (VPI)
Reduced torque characteristics,
1.5 power
NOTE : set torque boost in 7o to 90.
V/f control (VP2)
Reduced torque characteristics,
1.7 power
NOTE : set torque boost in 70 to 90
V/f control (VP3)
Reduced torque characteristics,
2.0 power
NOTE : set torque boost in 70 to 90
Sensorless vector control (SLV)
Vector control with sensor (V2)
NOTE : Vector control INV only
(Feedback board is nesessary)
Set the motor capacity and number of motor poles according to the motor to be used.
The maximum rating of the applicable 4-pole motor for each inverter
is set initially.
Motor capacity No. of motor poles
FU FUNC
FUNC FUNC -- A
5| Initial
value
UF 7-
NOTE:
When the data does not match
that of the mootor. satisfactory
characteristics may not be
obtained during the sensorless
vector running.
The full performances may
not be demonstrated if the
rating of a motor used is tow or
less than the maximum
applicable rating when
the sensor-less vector function
is used.
The sensor-less vector opera.
tion is disabled when two or
more motors are running.
Set this data properly according
to the motor used if its rating is
not the same as the maximum
applicable rating in V/f
operation.
7-15
Control
method
setting
V
V-
0 f
0
0 f
V -
0 f
Motor
capacity,
motor poles
setting
Contents and display
Set the response speed (ASR system gain) between the inverter and motor. When increasing
or decreasing the current motor response speed, adjust the ASR system gain. When the set value is
decreased, the response speed is increased. When the set value is increased, the response speed is
decreased.
Initial value A
|RI 3 2L O |/ . l | |. |
FUNAP 3uzr 8| 10Q 16|551
riT 71-Thl _
FV
A constant between 0.01
and 9.99 is set in units of 0.01.
A constant between 10.0
and 99.9 is set in units of 0.1.
A constt between 100
an d 655 is set in units of 1.
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Set the frequency for starting output of the inverter.
Set a frequency between 0.1 Hz and 9.99 Hz in units of 0.0 1 Hz.
Initial value FUNC
F75-
7-16
Output voltage
v-- ------ / ------- I
0 0.10 9.99 f
Maximum
frequency
When the start frequency is increased,
the acceleration or deceleration time is
decreased.
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Extension
function
code
Speed
control
response
constant
setting
Start
frequency
adjustment
Contents and display
Set the limits of frequency setting within the EI7 start frequency adjustment range andR '
maximum frequency setting range. When a value beyond the limits is inputted from the operator,
it will not be stored. Even if a value beyond the limits is inputted as external analog input, the set
value will not be changed.
Extension
function
code
Frequency
tipper,
lower
limiter
Setting example
(When an upper limit of 45 Hz and a lower
limit of 20 Hz are set)
Output frequency
(60 lHz)
Upper limiter 45
Lower limiter 20
0
-C--- -- ----- -
Frequency command
(F-SET)
NOTE: Setting conditions
0 Hz or upper limit lower limit
When 0 Hz is set, the limiters will not operate.
To avoid a resonance with the load, the frequencies at up to 3 points can be jumped. The setting
order and the execution order may be changed.
The frequency equivalent to the jump frequency setting width (= 0.5 Hz) (Note 1) cannot be set as
a jump frequency.
NOTE I The jump frequency can be set by the remote operator.
NOTE 2 As to the frequencies which are set by the jump frequency setting function, the set
frequencies are jumped but the output frequencies pass.
0
Set frequency (V) Output frequency (V)
In the case
ofjump frequency I
FUNC
Initial value
4 - 7-|RI S -' . 0.0
FU NC
In the case
ofjump freque
RB7
In the case
ofjump freque
7PI9|
Output
frequency
45
30
ncy2 t0
0
ncy 3
Setting example
Jump frequency 1: 10 Hz
Jump frequency 2: 30 Hz
Jump frequency 3: 45 Hz
Jump frequency width: 0.5 Hz
(V)
Speed command
frequency
Acceleration
7-17
Maximum (400)
frequency limiter
FUNC
Minimum j20 (400)
frequency limiter
FUNC
PR 5SIr 7.9 Initial value
FUC
Is'
Jump
frequency
setting I
Jump
frequency
setting 2
Jlump
frequency
seting 3
Extension
function Contents and display
code
Set the switching frequency of the power module.
^lIILJI m(NOTE ) Carrier frequency initial value
FUNC Initial value FUNC model type initial value
-CT FVT
Carrier , 1 - r 055 to 150 L. HF 16 kHz 8 kHz
frequency 220 L,HF 12 kHz 6 kHz
setting -i - 300 to 370 L/HF 10 kHz 5 kHz
8 0 450 to 550 LHF 6 kHz 3 kHz
750to lI00HF 3kHz 2kHz
NOTE 1: The initial value of carrier frequency 1320 to 2200HF 2 kHz 2 kHz
varies with the inverter capacity.
When VPI to VP3 is selected,carrier
frequency is automatically changed to
VT.
Set the frequency commands (voltage frequency command (0-L terminal signal), current frequency
command (Ol-L terminal signal), and the number of samplings.
NOTE: How to set
Initial value FUNC| : The number of samplings is setto 1.
F The reaction time becomes shorter, but
Frequency Y the output frequency becomes likely to
command y vary.
sampling 2|: The number of samplings is set to 8.
frequency - The reaction time becomes longer, but
setting the output frequency becomes stable.
Set the output frequency of each multispeed speed. When setting four or more speeds, refer to the
I-,H-~l item of {F ioutput frequency setting.
71C L IExample of the connection method
Refer to Page 5-5
1 Initial value FM CMI PLC P24 FW V F F2
-I In the caseRE
CF 2
of multispeed
- setting I FUNC
FUNC (400) Example of Multispeed setting
Multispeed Control
circuit
setting [ n the case of multispeed setting 2
Multispeed termina
___________(7) CFI1 (6) CF2
|RI /3 Multispeed I ON OFF
Multispeed In the case of multispeed setting 3 Multispeed 2 OFF ON
setting 2 / Multispeed 3 ON ON
Multispeed NOTE: When using four or more multispeed commands,
setting 3 use the multispeed terminal (CF3) as an input terminal.
7-18
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Contents and display
Set the electronic thermal level. Set the thermal level in accordance with the rated current of the
motor in units of I (%).
motI Adjustment level = Motor rated current x 00
Inverter rated current
- |
Time(s)
Setting method 5 iF
FNC Initial value ENC
R|233|"- :|R|-*P23
nas-~ ~Fv7J j~ FA8
802
0
20% 120%
i Inverter rated current
'20 100 150 200
Inverter current (A)
Select the electronic thermal characteristics. Set the thermal characteristics in accordance with
the load to be used. For free setting of set value 2, the current and frequency can be set by each
remote operator.
Initial value
L
Setting method F
FUNC Initial value PFUNC
R -i |R29|
eF 00
St Constant torque (Each characteristic
charactenstc at 60 Hz or more is 100%.)
0 Reduced torque
characteristic
01
5 20 60 120
Output frequency (Hz)
Set the pole number of motor to convert output frequency into motor rotation speed on monitor
mode funciton JI/
L. E
- Settable numbers
2, 4, 6, 8. 10. 12, 4. 16, 18 20, 24. 32. 36, 48
Setting method y J1 F
FUNC Initial value FUN
|R|2S : 1 zP:|R29
|4 | 2
7-19
Extension
function
code
Electronic
thermal
level
adjustment
Electronic
thermal
characteristic
selection
Motor
poles
setting
for motor
speed
monitor
Set valuej Function
0 Constant torque characteristic
I Reduced torque charactenstic
Free setting2 (Can be set by the remote operator)
60
Extension
function Contents and display
code
Set the frequency for starting output for an external frequency command (0 to 10 V, 0 to 5 V,
L _ . 4 to 20 mA) and the frequency for ending output. When 0 Hz is set, this function will be canceled.
- External frequency Initial value - NOTE 1: The standard setting is 0 Hz.
setting start 60 --------------- In this case, the selected V/f
S1001 = pattern is used for running.Setting method 50 NOTE 2: When changing the V/ attern-[- after A 26 (start andl27 (end)
30 -are set, readjust A 26 start and
FUNC3 end
ExtNOTE 3: en 26 (start)> A27 (end)frerenay- - _ is set an t frequency command
fr nl 2 '_- __ _ value is minimized (0 V or 4 mA),
I n (400) the output frequency may besetting FUNC 0 - 0 V Frequency lowered than the value which is
____0 5 V comn sebyLstart 20 command set by 26 by 0.1 to 0.3 Hz.
External frequency The reason is that it is judged that
Output there is some frequency due to
Extenal se d60 - - noise on the signal line and it is a
' c - S(Hz) normal operation.Frequency 9 Same as A26 NOTE1: The setting shown left is also
setting end possible with F31 of the remote
0 - 8V 10V Frquency operator.
- V 5V cmmand
4 2 168 "A
San seting End sening
command (200) conmand (0%)
Set the inverter retry method when a power error occurs.
I IILI Select the set value of the retry method to be used.[lij,~{~ Set value Function
Initial value 0 Alarm output after tripped
Instanta- Setting method I Deceleration stop at the time
neous of restart
restart Initial value NC Frequency matching start at the time
selection le.F 2 of restart ( Note 1)
3 0 Hz start at the time of restartRestart
selection NOTE 1: When the base frequency is one of the following ones, frequency matching may restart at 0 Hz.
When the base frequency is 60 Hz: Driven at 40 Hz or less
When the base frequency is 50 Hz: Driven at 30 Hz or less
For other precautions, refer to Chapter 1, "Instantaneous stop restart" of Appendix 2.
NOTE 2: Since the retry mode is selected, the equipment restarts for trips of overcurrent, overvoltage, or undervoltage.
For undervoltage, 16 retries (17th trip) are executed.
For overcurrent or overvoltage, 3 retries (fourth trip) are executed.
Do not use this function for a case that a fallen substance should be held by the machine brake when the motor
is in the free-run mode.
7-20
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Extension
function Contents and display
code
Set the usage ratio (%) for 100 seconds of BRD.
I . LI When the BRD operation exceeds this setting, NOTE 1: The internal BRD circuit is not mounted
ithe operation will be stopped an nverterother than the
types 055LHF,31Lheoerto l b topd and 075LHF.
/ DNOTE 2: When 0 % is set, the BRD will not be
Dynamic Setting method operated.
braking NOTE 3: When T exceeds the set value, the BRD
usage ratio wil be stopped.
FUNG F7C
FN Initial value F NOTE 4: When mounting an external BRD unit, set
P3B - N [R11P38 the usage ratio to FlG " and remove the
external resistors.
NOTE 5: The initial settings of I 10-55OLHF00are W%
Function contentsamQ% NOTE 6: Conditions when using the external
t I t3 resistor are shown in the table.
BRD ON
00 seconds O
Inverter requiring an external resistor
T= (xt +t2+t3) x100 Model 055, 075LF 055, 075HF
100 seconds
External RB to RB3 RB2, two each in serie:
resistor (l7 ohm or more) (70 ohm or more)
Usage ratio Max. 10 (%) Max. 10 (%)
NOTE 7: This function cannot be used for the inverter types I10 to 550LiHF which have no built-in BRD
(dynamic braking) circuit.
When p H frequency arrival signal output method 2 is selected, an output signal is outputted
11 jIj at an optional frequency. When frequency arrival signal output method I is selected, an output
signal is outputted at an optional frequency or more. For acceleration M and deceleration
- |RIY V l, the frequency is set in units of 0.1 Hz (in units of I Hz for 100 Hz or more).
- RTC At the time of acceleration. an output signal
ArrivaiSetting method turned ON in a range from the set frequency
Arrival Se-0.5 Hz to the set frequency +1.5 Hz. At the
Intional ttime of deceleration. an output signal is turned
optional In the case of optional ON in a range from the set frequency 0.5 Hz
frequency arrival frequency FUNC to the set frequency -1.5 liz.
of acceleration Initial value
at accelera- -o , -. w -i1 Output
tion R J frequency f
Arrival M -- . 0.5 Hz
optional .t5
frequency - 1.5Hz
at decelera- set5 g 0.5 Hz:
tion In the case of optional
ung
arrival frequency FUNC
of deceleration Initial value 0
|R 0 2 n Output. ON nning-L?4.~. (3LJ Signal . unin(FAt)
60 ms 60 s
7-21
Contents and display
Select the output monitors signal at the control circuit terminal FM from
the table indicated below.
Extension
function
code
I lUfI
Monitor
signal
selection
Output monitor signal Output fIll-scale value
Frequency monitor M Maximum frequency
Current monitor 200% of the rated current
Torque monitor 200% of the rated torque
Set value Function
0 Analog output frequency monitor
I Analog current monitor
2 Analog torque monitor (Note)
3 Digital output frequency monitor
NOTE: Use the analog torque monitor function only in the
sensoress state. Under the V/fcontrol, an appropriate
value is outputted. The accurcy is +20%
(a rough value).
Set a converted value for frequency converted value monitoring. The product of this setting and the
ouptut frequency (d0) is displayed as the value for the frequency converted value monitor (d3).
Setting method FUNCFUNC F
Initial value
|Y % F|
Set the maximum voltage to be supplied between the terminals 0 and L.
H .
Setting method ELt
VRO
(500 Q to 2k
| lS'| Setvalue
Initial value
10
Initial value 1 |
ermina
H O 0o1 L
DCO To 5V
DCO To IOV
Input impedance
30 cle
I connection examiple
Function
Max. 5 V input
Max. 10 V input
7-22
Setting method Initial value
FUNC
Initial value
II l)I
Frequency
converted
value
setting
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Analog
input
selection
Extension
function Contents and display
code
When selecting the frequency arrival signal at the output terminal, select the arrival signal output
l UUI method.
Setting method -T 7qput 5Hz
frequency Fsetting
t (Hz) 1.5Hz
FrequencyFUNC
arrival
signal fl : - : i
output Initial value Arrival 't6 0 ms ON Time
method signal
Li :1At the time of constant
Output speed arrival
frequency .
(Hz)
Set value Function 0.5 Hz/
0 At the time of constant speed arrival g e 1.5Hz
I Optionally set frequency or more 0
2 Only optionally set frequency Anival 60ms ON Time
Set optional frequencies of set value I and set
value 2 by = andI . Optionally set frequency
value 2 by 2 579 and 9 or more
Output
frequency 01 5Hz
NOTE 1: The frequency arrival signal (Hz) setting 1.5Hz 9
can be allocated only to one setmg
of the intelligent output terminals. 15Hz
It cannot be outputted to 0.5Hz
an individual output terminal
for acceleration and deceleration. Aival ON ON Timesignal
NOTE 2: Selection of arrival signal output 60 ms +i4+60 ms
method for relay option board (J-RY) nl optins
can be done by remote oprator and : Only optionally set
F-48 funciton. frequency
Select an operation after a free run stop.
Set[ jjTjSe and I | 1 with the and keys.
