Professional Documents
Culture Documents
Jaw Crusher
and
Reciprocating Plate Feeder
Codelco El Teniente, Chile
Pipa Norte
2-443-20351
P.O.4500297631
07/2003
This operating manual in all its parts is protected by copyright. All rights reserved including those of translation into
other languages. This manual as a whole or part of it is not allowed to be processed, reproduced or distributed in any
form, electronic systems included, without the written permission of ThyssenKrupp Frdertechnik.
2-443-20351
-1
File 1
Pipa Norte
Ind. 3
Ind. 4
Ind. 1
Ind. 4
Ind. 2
Ind. 6
Ind. 1
File 2
2. Medium Voltage Smart Starter
Medium voltage smart motor
controller Bulletin 1562 D
Construction diagram and technical data
SMC for crusher
Circuit diagram SMC for crusher
Medium voltage dialog plus TM motor
controller Bulletin 1562 D
Multifunctional motor management
Bulletin 825 smart motor
File 3
4. Video control jaw crusher inlet
Technical documents
Operating instructions camera
Operating instructions monitor
8. Data sheets
Limit switch bal valve oil tanks
Limit switch plate feeder
Speed control jaw crusher
2
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Check.
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30.07.02
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Ident no.:
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Manual bsico
Mdulo de control
EASY 412-DC-R...
EASY 412-AC-R...
Dieter Bauerfeind
Editor:
Cuidado!
Peligro. Alta tensin.
Antes de instalar:
Conecte los dispositivos con la
alimentacin elctrica desconectada.
Asegrese de que los dispositivos no
puedan conectarse de forma accidental.
Verifique el estado del aislamiento desde la
fuente de alimentacin.
Conecte la puesta a tierra y proteja la
instalacin contra cortacircuitos.
Cubra o proteja las dems unidades
activas.
Siga las instrucciones tcnicas (AWA) del
dispositivo.
Slo el personal tcnico cualificado est
autorizado a manipular los dispositivos/el
sistema.
Antes de instalar o tocar el dispositivo,
asegrese de estar libre de carga
electroesttica.
Los cables de conexin y de transmisin de
seales deben instalarse de modo que las
interferencias inductivas o capacitivas no
interfieran en las funciones automticas.
Instale los dispositivos automticos y los
correspondientes elementos operativos de
modo que se prevenga la puesta en marcha
involuntaria de los mismos.
Tome las medidas de seguridad
adecuadas, tanto en hardware como en
software, para el interface I/O, de modo que
una ruptura de lnea o cable en la fuente no
cause estados indefinidos en los
dispositivos conectados.
Aplique un aislamiento elctrico fiable a la
fuente de 24 V de baja tensin.
ndice
15
Manejo easy
15
16
Configurar hora
16
17
18
20
Rels de funcin
24
30
Circuitos principales
33
3 Interface easy
35
4 Caractersticas tcnicas
37
Caractersticas tcnicas
37
Gama easy
38
ndice alfabtico
39
Aplicacin universal
mbito domstico, sistemas de control de
iluminacin, marquesinas y persianas.
Extractores, puertas giratorias, invernaderos,
instalaciones de iluminacin exterior, accionamiento
de ventanas, iluminacin de escaparates.
alimentacin
entradas
DEL
ALT
Teclas de
funcin
Pantalla
ESC
OK
Interface para
la conexin de
la tarjeta de
memoria PC
salidas
.1
El mecanismo de muelle
permite que el easy
encaje automticamente.
.2
"1" 79 V
"0" 40 V
L
N
> 1A
e = 115/230 AC
50 / 60 Hz
(97...264 V AC)
e = 40 mA 115 V
20 mA 230 V
0.5 Nm
3.5 mm
L
1
Q1
l1
1
Q2
I2
I4
I3
2
Q3
I5
I6
I7
I8
Q4
10 000 000
0 V DC
N
24 V DC
115 V AC
230 V AC
8A
8A
8A
2A
2A
2A
8 A / B 16
L1, L2, L3 ( 115/230 AC )
+ 24 V DC
10 58 W
25 000
1000 W
Teclas de funcin
DEL: Eliminar del esquema de contactos
ALT: Funciones especiales en el
esquema de contactos
Teclas de cursor :
Mover cursor
Seleccionar opciones de men
Establecer nmeros, contactos y valores
OK: Seguir, guardar
ESC: Ir atrs, cancelar
Modificar valor
Cambiar posicin
Funciones de la tecla P:
entrada P1, entrada P2
entrada P3,
entrada P4
Salidas
On / Off
Da de la semana
Hora
Modo de funcionamiento
RUN/STOP
"""
!"!#
!"!#
Cursor /
Mover cursor con
o tambin con en el
esquema de contactos
Valor /
Cambiar posicin con
Cambiar valores con
En el manual, los valores
parpadeantes se representan en
color gris
10
$"%
!