Restarting Setting method
after FRS Initial value
signal |RIN' 0 / Set value Function
selection .,0 fmatching
FU N C11 0 s ta t Initial value
FFD|L
7-23
Extension
function Contents and display
code
Adjust reduced voltage start.
-' -NOTE: How to set
FUNC Initialvalue FUNC
There is no reduced voltage. The rush
Reduced 31R0 %9 W current at the start of the inverter isy increased but the motor reaction time is
voltage - V decreased.
soft start El: The effect of the reduced voltage is
setting large.
The rush current is reduced but the
motor reaction time is increased.
Select the running mode. Set the running mode to be used.
- Setting method Set value , Function
Initial value 0 Normal running mode
Running FUNC I FUNC I Energy conservation running mode
modeL2 F and de celeration
selection vale Fuzzy most suitable accelerationselctonInitial value and deceleration mode
NOTE: When the fuzzy most suitable acceleration and deceleration are selected and the load inertia (motor shaft
conversion) is more than about 20 times of that of the individual motor, an overvoltage trip may occur.
If this occurs, reset the mode to the normal running mode. For other precautions, refer to "Precautions for
fuzzy most suitable acceleration and deceleration" of Appendix i.
Set the running command so as to be inputted to the terminal.
- -JJ (Set F I to LI1EorL J)
Since jogging is a direct input operation and may be easily tripped, set the jogging frequency
to 5 Hz or less.
Jogging Setting method 9. 99
frequency
settingFUCUN
(REV) (JG)
R,5/- FOM| |RIS CMI FW n8 3
Initial value
NOTE:
No frequency can be set SWFW SWJG
I11JU l between 0o Hzand 009 Hz.
Operation timing
SWJG
20 msec mn
SWFW 7 F7
Motor Free run
rotation The free run operation is performed immediately after
SWFW is tamed OFF.
Nojogging operation is performed when the set value is smaller than the star frequency ||9 .
7-24
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Contents and display
Set the P7 57 base frequency and FR 6 maximum frequency.
Extension
function
code
Base
frequency
setting
Maximum
frequency
setting
v 1030% NOTE
Setting example
V
100%[---------- 10
60 Hz
(A62) base frequency
and (A63) maximum
frequency: 60 Hz
V
60 Hz 120 Hz
f (A62) base frequency: 60 Hz
(A63) maximum frequency:
120 Hz
Setting method 37
FUNC FUNCA
Initial value
(400)
When the frequency is set so that the base
frequency is larger than the maximum
frequency, the base frequency is forced NOTE
to be made equal to the maximum
frequency at the start of running.
30 Hz 60 Hz 120 Hz 400 Hz
I f]j Select 120 Hz or 400 Hz as the upper limit that can be set in the maximum frequency setting (A63).
IU LIUfi Fi |
Initial value
Maximum
frequency
selection
-gj] g-Adjust the relationship between the external frequency command and the inverter output frequency.
L± J jjl Sl: Voltage command (0-L)
,B,,, RI i : Current command (OI-L)
i-fiiiI This function is factory-set to the appropriate position. If this setting is changed unnecessarily, the
correct relationship between the external frequency command and output frequency is no longer
Frequency maintained. This will result in poor control performance. Adjust the setting of this function only
command when the output frequency does not conform to the external command.
output Adjustment method
frequency Voltage command: Put voltage command (0V of 5V) to O-L terminal, and adjust fl|90 unit
output frequency comes to maximum.adjust Current command: Put current command (4-2OmH) to OI-L terminal, and adjust FRi S / unit
(0-L, O1-L) output frequency comes to maximum.
7-25
1: When a frequency more than the base frequency 60 Hz
is used. the motor is not a general purpose motor but
a special motor. Therefore, the maximum applicable
motor set value is different.
When the kW display is the same, the inverter
capacity may be increased.
2: Set the base frequency according to the specifications
of the motor. When the base frequency is set to less
than 50 Hz. the motor may be burned.
Extension
function
code
Contents and display
Possible to select a performance of a release timing of alarm signal when giving reset signal
.. I from [RS] terminal
- C Set value | Performance
FUN Initial value finN R]S
Selection
of reset P...Aa
terminal
perfor- I ft. .an outnut
mance
These functions are used to set PID control operation gains.
_ _ 90 P (Proportional) gain, 9 I (Integral) Gain adjusting range
gain, fl 9L D (Differential) gain P 0.0 to 5.0
- Set each gain. 1 0.0 to 15.0 s
Setting method , D 0 to 100.0
Propor- | 1730- |R| f90
tional gain Initial value
setting
[ntegral 711 A
gain
setting
Differential
gain setting
- This function is used to control the PID functions incorporated in the inverter.
- ~ This function is also used to select a feed-back signal input and set a magnification of the integral
gain setting value.
For details of PID control, refer to "Appendix 8 PID Control Functions".
PID
control Setting method Setting Feed-back signal I Iintegral)gainseecio value input terminal magnification
0 Built-in PID function disabled.
I Analog current (OI-L) X I
R I Li|R9 2 Analog voltage (0-L x I
Initial value 3 Analog current (0l-L) X 10
4 Analog voltage (0-L) x 10
Note 1: Set "0" for the use of a PID optional board.
Note 2: Do not assign a feed-back signal input and an target frequency command
to the same terminal. If assigned, the PID function will be disabled.
7-26
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Extension
function Contents and display
code
_l _1 _ iThis function is used to select a method to enter the target value for executing each PID function.
Setting method -Set value Performance
0 The target value depends
Target on the |R 95 level set value.
value FUNC FC l
setting The target value is set using
method I 95| ||R9i the |~l 9| frequency setting
selection Initial value m
method.
NOTE 1: Set "I " when a PID optional board (J-PI) is used.
The value entered to the OS terminal of J-PI is assumed as the target value.
NOTE 2: The target value at set "I" is O-L, Ol-L input signal, P-2| setting or multispeed
setting.
This function is used to set a target value level of PID controlling within 0 to 200%.
This function is valid when 0 is set for flI S
Setting method If an analog voltage is entered as a feedback
Internal tI0 value, the feedback voltage (0 to IOV)
target _corresponds to this target value level
value level FUNC FUNC setting (0 to 200%). In other words, if,
setting FpT i " when 5V is entered as the target feedback
sti |R 96 9| value of a sensor, it is converted to an
Initial value internal target value, set 100% as this
internal target value.
Select whether to start auto tuning as well as a mode. When I or 2 is set, auto tuning is started
during the first operation.
Set value Function
0 Auto tuning is not performed. Initial
Auto FUNC Initial value valueFA I Normal measurement mode
tuning (The motor runs.)
setting ,Y 2 R 1, R2, or L measurement mode
772~ (The motor does not run.)
(For details of auto tuning, see Appendix 1.)
Select the motor constant used for sensorless vectror control (SLV).
Set value Data used
Motor FUNC FUNC 0 Old Hitachi general- Initial
data purpose motor data value
selection 7PF37 995'L~
Initial value I New Hitachi general
purpose motor data
(OThe MotorO)
2 Auto tuning data
7-27
7-28
Extension
function Contents and display
code
Unusable
Ro-Toption
selection
Contents and display
A terminal function is allocated to each of the input intelligent terminals I to 8. When using a
function other than the standard set functions or changing the terminal order, set the function
for each terminal. The minimum input signal acceptance time of the input intelligent terminals is
about 20 ms.
Extension
function
code
to Input
terminal
setting
I to 8
PCB terminal array
FM
CMI
PLC
P24
FW
8
7
6
5
4
3
2
Input intelligent
terminal section
Setting method
Press the FUN key once for the terminal code to be set.
The set values of the terminals which are set at present are displayed. Display the set value
of the terminal to be used from the function list indicated below by pressing the key A
and and then press the FUNC keyThe display is returned to the code display and the terminal function is changed.
Enter the set value of the terminal name
to be used bypressing the keys and -. UNC
Setting example: The RS (reset) function is changed to the SFT (treminal software lock) function.
Input terminal function list
Set value Abbreva- Function namelion
.0 REV Reverse
I CF1 Multispeed 1
2 CF2 Multispeed 2
3 CF3 Multispeed 3
5 JG Jogging
6 DB External DC braking
7 STN Initialization
8 SET 2nd function
9 CHI 2-stage acceleration and deceleration
Precautions for terminal setting
Set vaiue Abbe via- Function nametion
II F RS Free run
12 EXT External trip
13 USP USP function
14 CS Commercial power source switching
15 SFT Terminal software lock
16 AT Analog input voltage/current switching
18 RS Reset
27 UP Remote operation function, acceleration
28 DWN Remote operation function, deceleration
Same terminals cannot be set between I 0| and lf |
When moving a terminal name to another terminal, set another terminal which is not to be
ued at the setting source before inputting the set value to the setting destination and then
select the terminal name which is to be set at the setting destination.
7-29
Arrary of codes and intelligent terminals
Code Function name Terminal Initial settingI rating plate
C 0 {Input terminal setting I I I8S
C 1 Input terminal setting 2 2 16
C 2 Input terminal setting 3 3 5
C 3 Input terminal setting 4 4 II
C 4 Input terminal setting 5 5 9
C 5 Input terminal setting 6 6 13
C 6 Input terminal setting 7 7 I
C 7 Input terminal setting 8 [ 8 0
Extension
function Contents and display
code
A terminal function is allocated to each of the output intelligent terminals I I and 12. When using
a function other than the standard set functions or changing the terminal order, set the function for
each terminal.
Arrary of codes and intelligent terminals
Code Function name ratin pate iting
CIO Output terminal setting I I I 1 0
C1I Output terminal setting 12| 12 L
Input terminal function list
Abbrevta-Set value tia Function name
0 FAI Frequency arrival signal
I RUN Signal during running
2 OTQ Overtorque signal (Note)
PCB terminal array
CM2
12
AL2
ALI
ALO
The s'etting method is the same
as that of the input terminals
|R| /8|to R25
NOTE: The torque of the overtorque signal can be set by the remote operator. The initial
values of motoring and regeneration are 100% torque. The overtorque signal can be
used only under the sensorless vector control.
Setting method
Press the EN key once for the terminal code to be set.
The set values of the terminals which are set at present are displayed. Display the set value
of the terminal to be used from the function list indicated below by pressing the key A
and Y and then press the FUNC key.
The display is returned to the code display and the terminal function is changed.
Enter the set value of the termninal name
to be used by pressing the keys and . F
|cl~~) /|| | |2|1 lC /0|
Precautions for terminal setting
Same terminals cannot be set between |JE j and C/]IlI .
When moving a terminal name to another terminal, set another terminal which is not to be
ued at the setting source before inputting the set value to the setting destination and then
select the terminal name which is to be set at the setting destination.
7-30
I
Output
terminal
setting
11 and 12
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Contents and display
The input intelligent terminals 4 to I can be changed individually to the a contact or b contact
specification. Select the set value by pressing the keys 7 and F by combining the contacts
a and b with reference to the table indicated below.
Example: When the set value is A: -r Contact a: Input terminals 3, 1
L Contact b: Input terminals 4, 2)
Setting method
Press the j key 10 times. FUNC
> OP ([|20|
Select the contact specification with
reference to the table indicated below.
Initial setting
Set value F E d C b A 9 8 7 6 5 4 3 2 1 0
4 b b b b b b b b a aa a a a a
3 b b b b a a a a bjb b b a a a a
2 b b a a b b a a bjb ala b b a a
I b a b a b a b a b a b a b a b a
Input terminal a and b contacts function list
a: Contact a specification
(Shorted when power
is turned ON)
b: Contact b specification,
(Opened when power
is turned ON)
The output ingent terminal I1 and 12 and alarm output terminal can be changed idividually to the
a contact or b contact specification. Select the set value by pressing the keys [ and y by
combining the contacts a and b with reference to the table indicated below.
Example: When the set value is J 7 ":- Alarm output: Contact b
Terminals I I and 12: Contact b
Setting method
Press the key 3 times.FU QNC
31
FTDI
Initial value
Set the high
order to 0.
I UNC
Initial setting
Set value 7 6 5 4 3 2 1 0
11 b a b a b a b a
12 b b a a b b a a
Alarm b b b b a a a a
(NOTE)
Output terminals I I and 12
a: Contact a specification
(Shorted when power
is tumed ON)
b: Contact b specification
(Opened when power
is turned ON)
Output terminal code list
NOTE: For details of the Alarm terminal, see page 6-5.
7-31
Extension
function
code
Input
terminal
a and b
contact
setting FUNC
CE '20| |t TO
Initial value
Set the high
order to 0.
Output
terminal
a and b
contact
setting
( 8. PROTECTION FUNCTIONS
The J300 series inverters are equipped with protection functions against overcurrent,
overvoltage, and undervoltage which protect the inverter. If the protection functions are
engaged, the output is shut down, motor runs free and holds that condition until it is reset.
Description Contents Display
Over current A currrent due to the alternating current CT between the power module Constantprotection and output terminal {U(TI), V(T2), W(T3)} is detected. speed
When the motor is restricted or decelerated suddenly. a large current
flows through the inverter and causes a fault. Therefore, when an Dec.abnormal current is detected by the alternating current CT and it exceeds
a specified value, the output is cut off. (An abnormal current is also
detected in the power module. Refer to M, M, M, and* IT.) Acc.
Overlo ad When a motor overload is detected by the electronic thermal function, the outputprotecIon of the inverter is cut off.
Braking When the braking time exceeds the satting by E braking duty factor, an
resistor overload overvoltage the output of the inverter is cut off.
Overvoltage When the converter voltage exceeds a certain level due to regenerative energy from Eprotection the motor, this protection function engages, and the output of inverter is cut off.
EEPROM error When the memory built in has problems due to noise or excessive temperature rise,
(NOTE 2) this protective function engages, and the output of inverter is cut off.
Undervoltage A decrease of the input voltage of an inverter results in improper function of the
protection control circuit. It also generates motor heat and causes low torque. Output is cut offwhen the input voltage goes down to less than 150-160V/300-320V(200/400Velass).
CT error Abnormality on built-in CT and the output of the inverter is cut off.
CPU error Malfunction or abnormality on built-in CPU and the output of the inverter is cut
off.
.i An abnormality signal from external equipment cuts off the output of the inverter.External tnip .(When external trip function is selected)
Uisp error It indicates an error when power is turned on while the inverter is being run.USP error _(When USP function is selected)
Ground fault The inverter is protected by detection of ground faults between the inverter output
protection and the motor upon power on. There may be the possibility of power module failure.
When the input voltage is higher than the specified value, it is detected 100 seconds
after power is turned on and the output is cut off. However, when a voltage higher
iput overvoltage than approx. 250 to 270 V (200V class), / S
500 to 530 V (400 V class) is inputted, it is higher than the rated value of the part
in use, so that the part may not be protected and damaged.
Instantaneous When an instantaneous power failure for more than 15 ms occurs, the output is cut
power failure off. When the instantaneous power failure time is long, the fault signal is released. £ IS(NOTE 4) Note that when restart is selected, the equipment restarts when the running
command remains.
8-1
Description Contents
Display
Optional An error occurs in the optional connection (connector, etc.).
Option I
connection error Option 2 E B
Optional An error message outputted from the optional PCB NOTE 5
Option I FE D
PCB error Option 2 El2OI
Phase failure When a phase failure is detected on the receiving side { R(L 1), S(L2), T(L3)}
protection error of the inverter, the output is cut off. (NOTE 3)
Power module The detector which is built in the power module operates. Constant speed
-11
protection When the output side of the inverter is shorted
or the motor is
restricted, a large current flows through the inverter and causes a Deceleration
F-2
fault. Therefore, when a current in the power module or an Acceleration
abnormal temperature of the main device is detected and it
exceeds a specified value, the output is cut off. Stop
NOTE 1: If a trip occurs, press the RESET key or short the reset terminal RS-CMI'assigned as a control
circuit terminal after a delay of 10 seconds.
NOTE 2: A trip can be cleared by pressing the RESET key or shorting the reset terminal RS-CM I assigned
as a control circuit terminal. Resetting the power supply cannot clear a trip. (To reset
the power supply is
to turn power off and turn it on again after the CHARGE lamp at the upper right corner
of the control PC
board goes off) Check again whether the set data is correct.
NOTE 3: Power OFF during motor deceleration may cause an input phase failure error.
NOTE 4: The instantaneous ride-thru period of 15ms may be shortend depending on the power
supply voltage or load.
NOTE 5: When the J-FB is installed, an error is displayed for each factor as shown below.
Encoder line break:
Overspeed: 6 l
Positioning error: E 2
Thermistor line break: E 6 4
Motor overheat: |E6Sl
Malfunction or banormality on built-in CPU of the option: El6721
Other display
Display Contents
It is displayed when the reset signal is kept supplied or an error occurs between the digital
operator
and inverter. When one of the keys Y I , and FUNC is pressed, it is recovered.
When it is not recovered, turn power on once again.
- It is displayed when a data set value more than 3 digits in length (for example, W 1000) is set.
It is displayed when power is turned off.
r -There is no trip history available.
This is not an abnormal operation because the instantaneous stop restart function is being
performed.
(When I to 3 is selected by the extension function Fl.)
-7 The autotuning operation terminates normally.
-- J The autotuning operation terminates abnormally.
-ZUJ Waiting due to insufficient voltage. After recovery, the original
display appears.
8-2
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9. TROUBLESHOOTING
9.1 Error Messages and Diagnosis
When the inverter goes wrong, it operates as indicated below. Find the cause and take
contermeasures.
Error Messages nd Diagnosis
Symptom
Display on the
digital operator r Cause
-Check Countermeasure
(display on the
LCD of the (explanation
remote operator) of message)
E 0 1 Overcur-ent detected A Check whether a load was Do not change loads
(OC. Drive) by the AC CT while changed rapidly. rapidly.the motor was running
at a constant speed Check whether there is a Check whether the output
(overcurrent during shorted output or ground lines or motor is shorted.
operation) fault.
E 0 2 ( Overcurrent detected A Check whether the speed Set a longer deceleration
(OC. Decel) by the AC CT during wasdecreased rapidly. time.motor deceleration
(overcurrent during Check whether there is a Check whether the output
deceleration) shorted output or ground lines or motor is shorted.
fault.
E03
(OC. Accel)
Overcurrent detected
by the AC CT during
motor acceleration
(overcurrent during
acceleration)
A Check whether a load was
changed rapidly.
Do not change loads
rapidly.
Check whether there is a Check whether the output
shorted output or ground lines or motor is shorted.
fault.
Check whether the start Lower the start frequency.
frequency is too high.
Check whether the torque Lower the torque boost.
boost is too high.
Check whether the motor is
locked.
Check the motor or loads.
E Q 5 0 Overloaded inverter A Check for an overload. Lower the load ratio.
(operation under an
overload) Check whether the Set an appropriate level.
electronic thermal level is
correct. (Check whether the
level has been changed.)
NOTE 1: How to reset
A: Stop the inverter. Then, connect the and control terminals or press the S OP/RESET y on
the operator.
B: Opeate the circuit breaker and electromagnetic contactor (turn the power on again).
C: Stop the inverter. Then, reset the thermal relay.
9-1
Symptom
Display on the
digital operator 7 Cause C
C heck Countermeasure
(display on the E
LCD of the (explanation
remote operator) , of message)
E 0 6 O The regenerative A Check the braking resistor - Set a longer deceleration
O L .R D) braking time is longer ! use ratio set in A 38 . time.
by the value set by - Set a larger operation
BRD%ED. duty cycle.
* Set 38 to 0.0.
E 0 7 O Overvoltage in the DC A Check whether the speed Set a longer deceleration
(Over. V) smoothing circuit was decreased rapidly. time.
Check whether the motor Do not use consecutive
was run from the load side. regenerative loads.
Check whether there is a Check whether the output
ground fault. lines or motor is shorted.
E 08 O EEPROM error A Check whether there is a Move the noise source(E 08 large-noise source near the away.(FEPROM) inverter.
Check whether the ambient Replace the cooling fan.
temperature is too high.
E 0 9 Defective power A Check whether the voltage Check the power supply.
(Under V) supply (insufficient is lowered.voltage)
Check whether the MCB or Replace the MCB or Mg.
Mg has a poor contact.
Check whether 10 or more Check the power supply.
instantaneous power
outages within 100 ms
occurred in 10 minutes.
E 1 0 0 CT error A Check whether the CT is Repair the CT.
(CT) defective.
E 1 1 0 CPU error A Check whether there is a Move the noise source
(CPU) large-noise source near the away.inverter.
Check whether the inverter Repair the inverter.
is defective.
E 1 2 O External trip A Check whether there was a Eliminate the error fromdefective external unit the external unit.
(EXTERNAL) when the external trip
function was selected.
o USP error A Check whether power was Eliminate the error from
E 13 turned on while the inverter the external unit.
(USP) was running when the USPfunction was selected.
9-2
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Symptom
Display on the
digital operator 5 Cause
Check Countermeasure
(display on the
LCD of the - (explanation
a. remote operator) of message)
E 1 4 1 Ground fault on the A Check the wmng between the Correct the portions having
(G ND. Fit) output side of the inverter and motor and also a ground fault.
inverter check the motor for a ground
I fault. (Use a megger)
E1 5 Excessive received A Check whether an - Lower the voltage to be
(OV SRC) voltage excessive voltage wa received.
received during an - Reduces fluctuations of
operation other than the received voltage.
deceleration. - Install an AC reactor on
the input side.
E 1.6 Defective power A Check whether the voltage Restore the power supply
I n s t . - F) supply (instantaneous is lowered, to normal.power outage)
Check whether the MCB or Replace the MCB or Mg.
Mg has a poor contact.
E 17 . Incorrectly connected A Check the connectors and Repair the defective
(N G . 0 P I ) option- I PC board other connections for connections.abnormal conditions.
E 1 8 Incorrectly connected A Check the connectors and Repair the defective
(NG OP 2) option-2 PC board other connections for connections.
abnormal conditions.
E 19 C Defective option-I PC A Refer to the instruction
(O P I ) board manual.
E 20 C Defective option-2 PC A Refer to the instruction
(OP2) board manual.
E 24 K Defective power A Check the power supply Repair the abnormal
(PH. Fail) supply (missing phase I connections for abnormal portions.
conditions.
Check whether the MCB or Replace the MCB or Mg.
Mg has a poor contact.
E 3 1 C (NOTE 1) Failure detected A Check whether a load was Do not change loads
(PM, Drive) by a detector in the power changed rapidly. rapidly.
module while the motor
was running at a constant Check whether there is a Check whether the output
speed. or excessive tem- shorted output or ground lines or motor is shorted.
perature nse in the inverter fault.
E 3 2 (NOTE 1) Failure detected A Check whether the speed Set a longer deceleration
PM 3. Deel) by a detector in the power was decreased rapidly. time,
module dunng motor
deceleration, or excessive Check whether there is a Check whether the output
temperature nse in the shorted output or ground lines or motor is shorted.
inverter fault.
NOTE 1: The failures detectable in the power module are overcurrents, excessively hot main devices. and insufficient
voltages from the gate circuit power supply.
9-3
Symptom
Display on the
digital operator Cause
Check Countermeasure
(display on the
LCD of the - (explanation
remote operator) of message)
E 3 (NOTE 1) A Check whether the speed was Set a longer acceleration
(PM. Aceel) Failure detected by a increased rapidly.
time,
detector in the power
module during motor Check whether a load was Do not change loads rapidly.
acceleration, or changed rapidly.
excessive temperature
rise in the inverter Check whether there is a shorted Check whether the output
output or ground fault. lines or motor is shorted.
Check whether the start Lower the start frequency.
frequency is too high.
Check whether the torque Lower the torque boost.
boost is too high.
Check whether the motor is Check the motor or loads.
locked.
E 34 (NOTE 1) A Check whether the Check the installation.( Failure detected by a installation is vertical and the
(PM. ERR) detector in the power wall is a nonflammable wall
module while the motor such as an iron plate.
was stopping, or
excessive temperature Check whether the cooling fan Replace the cooling fan.
rise in the inverter is running and the ambient
temperature is too high.
Check the internal power Repair the internal power
supply. supply.
Check the main devices. Repair main devices.
E 60 0 Defective J-FB PC A Refer to the manual supplied
(OP 1 0) board with the J-FB PC board.
to E67
(OP 1 7)
E 70 0 Defective J-FB PC A Refer to the manual supplied
(0 P2 0) board with the
J-FB PC board.
to E77
(OP2 7)
NOTE 1: The failures detectable in the power module are overcurrents, excessively hot main devices, and insufficient
voltages from the gate circuit power supply.
9-4
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9-5
Symptom
Display on the
digital operator ar Cause
Check Countermeasure
(display on the V
LCD of the (explanation
remote operator) of message)
-- C Check for an overload. Lower the load ratio.
Check whether the thermal Set the thermal relay to an
relay is set to an appropriate appropnate value.
value.
- B Check whether there is a Remove the short or ground
short or ground faultin the fault.
power supply.
Check whether the MCB Increase the MCB capacity.
capacity is sufficient.
Check whether the inverter Repair the inverter module or
module or converter module converter module.
is defective.
-- Power outage B Check for a power outage. Restore the power supply to
normal.
Check whether the MCB or Replace the MCB or Mg.
Mg has a poor contact.
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9.2 Trouble shooting
Symptom Probable cause Countermeasure
- Is power being supplied to terminals
R(L1), S(L2) and T(L3)?
If it is, the POWER lamp should be on.
- Check terminals R(L l), S(L2), T(L3), U(TI),
V(T2), and W(T3).
. Turn on the power supply.
- Is the display EE - Press 7 and check the content.
Then press the reset key.
-Is the operation instruction RUN ON? - Set to ON.
- Is terminal FW (or REV) connected to - Connect terminal CMI to terminal FW
terminal CM I? (or REV) on the printed-circuit board.
(When the terminal mode is selected.)
- Has the frequency setter been turned on - Push downkeys and set.
- When terminal mode is selected, connect the
by pushing FUNC key and then potentiometer to H, 0, and L, and then set.
. In the case of the internal interface power
key, source, short the terminals P24 and PLC or
CM I and PLC.
- Are the printed-circuit board terminals - In the case of the external interface power
H, 0 and L connected to source, turn the PLC terminal on.
the potentiometer?
- Are the terminals connected to the
external and internal interface power
source the terminal mode is selected?
- Has RS/FRS been left ON? - Release reset.
Contact FRS.
- Is the mode key Fl 91 setting correcti. Read the explanation of the function mode
once again. (Page 7-12) F9 frequency/run
commanding method
Inverter - Has the motor seized or is the load too * Release seizure or lighten the load.
outputs great? * Test the motor independently.
U(T I), V(T2)
and W(T3)
are supplying
voltage.
- Are the remote operator and equipment
body switched coorrectly ?
- Is the setting of the DIP switch on the
back of the remote operator correct ?
- Check the operation of the optional remote
operator. (copy unit)
ON i 2 3 4
OFF 6M6
IF OFF
2: ON (Same as VWA, J1100)
The - Are the connections of output terminals - Make the connections according to the phase
direction U(T1), V(T2) and W(T3) correct? sequence of the motor. (In general, forward
of the - Is the phase sequence of the motor should be in the sequence: U(TI), V(T2)
motor is forward or reverse in respect to U(TI), and W(T3).)
reversed. V(T2) and W(T3)?
- Are the terminals on the printed-circuit - Short the FW terminal for forward rotation or
board correct? the intelligent input terminal 8 (the intelligent
input terminal 8 is allocated to run command
REV by initialization at factory before
shipment) for reverse rotation to the CM I
terminal (Sink type).
9-6
I
The
motor
will not
run.
The inverter
outputs
U(T I), V(T2'
and W(T3)
are not
supplying
voltage.
The optional
remote
operator is
used.
(copy unit)
Symptom Probable cause Countermeasure
The rpm After checking the wiring of Replace the frequency setter.
of the the frequency setter, the rpm still
motor does not increase when the setter
will not is turned.
increase.
Are terminals 7 and CM 1, terminal 6 Turn off terminal 7 and 6. (When the
and CMI ON (Sink type)? frequency and multistage speed are fixed at
a given frequency, the speed potentiometer
will be invalid.)
Is the load too great? Decrease the load.
When the load is too great, the limiting
function will be activated, so that
the rotational speed will be lower than
the setting.
The rpm Is the maximum frequency setting Check the speed-change ratio.
of the correct?
motor Are the number of motor poles.
does not the gear ratio, and pulley ratio correct?
match the
inverter.
The data The data is The STN terminal is turned ON and the Tum the STN terminal OFF.
is returned to power is turned on. Input the data again.
incorrect. the initial The input terminals I to 5 are turned Replace the logic PCB.
setting. ON and then power is turned on.
The data has Was the power turned off without Input the data and push the FUNC key once.
not changed. k e
pushing the F key afer the data
was changed with keys.
The data is memorized upon power off. Take six seconds or more when turning power
Is the time from power OFF to ON less OFF and ON after changing the data.
than six seconds?
Data copied Is the power turned off for five seconds Copy again and turn the power off five
by the copy or more after the display changed seconds or more after copying.
unit from REMT to INV.
is not input. (HRW-OJ)
The data Frequency The change of the terminal mode and Confirm the change in |FIjsetting mode.
is not setting can digital operator mode were correct?
changed. not be
changed.
Run and
stop can not
be done.
The data can Is the input terminal SFT ON? Turn the SFT terminal OFF.
not be Is the software lock mode set at MD2 Turn the switch OFF.
changed, or MD3 ?
Note: If software lock is ON because of
use with an explosion proof motor,
do not release the software locks.
9-7
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9-8
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Symptom Probable cause Countermeasure
Overload Is the FI 8|torque boost too high ? Decrease the torque boost.
(Electronic Do the electronic thermal characteristics Reset the electronic thermal characteristics
thermal match the set characteristics of the and level.
trip) motor ?