$&
$"%
!
$
El cursor parpadea
alternativamente
Campo de bobina
Campos de
Vas de
corriente
Conexiones
Contacto: Tecla P
Contacto: Entrada
Contacto/bobina: Salida
Contacto/bobina: Marcador
Contacto/bobina: Temporizador
Contacto/bobina: Contador
'(')
'*+&&&&&
&&&&&&&&&
&&&&&&&&&
Va de corriente 1
Va de corriente 2
Va de corriente 3
...
Va de corriente 41
11
Men
Esquema de
contactos
RUN
STOP
Pantalla de
parmetros
Registro de
parmetros
Pantalla de
parmetros
Registro de
parmetros
Pantalla de
configuracin
del reloj
12
cuatro
entradas
errneas
Introducir
contrasea
entrar en el
easy
Contrasea
entrada
correcta
Visualizzazione
di stato
Men especial
Introducir
contrasea
Men
Establecer contrasea
Contrasea
impostazione
password
Cambiar
Contrasea
13
14
Manejo easy
15
GB Ingls
D
Alemn
Francs
Espaol
Italiano
-.""
!
Configurar hora
"""
!
!"!#
"""
!"!#
$"%
16
!"!#
Seleccionar el modo de
funcionamiento del easy
Configurar da de la semana y hora
!"!#
$"%
$"%
!
$
seleccionar posicin
modificar valor
Guardar configuracin
o
mantener valores anteriores
Indicacin: HOR.VERANO
establecido horario de invierno
Indicacin: HOR.INVIERNO
establecido horario de verano
cambiar configuracin
salir del men
Seleccionar el modo de
funcionamiento del
easy
"
17
Contactos de conmutacin
Contacto de conmutacin
...
Tecla de cursor
...
...
...
...
...
...
...
Tipo de rel
Smbolo rea
easy
Funcin Parmetro
de bobina
Rel de salida
...
...
18
Rel de funcin
Temporizador
...
Rel de funcin
Contador
...
...
...
X
04/98 AWB 2528-1316 E
Rels
on
on
Rels de impulso
on
on
,
Rels enclavados
19
Cableado easy
"""
!
!"!#
"
#"""
&
Introducir contacto I1
Pantalla del esquema de contactos
&
20
&
Ejemplo: Crear un
esquema de contactos
Introducir contacto I2
&
'&
'/
''''/
''''&
'''')
'''')
''''')
&
21
"
"""
""
!"!#
!"!#
"""
"""
!"!#
!"!#
22
''''')
Ejemplo: Crear un
esquema de contactos
Conectar los conmutadores S1 y S2
S1 on
'''')
)
S2 on
)
)
!
""
!"!#
23
Representacin en el
esquema de contactos
Rels de funcin
Rels de temporizacin
on
TRG
on
on
24
RES
Rels de funcin
on
TRG
on
RES
on
on
TRG
on
RES
on
25
Frecuencia
1
di inter=
2 veces tiempo nominal
mitencia
on
TRG
on
RES
on
Margen de tiempo
Bobina de activacin
N.
26
Tempo
nominal
Pantalla de
parmetros
Bobina de
reinicializacin
Tiempo real
Rels de funcin
Rel contador
on
CNT
on
DIR
on
RES
8
6
4
2
0
7
5
3
1
on
Bobina de
reinicializacin
N.
Pantalla de
parmetros
27
0!'%1
23*
23*
42
42-
..5867
..567
LU
MA
MI
JU
VI
DO
A on
B on
on
28
!"
Hora
#
N.
Hora de conexin
$ #%
Canal
Hora de
desconexin
$&&#
Pantalla de
parmetros
Da(s) de la
semana de ... a
Rels de funcin
Comparador de valores analgicos
Opciones de comparacin
I7 I8, I7 I8
I7 valor nominal, I7 valor nominal
I8 valor nominal, I8 valor nominal
% %!$
Entrada I7
'()
Valores
reales
Comparacin
*%
N.