(Low
frequency
zone)
The input Is the input voltage high ? Lower the input voltage.
voltage Is the equipment stopped with the Set a deceleration time which is a little longer.
trips. inverter DC voltage increased after Increase the AVR set value above the current
sudden deceleration ? input voltage and lower the V gain by
the ratio.
( )
General precautions
Always keep the unit clean so that dust or other foreign matter does not enter the inverter.
Take special care in regard to breaking lines and connection mistakes. Firmly connect
terminals and connectors. Keep electronic equipment away from moisture and oil. Dust,
steel filings and other foreign matter can damage insulation, causing unexpected accidents,
so take special care.
10.2 Inspection Items
(1)
(2)
(3)
Daily inspection
Periodic inspection (Approximately once a year)
Insulation resistance tests, withstand voltage tests
- See 10-3.
10-1
10. MAINTENANCE AND INSPECTION
0.1 Maintenance and Inspection Precautions
WARNING
* Be sure to turn off the power supply during maintenance and inspection.
* After the power supply has been turned off, you must always wait 10 minutes so that
DC bus capacitors can discharge then start maintenance and inspection after the
CHARGE lamp on the printed-circuit board has gone out. (Immediately after the lamp
has gone out. there will be a residual voltage of about 50 V DC in the DC bus
intermediatecircuit.)
Perform the work after the CHARGE lamp has stopped flickering.
* Make sure that only qualified persons will perform maintenance, inspection and part
replacement. (Before starting the work, remove metallic objects from your person
(wristwatch, bracelet, etc.)
(Be sure to use tools protected with insulation.)
Otherwise, there is a danger of electric shock and/or injury.
/ \CAUTION
* When removing connectors, never pull the wires. (Wires for cooling fan and thermal
relay)
Otherwise, there is a danger of fire due to wire breakage and/or injury.
Conduct these tests by short-circuiting the terminals as shown below, and by following the
conditions described.
- In regard to insulation resistance tests, measure the terminals below and the grounding at
500 VDC, and make sure that 5 Megohms or greater is indicated.
- Do not perform the withstand voltage test. When it should be done,
in regard to withstand voltage tests, supply the terminals below and the grounding with
1500 VAC (200 V class), 2000 VAC (400 V class) for one minute, and make sure that
there are no abnormalities.
- Do not conduct insulation resistance tests and withstand voltage tests for terminals other
than those indicated below.
- Increase or decrease the applied voltage for the withstand yoltage test slowly and turn the
equipment 0 V again.
Applied
voltage Bad example
(LI) (L2) (L3) (RB) (-) (-) (TI) (T2) 'T3)
R S T RB P N U V W
Megohm-meter
Good example
Time Time
NOTE 1: If the inverter is used under high temperature and heavy load conditions, its operating life will be significantly reduced.
NOTE 2: If the inverter has been stored for three years or more, apply the following conditions.
1) Apply 80% of the rated voltage of the capacitor for 1 hour at normal temperature.
2) Increase the voltage to 90% and apply it for 1 hour.
3) Apply the rated voltage for 5 hours.
NOTE 3: Precautions in handling printed-circuit boards.
When maintenance and inspection of printed-circuit boards is necessary, be sure to
follow the precautions below.
Prevent damage caused by static electricity. The IGBT of the inverter module,
the MCUs and ICs on a printed-circuit board can be destroyed by static electricity, so be sure to ground work benches, soldering irons, and yourself before
working on a printed-circuit board.
10-2
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2 2
-e 2
A .. >
C E.
- 4)=4
7] a-.0Cu C). o - NN-.' - e - C .0o o = sa'0 =( Sm4) -: .. .. - - . o e a -.. - - e
z z - - ----4) ~ -J -- 0 -
~C~0 C 0 l el r t.
- - --- .
-- -- - n$$0$ 4 ) 0
-4 - - Ce 2 .
-- e 0. 0 >.5
-J -
. >.Q
-- -- e
0 t2C-o ~ o fl- - - t2
C- C x
-
-o U - 0?
4) I~C C ~ a 4)
4)'0 ~ )1
-- 2" -
10-3
3
-
I
:2
-, - .33 - C3
E 32 2 n
A A
A A-- - . o
o o 1 o .'-c '-:0 0
E ~- 0o o 0 I o 0> '
2 - -3Zo
-.. --
3 2 A A
o - .o
:n a a 010-4
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r c) a - ,
-- 31 a,
a)Z Z
C,
0
o.-.A-A '- J
.-- '-" A y e o - - o .... )
--- x . - -i oN -O- -o - I"" . .o
>a) 2 - x U" -3.0 -o
.5 8 .) -= 0
Z-
0 a ci
~0. 0
ci o - .s
-) a.~~ 2 2 -. c43~e5e ..... , o-a
- - i.- C. 5.
a) a)o
-20
10-5
10.3 Measurement Method for I/O Voltage, Current, and Power
General measuring instruments for I/O voltage, current, and power are indicated below. The
voltage to be measured is the fundamental wave effective voltage and the power to be measured is the total effective value.
R R U lu I(TI)
(LI)
ER wl General Euv
wo V
Power s s s purpose v Iv ,o)
supply L2 I inverter (T2)
Table 3 Parts to be measured
Measurement Parts to be Measuring instrument Remarks Reference
item measured value
Supply voltage Between R and S, S and Moving-iron type Fundamental
E T, T and R (ER)(ES)(ET) voltmeter or rectifier wave effective
-0j- type voltmeter value
Supply current R, S. T (IR)(IS)(IT) Moving-iron type Total effective
ammeter value
Supply power Between R and S, S and Electrodynamic type Total effective
WI T (Wi 1)(WIz) wattmeter value
Supply power Calculate the supply power factor from the measured supply voltage, El,
factor supply current I1 and supply power WI.
Pf1 Pff= WI xlO0(%)
Output voltage Between U and V, V and Rectifier type Total effective
E W, W and U voltmeter valueF0 (EU)(Ev)(Ew)
Output current U. V, W (IU)(lv)(lw) Moving-iron type Total effective
10 ' ammeter value
Output power Between U and V, V Electronic type Total effective
W and W EB wattmeter value0 (Woil)(Wo2)
Output power Calculate the output power factor from the output voltage E, output current I,
factor and output power W.
Po Pfo= x (%)
fi3 E0l0
NOTE 1: Use a meter indicating a fundamental wave effective value for voltage, and meters
indicating total effective values for current and power.
NOTE 2: The inverter output waveform is a distorted wave, and low frequencys may cause
errors. However, the measuring instruments and methods indicated above provide
comparatively accurate values.
NOTE 3: A tester (general purpose) may not be suited often to measurement of a distorted
wave. 10-6
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Measurement method for output voltage
Fundamental wave effective value:
VAC=l.IxVDC
VDC
3
300 V (400 V class)
600 V 400 V cilass
movtng-coil type
10-7
11. STANDARD SPECIFICATIONS D
11.1 Common Standarsd Specifications
Item Description
Input voltage 200 V class 400 V class
'055 5 [ 10 i o l 300 370 450 I50 055I07SIL0 1 2 0 370 45Q 550 750 900 100320 1600 2200Model Name (Type) F FiLFLF iFL F LF ,LF *F hFIHFHF HF iF HF HF HF HF HF HFHF F HF HF HF
Enclosure (NOTE 1) Sem ene 1 d On t(IP00) Se enc sed Open type (IP0O)
Rated AC input power supply (V) Three-phase (3 wies). 200 to 220 or Three-phase (3 wires), 380 to 415 oro200230 v1t0%. 50or 60 Hz±5% 400 to 460 V±I0%, 50 or 60 Flz±5%
Rated output voltage (V) (NOTE 2) Three-phase. 200 to 230 V Three-phase, 380 to 460 V(Corresponding to the input voltage) (Corresponding to the input voltage)
Output frequency range (NOTE 3) 0.1 to 400 Hz
Frequency accuracy Digital command i0.01% and analog command ±0.I% for the maximum
frequency command
Frequency setting resolution Digital setting: 0.0 1 Hz/60 Hz, Analog setting: Maximum frequency/1000
Voltage/firequency characteristics V/f vanable, high start torque, standard starting torque (constant torque,
reduced torque)
Accelerationdeceleration time 0.0 1 to 3000 seconds, acceleration and deceleration individually set
Starting torque (NOTE 4) 150% or more (I Hz)
Brak- Dynamic braking About
ig (NOTE 5) 20% About l0to2O% About 20% About l0to 15%
torque Feedback to capacitor
Dynamic braking using Braking resistor optional for 055 and ' Braking resistor optional for 055 and
external resistor or unit 075L, use braking unit (BRD) for 075H, use braking unit (BRD) for
(BRD) 220 to 550L. 220 to 2200H.
DC injection braking Operated at the DC braking frequency or by external input
Input Frequency Digital operator Set by E and Y
signals setting
2 W 500 Q to 2 kO potentiometer. 0 to 5 VDC (nominal),
External signals 0 to 10 VDC (nominal) (input impedance 30 kW). 4 to 20 mA (nominal)
(input impedance 250 Q)
Forward/ Digital operator UN/ STOP (Only for forward run or reverse run, the function mode
reverse should be switched.)
run,
stop External signals FW (forward run command)/stop
REV (reverse run command), FRS (free run stop command), CF I to CF3
(multistage speed setting), USP (USP function). JG (jogging command),
CHI (2-stage acceleration and deceleration), DB (external DB command),
Intelligent input terminal RS(reset input), STN (initialization), SFT (software lock), AT (current input
selection). CS (commercial power source switching), SET (2nd setting
selection), EXT (external trip), UP (remote control, acceleration),
DOWN (remote control, deceleration)
Output Intelligent output terminal FA I (speed arrival signal), RUN (signal during run), OTQ (overtorque signal)
Analog output frequency monitor (0 to [0 VDC full scalelmA max.), digital
Frequency monitoring frequency signal by remote operator, analog current monitor, analog torque
monitor
11-1
Item Description
Input voltage 200 V class 400 V class
Model Name (Tye I) 0 2 20 30 450 0 0 055 O7 ill0 O 220 3o 370 4o go550 750 % l320 i6O220oLFpe BE [ELF L LF F LE LF LF HF FFHF HF HF HF HF HF HF HF HF HF HF HF HF
Fault alarm contact (ALO-AL 1) OFF when an inverter alarm occurs
AVR function, data batch setting, V/F characteristic switching, curve
Other characteristics acceleration and deceleration, upper and lower limiters, 8-stage speed,
start frequency fine adjustment, trip history monitor (up to three times
stored), fuzzeleration and deceleration, autotuning, etc.
Protection functions Overcurrent, overvoltage, undervoltage, electronic thermal, abnormal
temperature, grounding current, overload restriction, etc.
Vibrations (NOTE 6) 5.9 m/S
2 (0.6G) 10 - 55 Hz for 0550 to 075L /H
-. 0 m/S 2 (0.2G) 10 - 55 Hz for 220 to 550L and 220 to I IOOH
General
specifi- Operation location Altitude of 1000 m or less, indoors (free of corrosive gas and dust)
cations
Paint color Regel gray No. I (Munsell 9.IY 7.4/0.6 semigloss, cooling fan of aluminum
ground color)
Options Remote operator, copy unit, cable for digital operator, braking resistor, reactor
for improving power factor, noise filter for inverter, fitting for conduit tube
connection, fitting for removing cooling fins
Estimated mass (kg) 7.57.513 13; 21 37 37 51 51 7.57.13 13 213636146 46 70 70 80 130 1303
NOTE 1: Protective structure is based upon JEM1030-1977.
NOTE 2: The output voltage will decrease if input voltage decreases.
NOTE 3: Confirm with the motor manufacturer the motors maximum rpm when using a motor
running at frequency higher than 50/60 Hz.
NOTE 4: When using the standard four-pole motor, select the high start torque (SLV) at the rated
voltage (200 V class: 200, 220, 230 V; 400 V calss:400, 415, 440, 460 V).
(For details, contact the dealer you purchased the product.)
NOTE 5: Torque will be reduced when the base frequency exceeds 50/60 Hz.
The dynamic braking torque is about 70% for 055LF or about 60% for 075LF when one
of the 200 V class RB I to RB3 (17M or more) is used at the shorttime rating or about
60% for 055HF or about 50% for 075HF when the 400 V class RB2 x 2 series
(70 Q or more) is used.
NOTE 6: According to the test method shown is JIS C 0911 (1984).
11-2
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11.2 Individual Specification (USA version (J300- LFU, HFU))
Item Description
Input voltage 200 V class 400 V class
Model Name (Type) 055 075 110 ISO 0 370 450 550 o5 075 11 150 220 3 370 4q 550 70 9 9 I 1320 160 220
LF F LfLF LFLF [F LF LF LF F Hf IFHF HF fIFHFFAFHFHFHF HF HF HF HF HF
Applicable Constant torque 5 -i I i; I5, 22 30' 37i 45 5i" 5.5' 75/ 11 IS' 22 30/ 37 4S' 55 75, a Io I 32, I% 210,
motor rating .5 10 IS 20 30 40 50 l ' 5 0 15 20 30 40 50 60 75 10 0 i 50 20 250 300
(4P, max.
kW/HP) Variable torque 7 . i5: :1 30 7: 3 s 55' 5 I 15 2 01 3, 4 ;s5 :5 '1 IM 3 I 1 225 26WV
(NOTE 1) (NOTE 2) j :5 20 300 W50 0 -5 [o10 15 20 700 40 0 W -5 00 20 150 200 50 300 350
Continuous 200 V 8.3 11 16 22 33 42 50 63 76 - F
a)utput
kVA) 230 V 1 0 13 18 25 38 48 58 73 88
Constant 380 V 8.6 15 21 3238 49159 72 89 103 13, 158 207250
400 V 9.01 11 16 22 33 4 52 62 76 94 108144 166 218 263
4600l8 25 38 46i60 72 88los 124166 19 25i303
200 V 9 12 18 25 37 47 56 71 86
230 V 14 21129143 54165182199
Variable 380 V -9.6u-17 24 36 43556682 102 158 199 250 286torque I I
400 V 0 1 o2._ 18 25 37 45587086 1ot It 16 209 263 301
460 V i.6 4 21 29 43 52 67 80 991124 14: 191 241 303 347
Rated output Constant torque 24 32 46 64 95 12l1145 182220 13 1623 32 48 58 75 90 i1 13: i5 208 240 315 380
current (A) I
VaNabe torque 27 36 52 72 10 136 163 205 248 14 18 26 36 54 65 84 io2 i 180 24C 302 380 435
Carrier Constant torque 16 12 10 6 16 12 10 6 3 2
frequency
(Hz) Variable torque 16 12 10 6 16 12 10 6 2 2
(NOTE 3) 1
O erload Constant torque 150%, for I minutecurrent
capacity Variable torque 125%, for I minute(NOTE 3)
General Ambient (NOTE 4) -10 to 50 degree C
specifications tempera- VT
ture V
(NOTE 5) -10 to 40 degree C
Humiditv 20 to 90% RH
NOTE 1: The applicable motor is a Hitachi standard four-pole motor. When using another motor,
make sure that the rated motor current does not exceed the rated inverter current.
NOTE 2: Applicable motor rating at variable torque is valid with the condition that output current
does not exceed the rating at variable torque.
NOTE 3: When a V/F pattern (VPl, VP2, or VP3) for variable torque is selected (FfL
for the digital operator or F04 for the remote operator), the setting data are automatically
changed by the inverter.
NOTE 4: CT: Constant torque.
NOTE 5: VT: Variable torque.
11-3
12. FUNCTIONS WHEN USING THE OPTIONAL REMOTE OPERATOR)
12.1 Connecting the remote operator
Be sure to turn the power supply off when connecting the connector.
High performance remote operator (HOP)
High performance copy unit (HRW)
Digital operator
Remote operator (DOP)
Copy unit (DRW)
(1) Insert the connector straight into the remote operator and inverter unit
printed-circuit board.
(2) Turn on the power supply.
(3) Make sure that the liquid crystal display of the remote operator is lit.
When the power supply of the inverter is turned on, FSO00.0.bf the monitoring mode
will be displayed. If, however, any of the following is displayed when the inverter is
turned off, they will be displayed when power is turned on again.
Frequency setting, multi-speed setting or other frequency displays, motor rotational
speed display, frequency conversion display, or output current display.
NOTE: When conflicting data is set, a warning |WARN.. will be displayed. For 6 seconds
thereafter, do not perform the key operation, reset operation, running operation, power-OFF
operation. (Otherwise, a communication error may occur in the operator.)
12-1
NOTE: See the operation manual of the remote operator for instructions.
In addition, see the following pages for details on its various functions. Set the dip-switches
mounted on the backside of the remote operator and copy unit as below.
When turned ON,
os read out is inhibited.
OFF If pushing down "RD LOCK" is display
|Invalid
Set as below (When setting status do not match model,
the correct function can not be attained.)
Switch 121 2
Model
J300 series
(Same as VWA,J100) OFF ON
key with ON,
ed.
12-2
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12.2 Monitor mode
Monitor mode list when the remote operator (DOP) and copy unit (DRW) are used
Monitor mode initial values and display contents
Initial display contents, initialization, and change ranges are displayed
in the table indicated below.
Y Setting can be changed
during operation
N : Setting can not be changed
durng operation
Display only
Display Monitor name Display content Initial value Setting ca Remarks
sequence range postl'
I Frequency setting 0 to 120 Y (I ) displays the setting.
and output FS0000.0 - 0.0Hz 0 400) (2) displays the output.
frequency * is displayed
when run
T 0.0 Hz instruction is ON.TM 00 E .0Hz
F: Forward run
M 150000.0 i 0.0Hz 0.0 Hz R: Reverse run
Multistage-speed
setting and out- 250000.0 x 0.0Hz
put frequency
350000.0 x 0.0Hz
Jogging frequency G x0r 0.0Hz 1.0 Hz 0 to 9 A trip occurs easily.
setting at Hz or more.
-Valid when the multistage speed terminal
450000.0 .. 0.0Hz 3 is selected.The multistage speed
Expansion 0.0 Hz 0 Y are displayed when
multistage speed (400) the input terminal is
connected.
750000.0 : 0.0Hz - For terminal setting,
refer to F-34 "Input
terminal setting'.
2 Acceleration time ACCl 0030.005 30.0S 0000 Y2 setting C 0005 3.$ 30.0__________
3 Deceleration time DECI 0030.00S 30.0S 300Y0 Yselling 0.0
Frequency setting F-SETSELECT REM TRM TRM REM N REM: Setting from
command .PIP 2 the remote operator
TRM/REM TRM: Setting from the
5 Operationcommand F REM TRM opyepa N invertertemunal
6 Motor pole count Synchronized speedsetting and revolu- RPM 4P 0RPM 4P 2 to 48 Y displaytion speed monitor
7 Frequency converted The arithmetic value
value setting and /Hz01.0 0.00 Y by the frequency
converted value 1.0 Oto 99,9 converted value is
monitor displayed. (NOTE 1)
The (1) section depends
8 Current monitor / on the INV rated
Im 0.0 A 0.0% current.
The (2) section
displays the rate to the
rated output current.
9 Torque monitor Torque - % --10 boos adust ent V-Boost codet 0t99 Y
NOTE 1: The terminal output when the digital output frequency monitor is set at the FM terminal of the control
circuit is the "output frequency x frequency converted value". The upper limit of output is 3.6 kHz.
12-3
I. Setting andDisplay Monitor name Display content Initial value Settmg ding a Remarkssequence range possible?
r eana toradustme t V-Boost F 100% 10.0% 0 to 50.0 Y
12 Output voltage 1 00% :0io 100 Y12____ gain adjustment V-Gain 100%
13 Jogging frequency bogging 1.00 Hz .0 Hz 0 to 9.99 Y A trip occurs easilyadjustment at 5 Hz or more.
14 Aalo meter ADJ 172 172 oto250 Y
15 Terminal input TERM LLLLLLLLL[status monitor Fw 7 5e38erminal--- 8 6 42 m Wl tOFF
Display Monitor name Display content Trip cause, contents Remarkssequence
When the equipment is
16 Warning monitor [ WARN # Normal state normal, 4 is displayed.
When a value which is
WARN Flw>Fs Frequency setting error larger than the upper or
smaller than the lower
limit is set, a warning
is displayed.
17 Alarm display ERR1 Not occurred
Trip monitor ERR1 OVER Trip cause ,.;mssgei________________ ri ca e 4displayed on a priority
ERR1 31.0 Hz Output frequency when tripped basis when an alarm
occurs.
ERRI 12.5 A Output current when tripped Trip cause
Overvoltage trip
ERR1 787.0 Vdc iVoltage between P and N whenI R1 770Vd tripped
Cumulative years and months
when tripped
18 Total alarm count ERROR COUNT 0 Not occurred
ERROR COUNT 25 Total trip count
19 Trip history monitor ERR2 =# Not occurred
Last trip contents ERR2 OCAccel Trip cause 2iTrip cause
Overcurrent trip for
ERR2 5.0 Hz Output frequency when tripped acceleration
ERR2 20.1 A Output current when tripped
ERR2 580.0 Vdc_ Voltage between P and N when
ERR2 580.0 Vdc tripped
Cumulative years and months
IERR2 RUN flY 7D when tripped ________
Contents of last ERR3 # Not occurred
trip but one
ERR3 EXTERNAL Trip cause Trip cause
External trip
ERR3 0.0 Hz Output frequency when tripped
ERR3 0.0 A Output current when tripped
ER3 5Voltage between P and N whenERR3 560.0 Vdcl tripped
Cumulative years and months
ERR3 RUN OY ID when tripped
12-4
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12.3 Function mode
Function mode list when the remote operator is used
- Function mode initial values and display contents
Initial display contents, initialization, and change ranges are displayed in the table
indicated below.
(Function mode l) (Function mode 2) Setting chang
Function Function initializationdisplay Irunalization Setting contents
No. name contents
F-DO Base F-BASE 0060 Hz 60 Hz 1 30 to 20 400) -When 120 Hz is switched to
frequency 400 Hz by F-30, a frequency
setting more than 120 Hz can be set.
2 F-01 Maximum F-MAX 0060 Hz 60 Hz 30 to 120 (400)
frequency
setting
3 F-02 Start Fmin 0.50 Hz 0.5 Hz 0.1 to 9.9 - The equipment starts running
frequency at this set value.
adjustment
4 F-03 Motor input AVR AC 460 V 230/460 200.2 l 5,220,230 - The motor input voltage is set.
Input voltage 3 80,400,415
voltage setting 440,460,480
AVR AVRDEC OFF OFF ON/OFF 'ON or OFF of the AVR
function function fordeceleration
for is set. When dynamic
deceler- braking torque is necessary
tion 1 for deceleration, OFF is set.
5 F-04 Control CONTROL VC VC VC, VPI, VP2. VC, VPI, VP2, VP3:
method VP3, SLV, V2 V/F characteristics
setting SLV:Sensoriess vector control
V2:Sensor vector control
6 F-O5 Autotruning AUX AUTO NOR NOR NOR/AUT/NRT - At the first running after
I Motor setting AUT/NRT is set, the
constant autotuning measurement
(NOTE l)_ operation is executed.
Motordata AUX DATA NOR NOR NOR. Old Hitachi -The autotuning motor data
selection general purpose before starting autotuning
TMO: New measurement is data
Hitachi general equivalent to NOR,
purpose
AUT: Autotuning data
Motor AUX K 005.50kW Ratedcapacity 3.7 to 160 Setacapacity smallerthan the
capacity ofeachmverter rated capacity as capacity
setting data.
Motor pole AUX P 4p 4 p 2,4,6, 8 -The number ofpoles of the
count motor to be used is set.
setting
Motor AUX RI L.004 Ratedcapacity 0 to 65.535
constant ofeachinverter
Motor AUX R2 0.776 Ratedcapacity 0 to 65.535
constant ofeachinverter
Motor AUX L 13,l6mH Ratedcapacity 0to655.35
constant ofeachinverter
L setting
NOTE 1: The motor constants RI, R21, L, M, J, Kp, Ti, and KPP vary with the capacity.
12-5
(Function mode 1) (Function mode 2)
Function Function Initialization display Initialization Setting change Settingcontents
No. name contents contents
6 F-05 Motor AUX M 123.60mH Ratedcapacity Oto 655.35 -Primary self inductance per
Motor M setting ofeachinverter piase.
constant constant
Motor AUX J 0.44 kgm2 Ratedcapacity 0 to 655.35 - Motor and machine inertia
J setting . ofeachinverter
constant
Motor AUX Kp 002.00 2.0 0 to [00.00 - Smaller: High response
constant Larger: Low response
Kp setting
Motor AUX Ti 00100 ms 100 ms 0 to 10000 - Set this item after the
constant feedback option PCB is
Ti setting installed.
Motor AUX KPP 001.00 1.0 0 to 100.00 - Set this item after the
constant feedback option PCB is
KPP setting installed.
7 F-06 Accelera- ACC I 00 30.00s 30.00s 0.01 to 3000 - When the fuzzy most
Accelera- tion time suitable acceleration and
tion time setting deceleration (F-10) are set,
the time displayed here is
invalid, though it can be
set.
2-stage ACC 2 0015.00s 15.00 s 0.01 to 3000 . The acceleration time can
acceleration be used when the input
time setting terminal CHI is shorted.
- For input terminal
selection, refer to F-34
input terminal.
Curve ACC LINE L L L (Linear, *The curve pattern is set for
pattern S (S curve), accelerationand
selection U (U curve), deceleration respectively.
for RU (reverse
acceleration U curve)
Accelera- ACC GAIN 02 2 (common to Ito 10 -When the constant is set
tion and acceleration for one of acceleration and
deceleration and deceleration, it is common
curve deceleration) to both acceleration and
constant deceleration.
selection See appendix 4.
8 F-07 Decelera- DEC I 0030.00s 30.00 s 0.01 to 3000S . When the fuzzy most
Decelera- tion time suitable acceleration and
tion time setting deceleration (F- 10) are set,
the time displayed here is
invalid, though it can be
set.
2-stage DEC 2 0015.00s 15.00s 0.01 to 3000S -The deceleration time can
deceleration be used when the input
time setting terminal CHI is shorted.
- For input terminal
selection, refer to F-34
input terminal.
Curve DEC LINE L L L (Linear), -The curve pattern is set for
pattern S (S curve), acceleration and deceleraselection U (U curve). tion respectively.
for RU (reverse
deceleration U curve)
Accelera- DEC GAIN 02 2 (common to 1 1010 - When the constant is set
tion and acceleration for one of acceleration and
deceleration and decelera- deceleration, it is common
curve tion) to both acceleration and
constant deceleration.
selection - See appendix 4.
12-6
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F(Function mode) (Function mode 2)
Display ' . Setting, changeFunction Function I [nitializationdisplay Irutialization Setting contents
No. name contents contents
9 F-08 Accelera- Fsp F 0000.0 Hz 0 Hz 0 to 400.0 The frequency at which the
Accelera- tion stop acceleration operation is
tion halt frequency stopped temporarily is set.
setting
Accelera- Fsp TIME. 00.0 s 0 s 0 to 60.0 The time that the acceleration
tion stop is stopped temporarily at a
time setting certain frequency during
acceleration is set.
10 F-09 Pattern PARAM REM REM REM/ Theparametersettingcomcommand- OPI/OP2 manding source is selected.
ing method (Option REM (each operator).
selection connected) OP I (option i ), OP2 (option
F-10
Running
mode
Running RUN MODE NOR NOR NOROEN, NOR: Normalrunning
mode GOD OEN: Energy conservation
selection running
GOD: Fuzzy most suitable
accelerattionand
decelerationrunning
Restaring RUN FRS ZST ZST fST/ZST fST: Restart after frequency
after FRS maching
signal ZST 0 Hzstart
selection
12 F-1I Multistage SPD 1 0000.00 Hz 0 Hz 0 to 120.0 (400) -The input terminal CFI is set
'Multistage! speed and used.
speed I speed
setting
Multistage SPD 2 0000.00 Hz 0 Hz 0 to 120.0 (400) -The input terminal CF2 is set
speed and used.
2-speed
setting ---&to 120 -0(400)
Multistage SPD 3 0000.00 Hz 0 Hz 0 to 120.0 (400) The input terminals CF I and
speed CF2 are set and used.
3-speed
setting
Multistage SPD 4 0000.00 Hz 0 Hz 0 to 120.0 (400) The input terminals CFI and
speed CF3 are set and used.
4-speed
setting
Multistage SPD 5 0000.00 Hz 0 Hz 0 to 120.0 (400) 1 The input terminals CF2 and
speed CF3 are set and used.
5-speed
setting
Multistage SPD 6 0000.00 Hz 0 Hz 0 to 120.0 (400) - The input terminals CFI, CF2,
speed and CF3 are set and used.
6-speed
setting
*Multistage SPD 7 0000.00 Hz 0 Hz 0 to 120.0 (400) The input terminal CF3 is set
speed and used.
7-speed
setting
12-7
I
(Function mode I) (Function mode 2)
Display .. Setting, change |Function Function Initialization display Imtialization i Setting contents
No. name contents contents
13 F-20 DC braking DCB SW OFF OFF ON/OFF - DC braking
DC selection ON: DC braking available
injection OFF: DC braking unavailable
braking DC braking DCB KIND LVL LVL LVL EDG : DC braking method selection
type LVL. Level operation
selection EDG: Edge operation
DC braking I DCB F 0000.5 Hz 0.5 Hz 0 to 400.0 Hz - The frequency at which the
frequency DC braking starts is set.
selection
DC braking DCB V-STA 00 0 0 to 20 The DC braking force at start
force selec- is set.
tion(atstatt)
DC braking DCB V-STP 00 0 0 to 20 . The DC braking force at stop
force selec- Is set.
tontatstop)
DC braking DCB T-STA 000.0 s 0 s 0 to 600.0 , The DC braking time at start
time selec- is set.
tionlatstart)
DC braking DCB T-STP 000.0 s 0 s 0 to 600.0 - The DC braking time at stop
time selec- is set.
tion (at stop)
DC braking DCB STOP-T 0.00 s 0 s 0 to 5.00 The outiput frequency is
output cut- lowered to the DC braking
ofT time frequency and the free nan
adjustment time during execution of DC
braking is set,
14 F-21 Dynamic BRD-%ED 001.5% 1.5% Oto l00.0 'The allowable usage ratio of
braking Ithe braking resistor for 100
setting seconds is set. (NOTE 1)
15 F-22 Allowable , IPS TIME 1.0 s 1.0 s 0.3 to 25 s - When an instantaneous power
The instantaneous failure occurs, the allowable
allowable powerfadure time until the power failure is
usage time setting recovered is set.
ratio of Reclosing IPS WAIT 001.0s 1.0 s 0.3 to 100.0 s The waiting time until the
the standbyarfer rerunning starts after an
braking instantaneous instantaneous power failure
resistor powerfaidure occurs and is recovered is set.
for 100 recovered
seconds Instantaneous IPS POWR ALM ALM ALM/FTP/ ALM: Alarm output
is set. powerfailure RST/ZST ZST: 0 Hz start retry
restart FTP: Retry after frequency
selection matching is stopped
RST: Rerunning start retry
Tripselecton IPS TRIP OFF OFF ON/OFF When an instantaneous power
during stop failure occurs:
atunder ON: Trp
voltage OFF Non-trip
16 F-23 Electronic E-THM CHAR SUB SUB CRT/SUB/FRE | - ElectronicthermalcharacteisElectronic
thermal
thermal
characterstic
selection
Electronic
thermal level
setting
E-THM LEVEL 100% 100% 20to 120%
tic setting CRT: Constant
torque characteristic
SUB: Reduced torque charactenstic
FRE: Free characteristic
NOTE 1: Initial setting of usage ratio l.5%-055-075L/HF 0% - - Il10-550L.HF
12-8
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D Function mode 1) (Function mode 2)Display
Function Function Initialization display Initialization
No. name contents
16 F-23 Electronic E-THM A] 8.5A Ratedcapacitvof
Electronic thermal each inverter
thermal charaterstic
(NOTE 2) free setting
current (I)
Electronic E-THM F1 0000 Hz Ratedcapacityof
thermal each inverter
charactensticfree setting
tiequencv(1)
Electonic E-THM A2 8.5A Rated capacity of
thermal each inverter
Characteristic
free setting
current (2)
Electronic E-THM F2 5Hz Rated capacity of
thermal , each inverter
Characteistic
free setting
frequen2)
Electronic E-THMA43 13.0A Ratedcapacityof
thermal each inverter
|-characteristic
free setting
current13)
Electronic E-THM F3 73 Hz Rated capacity of
thermal each inverter
chiaraciensac:
free setting
tirquencyl3)
Setting, change
contents
0 to 600.0 A
0 to 400 Hz
0 to 600.0 A
0 to400 Hz
0 to 600.0 A
(Ito 400 LIz
17 F-24 Overload OLOAD LEVEL 125% 125% 50 to I50% Under the sensorless vector
Overload restriction controlan overload isdetected
restriction~ level setting from both the overload restricio tion and torque limiter.
Overload OLOAD CONSTO01. 1.0 0.3 to 31.0 When the setting is 3L0 in SLV
restriction or V2 control mode, the
constant overload restnction has no
setting effect.
Valid OLOAD ACC ON ON ON: Valid for Even if the function is set to
selection acceleration OFF, the overload restiction is
for overload Keep the invalid only for the first
restnction function ON acceleration when the forward
acceleration for operation. and reverse run command is
turned on,
IS F-25 Software S-LOCK MD MDI MDO/MDI MDO,MDI: Terminalsoftware
lock MD2/MD3 1 lock (SFT)
selection MD2, MD3: Software lock
(NOTE I)
NOTE 1: When MDO is set and the input terminal SFT is turned ON, the data of all functions is locked. When MD2 is
set (stored), the data of all the functions is locked. During locking, no data can be changed. MDI, MD3
can set only the output frequency.
NOTE 2: Electronic thermal characteristic free setting current and frequency depends on the inverter rating.
12-9
Setting contents
f (Function mode I) (Function mode 2)
Display Function Function Initialization display Initialization Setting,change Setting contents
S4iL~tCC No. name contents contents
19 F-26 Frequency LIMITL 0000.0 Hz 0Hz Oto 120.0 Thelowerlimitofthefrequency
Frequencyi lower limiterl (400) Hz to be set is set. When the lower
limiter setting limit is 0, the setting is invalid.
Frequency LIMIT H 0000.0 Hz 0 Hz 0 to 120.0 The upper limit of the frequency
upper (400) lz to be set is set. When the upper
limiter limit is 0, the setting is invalid.
settng
20 F-27 Jump JUMP Fl 0000.0 Hz 0 Hz 0 to 400 Hz + The section where frequencies
Jump frequency are to bejumped is set.
frequency setting ( I) Lp to three locations can be
set.
- When the number of locations
is 0, the setting is invalid.
Jump JUMP F2 0000.0 Hz 0Hz 0o 400 Hz
frequency
setting (2)
Jump JUMP F3 0000.0 Hz 0 Hz 0 to 400 Hz
frequency
setting (3)
Jump JUMP W 0.5 Hz 0.5 Hz 0 to 9.9 Hz 'The frequency width where
frequency frequencies are jumped is set.
width settin
21 F-28 STOP key STOP-SW ON ON ON: STOP key Whether or not to make the
validity valid STOP key valid during terminal
selection OFF: STOP key running is selected. In the
during invalid Remote mode, the STOP key is
terminal always valid.
running
22 F-29 Running F/R SW FRE FRE FWDiREV/ FWD: Only forward run
direction FRE REV: Only reverse run
selection FRE: Both forward nm and
reverse run valid
Reverse run F/R PREV OFF OFF ON/OFF Reverse run prevention
prevention ON:
selection OFF:
Reduced F/R RVS 6 6 0 to 6
voltage
soft stan
setting
23 F-30 Maximum F-MAX-L 120 Hz 120 Hz 120/400 Hz Maximum frequency switching:
frequency 120: 120 Hz 400: 400 Hz
selection I
24 F-31 Analog inpu IN ANA 10 V 10 V 10/5 Input voltage maximum level
External voltage 10: Max. 10 V 5: Max. 5 V
analog selection
frequency External IN EXS 0000.0 Hz 0 Hz 0 to 120.0 (400) - Frequency at which the
command. frequency i external input starts
start setting , 1
External IN EXE 0000.0 Hz 0 Hz | 0 to 120.0 (400) + Frequency at which the
frequency external input is maximized
end setting
External IN EX%S 000% 0% 0 to 100 - Input start level
frequency
start setting
rate
External fre- IN EX%E 100% 100% 0 to 100 - Input maximum level
quency end
setting rate
External IN LEVEL 0 Hz 0 Hz 0 Hz/ExS EXS: Stan at EX%S setting
command rate or less
start point
selection
12-10
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Frequency! signal outpu
arrival pattern
output selection
Signal
Setting, change
contents
I to S
CST PAT ANY
Setting contents
CST: Output at constant
frequency arrival
PAT: Output ofmore than
set frequency
ANY. Output of only set
tn-encv
q y
Amval ARV ACC 0.0 Hz 0 Hz 0 to 400.0
frequency
rate setting
for
acceleration
Arrival ARV DEC 0.0 Hz 0 Hz 0 to 400.0
frequency
rate setting
for
deceleration
100%
100%
RS
100%
100%
0 to 250
0 to 250
- During control of SLV
and V2: Power running
overtorquelevel
- Durng control of VC
and VPI to VP3:
Warning level for power
running regenerative
overload
- When 0 is set: Any signal
is not output.
- During control of SLV
and V2: Regenerative
overtorque level
- During control of VC
and VPI to VP3: No
effect
- When 0 is set: Any signal
is not output.
RS reset RS and 17
termnal other terminals
Input IN-TM 2 AT AT current AT and 17
terminal 2 input selectioni other terminals
I setting terminal
Input IN-TM 3 JG JGjogging JG andl7
terminal 3 terminal other terminals
setting
Input IN-TM 4 FRS FRS free FRS and 17
terminal 4 run other terminals
setting terminal
CHI CHI 2-stage
acceleration
and
deceleration
terminal
CHlI and 17
otherterminals
NOTE 1: When setting 20% or less, the error will increase (= 20% or more).
Therefore, set 20% or more.
12-11
'6 F-33
Overtorque
signal
(NOTE
Overtorque
signal rate
setting
(for power
running)
OV-TRQ V
OV-TRQ R
IN-TM I
Overtorque
signal rate
setting
(for regeneration)
Input
terminal I
setting
F-34
Intelligent
terminal
input
terminal
setting
Input
terminal 5
setting
IN TM 5
27
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Display Function Function Initializationdisplay Initialization Setting,change Settingcontents
No, name contents contts
27 F-34 Input IN-TM 6 USP USP USP and 17
Intelligenti terminal 6 i Power-ON otherterminals
terminal setting restart
input I preventioni
terminal Input IN-TM 7 CFI CFI CFl and 17
setting terminal 7 1 Multi-stage otherterminals
setting input
terminal
Input IN-TM 8 REV REV reverse REV and17
terminal 8 run command other terminals
setting input terminal
Input IN-TMO/C-l NO NO NO/NC Input terminal setting
terminal I NO: ON when shortNO/NC circuited
setting NC: ON when opened
input IN-TMO/C-2 NO NO NO/NC Inputterminal setting
terminal 2 NO: ON when shortNO/NC circuited
setting NC: ON when opened
input IN-TM O/C-3 NO NO NO/NC - Input terminal setting
terminal 3 NO: ON when shortNO/NC circuited
setting NC: ON when opened
Input IN-TM O/C-4 NO NO NO/NC -Input terminal setting
terminal4 NO: ON when shortNO/NC circuited
Ssetting NC: ON when opened
I8 F-35 Output OUT-TM I FAI FAI FAI/RUN/OTQ Outputterminal setting
Intelligent terminal FA 1: Frequency arrival signal
terminal I I setting RUN: Signal during ran
output OTQ: Overtorque signal
terminal Output OUT-TM 2 RUN RUN FAI/RUN/OTQ Output terminal setting
setting terminal FA1: Frequency arrival signal
12 setting RUN: Signal duringrun
OTQ: Overtorque signal
Alarm OUT-TM O/C-ANC NC NC/NO Alarmoutputterminal
output contacts a and b setting
NO/NC NC: b contact
setting NO: a contact
Output OUT-TM O/C-I NO NO NO/NC Output terminal I contacts
terminal 'a and b setting
I I NO/NC NO: b contact
setting NC: a contact
Refer to C 21
Output OUT-TM O/C-2 NO NO NO/NC Outputterminal 12 contacts
terminal a and b setting Short12 NO/NC NO: a contact
NC: b contact
29 F-36 Carrier CARRIER 16.0 kHz 16.0 kHz 2.0 to 16.0 Hz CThe IPM carrier frequency* hF1 carerfeqec
frequency Selectable is set.
setting in 0. 1 steps 1 - The setting value vanes
with the capacity.
12-12
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D Function mode 1) (Function mode 2)
Function Function Initialization display Initialization Setting, change Setting contents
No. name contents contents
30 F-37 Monitor MONITOR A-F A-F A-F AT/D-F TheF IM terminal monitor
signal signal output is selected,
selection A-F: Analog frequency
T: Torque monitor
A: Current monitor
D-F: Digital frequency
31 F-38 Trip histor TNIT TCNT CNT ' CNT CNT/CLR Trip count deletion selection
Iniiali- count clear CNT Tnp counting is
zation continued.
CLR: The tip count is cleared.
. Debug INIT DEBG OFF OFF ON/OFF - Debug mode setting ON or
mode OFF
display OFF: The debug mode is
selection turned off.
NOTE I ON: The debug mode is turned
on.
Digital INIT DOPE FWD FWD FWD/REV -The digital operatorrunning
operator direction is set.
rotation FWD: Forward run
direction REV: Reverse run
selection
Selection of [NIT RESET ON ON ON/OFF ON: Alarm release when reset
reset on
eroma OFF:Alarm release when reset
off
32 F-39 Encode OP P 01024 pulse 1024 255 to 65535 Effective with option board
Option pulse (J-FB)
settmng number
setting
Control OP MODE ASR ASR ASR/APR
mode
selection
Ro-To OP RO-TO OFF OFF OFF/ON Keep OFF. (No use)
option
selection
33 F-40 Stop OR POS IN IN IN/OUT Effective with option board
Orientatiot position (J-FB)
seting setting
switching
Stop OR P 00000 pulse 0 0 to 4095
position
setting
OR FC 0005.0 Hz 5.0 Hz 0 to 400 F-z I
Direction OR TURN FWD FWD FWD/REV
setting
Completion OR L 00005 pulse 5 0 to 10000
rangesetting
Completion ORTW 0.00 s 0 0 to 9.99
delay time,
setting
NOTE I : Keep debug mode " OFF ", this is factory use only.
12-13
l (Function mode 1) (Function mode 2) I
D Function Function Initializationdisplay lnitialzation Setting, change Settingcontentssequenct No. n contentsNo name contents
34 F-41 Position PO EGRP FB FB FB/REF Effectivewithoptionboard
Electronicl setting (J-FB)
gear switching
setting Numerator PO EGR-N 00001 1 [ to 9999
ofratio
Denominator PO EGR-D 00001 1 1 to 9999
Feed for- PO FFWG 000.00 0 0 to 655.35
ward gain
Position PO G 000.50 rad/s 0.5 0 to 100
loop gain crd/s
35 F-42 Torque TRQ LIMIT REM REM REM/OPI/OP2 REM: Each operator
Torque limit PO: Option I
limit setting P02: Option 2
setting switching
(Note I) Plus torque TRQ FWD 150% 150% 20 to 150%
linut
Minus TRQ REV 150% 150% 20 to 150% Regenerative mode
torque limit
36 F-43 PID target PID IN-SEL IN IN IN/OUT
PlDcontol value input
setting I method
switching
selection
PLD target PID LVL 000.00% 0% 0 to 200%
valuesettmg
Pgamnsetting PlD P 1.0 L,0 0.1 to 5.0
gainsetting PID I 01.0 1 1.0 0 to 15.0
Ogamsetting PID D 000.0 000.0 0 to 100
Selection PID MODS MDO MDO MD to 4
37 F-46 Transmission COM BAU 00600 bps 600 300/600/1200/ Effective with option board
Communi-, speed 2400/4800/9600/ (J-CM)
cation selection 19200
protocol Station COM NUMBER 01 1 1 to 32
setting number
selection
Transferbit COM LENGTH 8 8 8/7
length
selection
Parity COM PAR-SELl ON ON ON/OFF
ON/OFF
selection
Panty COM PAR-SEL2 EVN EVN EVN/ODD
even/odd
selection
Stop bit COM STOPBIT 2 2 2/1
length
selection
NOTE 1: Smaller levels of torque limit and overload restriction are given top priority and valid for any control
method.
12-14
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12-15
D (Function mode 1) (Function mode 2)
D Function Function Initialization display [ntialization Setting,change Setting contents
No. name contents contents
38 F-47 Main body OP-ERRI STP STP STP/RUN Effective with option board
Option I operation
PCB error selection for
setting option PCB
error I
Main body OP-ERR2 STP STP STP/RUN
operation
selection for
option PCB
error 2
39 F-48 Setting for RELAY RYA RUN RUN | CST/PAT Effective with option board
Selection RYA ANY/RUN {J-RY)
ofrelay terminal OTQ/NOR
output Setting for RELAY RYB CST CST - CST. Amval signal
RYB (constant speed)
terminal PAT Arrival signal
Setting for RELAY RYC OTQ OTQ (set frequency or more)
RYC ANY: Arrival signal
terminal (set frequency only)
RUN Running signal
OTQ: Over torque signal at
SLV, SLV2/Overload
signal at V/F control
NOR: No output
12.4 Protection function display list when the remote operator is used
There are protection functions for overcurrent, overvoltage, and undervoltage provided to
protect the inverter. When one of the functions is performed, the output is cut off, and the
motor is put into the free run state, and the status is kept until the inverter is forced to reset.
Remote operatori DOP)
Name Digital operator display copy unit(DRW)display
ERR] ****
Constant speed OC.Dive
protection Deceleration E 0 OC Decel
Acceleration IOC.Accel
-Overload D 5 Over L
Braking resistor E i BRD
overloadE06 O.R
Overvoltage E B 2 Over.
protection E071 ______________
EEPROM error E OB EEPROM
Undervoitage E D91 Under.v
protect ionE0- UneV
CT error E IQ1 CT
CPU error E /l CPU
External trip E I21 EXTERNAL
USP error E /31 USP
Ground fault
protection [E 9 19 GNDFIt
Other displays
Remote opentor(DOP)
Name Digital operator display copy unit(DRW)display
I IERRI ****
Input overvoltage; E /5 O0v.SRC F
Instantaneous I
power failure i r"E 16 1Inst.P-F
Option connec- Option I NGOPI
ton error Option 2 E lB NO 0P2
Option PCB Option I E / 1 opt
error
(NOTE 2) Option 2 0 OP2
Phase failure I NOTE 1) E 2 PH.FailProtection errorLP.Fi
Constant speed E 3 /i PDrive
Power module I Deceleration E 321 PM.Dee
protection Acceleration
ceeato 5 331 PM.Accel
Stop E 39 PE
"de'rvoltage UvWAIT
For error contents, see page 8-I.
Display Cause Description
Communication error This is displayed when an error occurs between the inverter and remote operator.
'1. Protocol error When the STOP key or another key is pressed, the onginal display appears.R-ERROR COMM<*> 2. Time-out error When the original display does not appear, turn the power off and then on once
again. Check whether any connectors are loose.
R [one ofthe displays on the left occurs when the copy unit is used to read or copy,
R-ERROR INV.RUN During inverter running take the corresponding countermeasure.
- NV. RUN: Stop the running.
R-ERROR INV.TRIP Under inverter inp [NV. TRIP: Press the STOP key to release the trip.
- INV TYPE: The inverter type of the copy source is different from that ofthe
R-ERROR INV TYPE Inverter type mismatch copy destination. Use the same type of inverter to read or copy.
The fourth switch of the DIP switch on the back of the remote operator is ON.
R-ERROR RD LOCK Inverter read lock When reading data, turn the switch OFF.
RESTART * * * .* s Instantaneous power This indicates that the instantaneous power failure restart function is being performed.
failure restart function in RESTART: 0 start is in execution.
ADJUST ***.*s operation ADJUST Frequency matching is in execution.
The supply voltage is lowered to the undervoltage level. When this display
Uv WAIT Undervoltage appears, turn the power on once again.
POWER OFF Power OFF The undervoltage after the power is turned off is displayed.
Tuning OK Autotunin function end This is displayed aftler the autotuning measurement is finished.
inauu - Tuning OK: The measurement terminates normally
Tuning NO display - Tuning NO: The measurement fails.
NOTE 1: Power OFF during motor deceleration may cause an input phase failure error.
NOTE 2: When the J-FB is installed, an error is display for each factor as shown below.
Digital operator DOP, DRW
display
Encoder line break:
Overspeed:
Positioning error:
Thermistor line break:
Motor overheat:
Malfunction or abnormality on built-in CPU of the option:
12-16
E GS
E 6E651
E 651
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12.5 Warning Error List
The following warning errors are displayed on the warning monitor in the monitor mode.
Check the set value. When an attempt is made to set a value larger than the set range, the set
value may be rewritten as shown below.
Warning error display Forced rewriting Description Alarm ecod
Fmax > Fet Fmax Fe ch
2 Fb > Emax Fb F max
3 Fs > Fmax Fs F Emax
4 Fm > Fmax Fm a Fmax
5 Flw > Fmax Flw a Fmax
6 Fup > Fmax Fup F Emax
7 Fes > Fmax Fes - Fmax
8 Fee > Fmax Fee Fmax
9 Fs > Fup Fs - Fup
[0 Fm > Fup Fm . Fup
II Fmin > Fup Fmin e Fup
12 Flw > Fs Fiw . Fs
13 Flw > Fm Flw a Fm
14 Fmin > Fs Fmin . Fs
15 Fmin > Fm Fmin a Fm
16 Emin > Fj Fmin a Fj
17 Fmin > Flw Fmin . Flw
18 Fp > Es Fp Fs
19 Fp > Fj Fp Fj
> Fm Ep
Fch: Frequency for maximum
frequency switching
(120,400)
Fmax: Maximum frequency
Fmin: Start frequency
Fb: Base frequency
Fs: Set frequency
Fm: Multistage speed setting
frequency
Flw: Lower limiter frequency
Fup: Upper limiter frequency
Fp: Jump frequency
Fes: External set analog start
frequency
Fee: External set analog end
frequency
Fj: Jogging frequency
OFF
I
12-17
20 Fp
- Ii
i 8
d0 Fm I
12.6 Dimensions
Remote operator, copy unit
Dimensional drawing (Unit. mm)
Remote operator (DOP-OA)
!4-
Mounting perforation diagram
Copy unit DRW-OA)
27
12
& a
* T
2-Md
Mounting perforation diagram
High performance 1300 ct
2l remote operator (HOP-Ol)
Copy anit (HRW-OJ) A d
C 0 00
-M.depth 5 (bacci
13'7
Mounting perforation diagram
For extension
between remote
operator (HOP),
copy unit (HRWl
and 1300
IC- I
Q
Cable between remote
operator (DOP) copy
unit (DRW) and 1300
ICA-1J
ICA-3J
1C0-3
NOTE 1: The cables for the VWS3A and VWA series are different in cable shape from those
for the J300. The cables for the J300 are the same as those for the J100. To change
only cables, various cables are in stock.
12-18
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ble
12.7 Copy Unit Function
Operation example (Procedure to transfer the data of inverter A to B,C, and D inverters)
Se- Operation Key Operation result
gquence
Set data is read out from the
1 inverter A (It is stored into the
memory. "veer Copy on
Turn off the power supply to
inverter A and remove the cable.
Connect the cable to inverter B and
'turn on the power.
4 1 Copy data stored in the copy unit is Data copy
iwntten to inverter B. -1 Cut off the power supply to inverter - - j5 1 Inverter B inverter C Inverter D
B. (* I ) Cony
Perform the above processes from 3 _
6 'to 5 sequentially for inverters C and
D. That is, the same process as at
for inverter B.
Operation example (Process to change and transfer to inverters B, C and D)
Connect the cable and press I Data change
the remdte key. -rm j
Change the data of the inverter 7 [n7erter
with copy unit. Copy umt Invere
A
Read out the data from READ
nverter A (It is stored into the
to 6 memory area of the copy unit).
The following procedures are the
same those of the operation 1, Inrtopy uni
12-19
12.8 Data to be copied by the copy unit
Precautions for copying
The copy units, DRW and HRW cannot copy some of parameters. For the details, see Appendix 7.
Do not carry out data copy and transfer between different version (ex. J300-E 1-4300-E4). Since
settable range is different, data may not be transfered correctly or an error may be occurred.
12-20
( 13. SERVICE
When inquiring about inverter trouble, please be ready to inform the distributor where you purchased
your unit or the nearest service station the following.
(1) Type
(2) Purchased date
(3) Production No. (MFG. No.)
(4) Malfunction symptoms
If the contents are unclear due to an old nameplate, give only the clear items. To reduce the nonoperation time, it is recommended to stock a spare inverter.
Warranty
The warranty period under normal installation and handling conditions shall be one
(1) year after the date of delivery. The warranty shall cover the repair of only the
inverter to be delivered.
1. Service in the following cases, even within the warranty period, shall be charged to the purchaser.
(a) Malfunction or damage caused by misoperation or remodelling or improper repair
(b) Malfunction or damage caused by a drop after purchase and transportation
(c) Malfunction or damage caused by fire, earthquake, flood, thunderbolt, or other
natural calamities, pollution or abnormal voltage.
2, When service is required for the product at your worksite, all expenses associated with field repair
shall be charged to the purchaser.
3. Always keep it handy. Please do not loose it. We are sorry but this manual cannot re-issued.
13-1
Appendix 1 Manual for New Functions
1. Autotuning
[Outline of the function]
This is a function for automatically setting the motor circuit constant necessary for the sensorless
vector.
When the autotuning function is performed by a motor which is designed according to JIS C
4210 and then the sensorless vector is controlled, even a motor (Hitachi general purpose motor)
whose constant is unknown at an output frequency of I Hz can generate a torque of 150%.
An Hitachi general purpose motor is given a constant which is a default value. Therefore, in
every case, the characteristics will be obtained without trouble. When the characteristics cannot
be obtained, measure the motor circuit constant by the autotuning function.
Autotuning starting method
Connect the motor.
Turn the autotuning mode
ON. (Note)
Turn the Run command ON.
I_ AC excitation (The motor does not rotate.)(2) DC excitation (The motor does not rotate.)
(3) The motor is accelerated up to 80% of the
base frequency and then decelerated and
stopped. (The motor rotates.)
(4) The motor is accelerated up to 40% of the base
frequency and then decelerated and stopped.
(The motor rotates.)
(4-1) Measurement (acceleration/deceleration)
time t
t< 50 seconds --- a = 40
502 t < 100 seconds --- a = 20
100 2 t < 300 seconds --- a = 10
After the measurement ends, the motor is stopped.
Select the control method. Select the motor data.
Standby state
(1) Before executing the autotuning function,
make sure the following set values.
1) a) Base frequency
b) Motor capacity
c) No. of motor poles
Set the values according to a motor
which uses a, b, and c.
2) Make sure that 0 Hz is not set. (When 0
Hz is set, the autotuning function will
not be performed.)
3) Cancel all the DC braking settings. (DC
braking is not set by initialization.)
4) Make an motor input voltage setting
(F-03 AVR AC =) according to the
motor rating.
(2) Drive the motor for about 60 to 120 seconds. (During autotuning, the motor automatically runs in the order of (1) to (4) given
on the left and the motor constant is measured. Therefore, make sure before starting
operation that no problems are caused to the
load to be connected during the automatic
running from (1) to (4).)
Example:
When the base frequency is 120 Hz, the
motor runs up to 80% of the base frequency
in (3), that is, 96 Hz and then decelerates
and stops.
The status for using the autotuning data is
set.
Running under sensorless vector control is
available.
A-1
Autotuning start
[Setting methodj
(1) Digitaloperator
FUNC
FA 97UN
FUNC Y
A 97 *1
(2) Remote operator
F-05 AUX
FLNC
Initial dispiay y
AUX AUTO NOR
51x 2
AUX AUTO AUT
STR
MON
FS0050.0 0.0Hz
When the autotuning operation terminates,
Display the|A 97| software switch and set it to
the data (0 1) for starting autotuning setting.
When the equipment starts running after the data
is set, the autotuning measurement is executed.
F-05 motor constant setting is displayed.
Display the AUX AUTO screen and select AUT
or NRT.
Autotuning
NOR: Setting OFF and autotuning end
AUT: Autotuning measurement start (Motor
rotates)
NRT: Autotuning measurement start (Motor
does not rotates)
When the equipment starts running after the data
is set, the autotuning measurement is executed.
"Display at end" indicated on A-4 page is displayed.
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When the autotuning operation temiantes normally, see the "running method by autotuning data"
indicated on A-5 page.
When the autotuning fails, set "measurement start" once again and perform rerunning.
When A 9 7 is set to | Q12| on the digital operator or NRT is selected on the remote operator, auto tuning is performed in a mode in which the motor does not run (only AC excitation
and DC excitation are possible). Then, the value of motor constants RI, R2, and L are measured.
Precautions
I. When the autotuning function is executed in the state that the DC braking is set, the accurate motor constant will not be set. Cancel the DC braking the then start measurement.
2. By the autotuning function, a capacity between the applicable motor capacity and motor
capacity under one frame can be set.
3. When acceleration or speeding up is not to be performed in the operation for accelerating
up to 80% of the base frequency, lower the set value of manual torque boost.
4. The autotuning measurement time is about 2 minutes or so. However, the measurement
time may be increased depending on the load inertia. When the measurement time exceeds
5 minutes, press the STOP key so as to decrease the set value of manual torque boost and
enter the run command once again.
5. Be sure if motor is in standstill before you carry out an autotuning. Autotuning data carried out when motor is still running may be not correct.
6. Do not interrupt an autotuning with power off or any stop command except emergency
case. It may case data lose.
In it is occurred, make an initialization and reprogram what you need, and carryout
autotuning again. A-2
(3) New remote operator
First hierarchy
1 Command
2 Initial
3 Function
4 Option
Second hierarchy V
y 1 Control
2 Acc/Dec
3 Run
4 Braking
Third hierarchy y
1 V/f
2 Motor
3 Carrier
Fourth hierarchy y
1 AUTO 0:NOR
(0-2)
2 DATA 0:NOR
(0-2)
Y
1 AUTO :AUT
(0-2)
2 DATA 0:NOR
(0-2)
Monitor display y
FS 50.00Hz
0.00Hz
AC1 10.00s
DC1 10.00s
Select "3 Function" in the first hierarchy.
x 2
SEL
Select "I Control" in the second hierarchy.
SEL
SEL
STOR
MON
Select "2 Motor" in the third hierarchy.
Change the content of "I Auto" from
0:NOR to 1:AUT in the fourth hierarchy.
When the data is changed, press the STOR
key.
When the MON' key is pressed to select
the monitor mode and the equipment starts
running, the autotuning is executed.
A-3
Display when the autotuning terminates
[Display in the normal statej
When the autotuning terminates normally, the following is displayed. When one of the keys is
pressed, the original screen is displayed.
Digital operator
- -: Normal termination display
eRemote operator
Tuning END
-New remote operator
OK Function 3 OR FR .
Normal termination display
[Display in the failure state]
- If the autotuning is executed when the motor is not connected to the inverter, the following is displayed and the measurement is stopped. As a motor constant when the measurement fails, the last
value is set. When one of the keys is pressed, the original screen is displayed. When executing the
measurement once again, change the autotuning measurement setting to "Start" and enter the run
command in the same way.
-Digital operator
-R t oAbnormal termination display
-Remote operator
Tuning NGI
'New remote operatorU
NG Function 3 OR FR
Abnormal termination display
When running the inverter using the autotuning data after the autotuning measurement terminates,
make settings by the method indicated on the next page.
A-4
Running method by autotuning data
When running the inverter using the autotuning data:
1. A-0 : The control method is set at SLV (sensorless vector control).
2. A-98 : The motor data is set on the autotuning side by the software switch.
Make the above two settings.
NOTE: When no torque is outputted during the sensorless vector run after the above settings are
made, make the following settings. Increase the set value of R1 of each remote operator
(motor constant) before starting running.
[Setting methodj
(1) Digital operator
FUNC
0 4
FUNC 4
_ _FUNC
FUNC 9x2A 98 Bil02
I. Select = (sensorless vector control) by
the 00|control niethod.
0: Constant torque characteristic
1: Reduced torque characteristic (1.5 power)
2: Reduced torque characteristic (1.7 power)
3: Reduced torque characteristic (2.0 power)
4: Sensorless vector control
2. Set the motor constant data to the data which is
A 9 8 measured by the autotuning function
using the software switch.
(Refer to the [A98] software switch of the operation manual.)
(When executing the second setting, change the
switch.)
By the above two settings, running by the autotuning
(2) Remote operator data is available.
F-04 CONTROL
Initial display y
CONTROL VC
zx 4 y
CONTROL SLV
Initial display y
AUX DATA NOR
I. Select [SLV] (sensorless vector control) by the
F-04 control method.
VC: Constant torque characteristic
VPI: Reduced torque characteristic (1.5 power)
VP2: Reduced torque characteristic (1.7 power)
VP3: Reduced torque characteristic (2.0 power)
SLV: Sensorless vector control
2. Set the [AUT] autotuning data by motor data
selection of the F-05 motor constant.
By the above two settings, running by the autotuning
data is available.
V
AUX DATA AUT
FS050.00 000.00Hz
FUNC
STR
x X
Tx 2
2
STR7
MON
A-5
(3) New remote operator
First hierarchy
1 Command
2 Initial
3 Function
4 Option
Second hierarchy y
1 Control
2 Acc/Dec
3 Run
4 Braking
Third hierarchy y
1 V/f
2 Motor
3 Carrier
Fourth hierarchy y
5 A-Dec 1:ON
(0-1)
6 MODE 0:VC
(0-5)
Third hierarchy y
1 V/f
2 Motor
3 Carrier
Fourth hierarchy y
1 AUTO O:NOR
(0-2)
y 2 DATA 2:AUT
(0-2)
Select "3 Function" in the first hierarchy.
I x 2
SEL
Select "1 Control" in the second hierarchy.
SEL
Select "1 V/f' in the third hierarchy.
SEL
Zx 5
STOR
RETN
SEL
STOR
Change the content of "6 Mode" from
O:VC to 4:SLV in the fourth hierarchy.
When the data is changed, press the STOR
key.
RETPress the TN key to return to the third
hierarchy and select "2 Motor".
Change the content of "O NOR" from O:NOR
to 2:AUT in the fourth hierarchy.
When the data is changed, press the STOR
key.
When the monitor mode is selected, running by the autotuning data starts.
A-6
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[NOTESI
* I: If the desired characteristic cannot be obtained in a sensorless vector control operation with auto
tuning measured data, adjust the motor constant according to the detected symptom shown
below.
(DOP, DRW, HOP, and HRW functions of the remote operator are needed for this adjustment.)
Operation Symptom Adjustment Adjusting item
Status (DOP/DRW Function No.)
Power running When low frequency Increase the motor constant R I in relation to [F-05 AUX RI]
(status with an (a few Hz) torque is auto tuning data step by step within 1.2 times.
accelerating insufficient
torque)
When the speed
fluctuation coeffi- Increase the motor constant R2 in relation to, [F-05 AUX R2]
cient becomes auto tuning data step by step within 1.2 times.
minus
When the speed
fluctuation coeffi- Decrease the motor constant R2 in relation to [F-05 AUX R2]
cient becomes plus auto tuning data step by step within 0.8 times.
Regeneration When low frequency I) Increase the motor constant RI in relation [F-05 AUX RI]
(status with a (a few Hz) torque is to auto tuning data step by step within 1.2
decelerating insufficient times.
torque) 2) Decrease the motor constant M in relation [F-05 AUX MI
to auto tuning data step by step within 0.8
times.
3) Decrease the carrier frequency set value. [F-36CARRIER]
(IA 10| for digital
operator
Combine the methods 1) to 3) above to adjust
the motor constant.
A-7
2. Energy conservation running
[Outline of the functionj
This is a function for automatically setting the output voltage corresponding to the load during
the V/F control running and suppressing useless power.
The function is effective for a load of reduced torque characteristics such as a fan and pump.
I
When the load of an induction
motor is constant as shown in the
drawing on the right, there is a
voltage at which the current is
minimized. When the current is
minimized, the power is also
minimized. The function automatically searches this voltage.
0
Large load
VI V2 V
1. The output voltage is decreased so as to minimize the current. The search limits are the
voltage of torque constant characteristic +50%.
2. The function is performed
under comparatively slow
control. Therefore, when a
sudden load change (such as
an impact load) occurs, the
motor may stall.
V
0
Range where the energy
conservation is effective
A-8
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[Precautions]
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[Setting method]
(1) Digital operator
FUNC
A 5930
FUNC
59 1
(2) Remote operator
F-10 RUN
FUNC
Initial display y
RUN MODE - NOR
5, _CEN
RUN MODE OEN
STR
MON
FS000.00 000.00Hz
Select r by A 5 9 running mode selection.
Running mode selection
0: Normal running
1: Energy conservation running
2: Fuzzy most suitable acceleration and
deceleration running
When the running starts after the data is set, the
energy conservation-running is performed.
F- 10 running mode selection is displayed. Display the RUN MODE screen and select "OEN".
Running mode selection
NOR: Normal running
OEN: Energy conservation running
GOD: Fuzzy most suitable acceleration and
deceleration running
When the running starts after the data is set, the
energy conservation running is performed.
A-9
(3) New remote operator
First hierarchy
1 Command
2 Initial
3 Function
4 Option
Second hierarchy V
y 1 Control
2 Acc/Dec
3 Run
4 Braking
Third hierarchy y
1 Freg.
2 Pattern
3 SPD
Fourth hierarchy y
I MODE 0:NOR
(0-2)
1 MODE 2:OEN
(0-2)
Monitor display y
FS 50.00Hz
0.00Hz
AC1 10.00s
DC1 10.00s
x 2
SEL
x 2
SEL
SEL
STR
Select "3 Function" in the first hierarchy.
Select "3 Run" in the second hierarchy.
Select "2 Pattern" in the third hierarchy.
Change the content of "2 MODE" from
O:NOR to 2:OEN in the fourth hierarchy.
When the data is changed, press the S
key. STR
When the MON key is pressed to select
the monitor mode and the equipment starts
running, the fuzzy most suitable acceleration
and deceleration running is executed.
A-10
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3. Fuzzy most suitable acceleration and deceleration
[Outline of the function]
The fuzzy most suitable acceleration and deceleration function realizes acceleration and deceleration characteristics using the inverter capability at its maximum under fuzzy control to eliminate
troublesome setting of the acceleration and deceleration time.
The acceleration time is a time for acceleration at the current specified by the overload restriction
constant.
The deceleration time is a time for decelerating so that the current does not exceed 150% of the
specified one or the DC voltage in the inverter circuit does not exceed 385V. (770 V for the
400V class.)
The function sets the acceleration and deceleration time automatically in response to a change in
the load or inertia in real time.
[Precautionsj
1. This function is not suitable for a machine which requires a constant acceleration and deceleration time. The acceleration and deceleration time varies with the magnitude of the load or
inertia.
2. When the inertia of the machine is more than about 20 times of that of the motor shaft, a trip
may occur.
3. The acceleration and deceleration time of the same motor always varies with a change of the
current.
4. The fuzzy most suitable acceleration and deceleration setting function is valid only under the
V/F control. In the high start torque running mode (under the sensorless vector control), the
normal running is performed.
5. If the jogging running is executed when the fuzzy most suitable acceleration and deceleration setting function is selected, the jogging operation cannot be performed due to the fuzzy
control.
6. When the load is more than the rated one, the deceleration time may be increased.
7. When acceleration and deceleration (the cycle is 2 [s] or less) are repeated frequently, a trip
may occur.
8. If an external braking unit is used, the motor cannot stop within the deceleration time set
with a braking resistor. In such a case, do not use the fuzzy acceleration/deceleration function.
A-11
[Principle]
The acceleration and deceleration ratio or acceleration and deceleration are set in accordance
with the fuzzy rule from the distance to the overload restriction level and the start slopes of
current and voltage.
Overload restriction level Restriction angle
Setting process
Th un rows.. Fuzzy control
Time
Slope
Distance
Membership function
>
Acceleration ratio, acceleration
determination,deceleration ratio,I
deceleration determination
A-12
[Setting methodj
(1) Digital operator
FUNC
A 59 o
FUNG Y
[A 59 2
(2) Remote operator
F-10 RUN
FUNC:
Initial display y
RUN MODE NOR
- 5
OEN
GOD
RUN MODE GOD
STR
MON7
FS0000.00 0.0Hz]
Select 2 by A 5 9 running mode selection.
Running mode selection
0: Normal running
1: Energy conservation running
2: Fuzzy most suitable acceleration and
deceleration running
When the running stprts after the data is set, the
most suitable acceleration and deceleration
running is performed.
F-10 running mode selection is displayed. Dis'
play the RUN MODE screen and select "GOD".
Running mode selection
NOR: Normal running
OEN: Energy conservation running
GOD: Fuzzy most suitable acceleration and
deceleration running
When the running starts after the data is set, the
most suitable acceleration and deceleration
running is performed.
* When the running starts after the data is set,
the acceleration and deceleration time display
is as shown below. During the fuzzy most
suitable acceleration and deceleration running,
the acceleration and deceleration time display
in the monitor mode is invalid. (The time can
be set but the display is invalid. It becomes
valid once again during the normal running.)
A-13
(3) New remote operator
First hierarchy
1 Command
2 Initial
3 Function
4 Option
Second hierarchy V
y 1 Control
2 Acc/Dec
3 Run
4 Braking
Third hierarchy y
1 Freq.
2 Pattern
3 SPD
Fourth hierarchy y
y 1 MODE O:NOR
(0-2)
1 MODE 2:GOD
(0-2)
Monitor display y
FS 0.00Hz
0.00Hz
ACI 10.00s
DC1 10.00s
x 2
SEL
x2 SEL
SEL
STR
Select "3 Function" in the first hierarchy.
Select "3 Run" in the second hierarchy.
Select "2 Pattern" in the third hierarchy.
Change the content of "2 MODE" from
0:NOR to 2:GOD in the fourth hierarchy.
When the data is changed, press the STR
key.
When the MON key is pressed to select
the monitor mode and the equipment starts
MON running, the fuzzy most suitable acceleration
MON and deceleration running is executed.
A-14
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Appendix 2 Instantaneous Power Failure Restart and Commercial Power Source Switching
L Instantaneous power failure restart
[Function Outlinel
This function allows an inverter operation to be selected according to the subject system as
follows when an instantaneous power failure occurs.
- Retry mode: When FTP/RST/ZST is set at IPS POWR
- Alarm mode: When ALM is set at IPS POWR
- fmatching: The rotation speed and the phase are detected while the motor is on a free
running to restart the operation accordingly.
WARNING
When the inverter stops due to a trip with retry mode selected, the motor restarts
suddenly. Stand clear of the machine. Otherwise, you may be injured. (Design the
machine in such a way that persons are protected against a restart of the machine.)
[Setting Method]
Aovercuernt/
Remote operator [F-22] Digital operatori At instantaneous power failure At low voltage overvoltage/ At other
powem ebnor error
IPS TIME 0.3 to 25.0 - Set an allowable instantaneous - - power failure time.
IPS WAIT 0.3 to 100.0 Set a waittime after an instantaneous power failure/powerrestoration in the retry mode or after an error.
Tripping with an instantaneous
power failure within the IPS
TIME. If an operation command
is issued for an instantaneous
power failure detected out of the
IPS TIME, restart the operation (0
Hz start).
The f matching stops with an The f matching stops The f
instantaneous power failure if power is restored matching is
detected within the IPS TIME. within 40s. retried.
The inverter trips with an The inverter trips
instantaneous power failure unless power is
detected out of the PIS TIME. restored within 40s.
The f matching is restarted if the The f matching is
instantaneous power failure is restarted if power is
within the IPS TIME. The restored within 40s.
inverter trips if the instantaneous The inverter nips
power failure is not within the unless power is not
IPS TIME. restored within 40s.
The inverter is restarted at 0 Hz if The inverter is started
the instantaneous power failure is at 0 Hz if power is
within the PIS TIME. The restored within 40s.
inverter trips if the instantaneous The inverter trips
power failure is not within the unless power is
IPS TIME. restored within 40s.
No retry at an instantaneous power failure and no trip - at low voltage during the inverter stop.
Retry or under voltage trip is performed during the inverter stop or running.
A-15
Tripping Tripping Tripping[PS POwR !ALM I
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NOTE: Since the retry mode is selected, the equipment restarts for trips of overcurrent,
overvoltage, or undervoltage. For undervoltage, 16 retries (17th trip) are
executed. For overcurrent or overvoltage, 3 retries (fourth trip) are executed.
Do not use this function for a case that a fallen substance should be held by the
machine brake when the motor is in the free-run mode.
In the following cases, the equipment may start at the lowest frequency (called 0 start).
1) When the reclosing standby time (function mode F-22, IPS WAIT) after the
instantaneous power failure is recovered is set to 3 seconds or more
2) When the output frequency is more than 60 Hz
3) When the base frequency is 60 Hz: Driven at 30 Hz or less
When the base frequency is 50 Hz: Driven at 25 Hz or less
4) When the induced voltage of the motor attenuates earlier (for example, a pump or highspeed gear which causes the motor to decelerate for several seconds or less)
NOTE: The inverter control power holding time may be slightly different depending on
the inverter rating, the load status, remote operator (copy unit) connection status,
and input voltage.