Entrada I8
(+)
Pantalla de
parmetros
% %!$
04/98 AWB 2528-1316 E
Entrada I7
'()
Valor real
Comparacin
,% N.
Valor nominal
Pantalla de
parmetros
29
Cableado fijo
Cableado easy
easy conecta H1
con un retardo de 10
segundos
Esquema de
contactos easy
''''')
'''''''
''''''')
2x
''''')
&
''''')
''''')
&
''''')
2x
30
2x
3x
'''''')
''''')
'''''')
'''''''
2x
''''')
'''''''
&
''''')
'''''''
'''''''
&
2x
''''')
'''''''
2x
9:1
'''''''
2"2
)4 3
567
31
9:1
2"2
2"2
)4 3
)4 3
567
567
2x
9:1
2"2
)4 3
567
2x
volver al esquema de
contactos
Cableado de la salida
''''')
''''')
'''''''
'''''''
&
/
3x
3x
''''')
'''''''
''''''')
&
32
Circuitos principales
Circuitos principales
Q1
1
0
0
1
;''''''')
Contacto permanente
---
Q1
''''''''')
Conmutador de impulso
I1
Estado Q1
Q1
0
1
0
1
0
0
1
1
0
1
1
0
'''''''<
Conexin serie
I1
I2
I3
Q1
Q2
0
1
0
1
0
0
1
1
0
0
0
0
0
0
0
0
1
0
0
0
0
1
0
1
0
0
1
1
1
1
1
1
0
0
0
1
0
0
0
0
''')
;';';')
33
('''''')
I1
I2
I3
Q1
Q2
0
1
0
1
0
0
1
1
0
0
0
0
0
1
1
1
1
1
1
1
+
0
1
0
1
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
0
;4
4
;('''''')
;+
I2
Q1
0
1
0
1
0
0
1
1
0
1
1
0
';(''')
;'+
Autoenclavamiento
I2
Contatto Bobina
Q1
Q1
0
1
0
1
0
0
1
1
0
0
0
0
0
0
0
1
1
0
1
0
1
1
1
1
1
0
1
1
('''')
+
alternativ
'''''''
;'''''''
34
I1
Interface easy
el esquema de contactos
todos los registros de
parmetros del esquema
de contactos
las configuraciones del
sistema
Interface easy
EASY-SOFT
EASY-SOFT es un programa de PC que le permite
crear, comprobar y gestionar esquemas de
contactos easy. Los esquemas de contactos
pueden transferirse directamente desde el PC al
easy y viceversa.
Para la transferencia de datos entre el PC y el easy
debe utilizarse exclusivamente el cable de PC
easy, el cual puede adquirirse como accesorio
easy-PC-CAB.
Para comprobar un esquema de contactos creado
en el PC con cableado real, el esquema debe
transferirse al easy y seleccionar el modo de
funcionamiento RUN del easy.
EASY-SOFT le ofrece una
completa ayuda para aprender a
trabajar con el programa.
36
Caractersticas
tcnicas
50
10.75
Caractersticas tcnicas
Peso
200 g
Temperatura ambiente
de 0 a 55 C
Grado de proteccin
IP20
Inmunidad a
interferencias
Normas
Aprobaciones
EN50178
UL, CSA
56.5
47.5
10.75
45
58
M4
35.75
04/98 AWB 2528-1316 E
90
100
110
4.5
71.5
37
Caractersticas tcnicas
Gama easy
EASY 412-DC-R
24 V DC
8 entradas digitales (2 de ellas pueden funcionar
como analgicas tambin)
4 salidas de rel
Pantalla LCD
Teclas de funcin
EASY 412-DC-RC
igual que EASY 412-DC-R, con reloj programable
EASY 412-AC-R
115/230 V AC
8 entradas digitales
4 salidas de rel
Pantalla LCD
Teclas de funcin
EASY 412-AC-RC
igual que EASY 412-AC-R, con reloj programable
Equipamiento adicional
Software EASY-SOFT
Tarjeta de memoria EASY-M-8K
Cable de conexin EASY-PC-CAB
Clips de fijacin ZB4-101-GF1
Documentacin
Manual bsico AWB 2528-1316 E
38
ndice alfabtico
B
Bobina, funcionnes de 19
C
Cable de transmisin 35
Circuito AND 33
Circuito NOT 33
Circuito OR 34
Circuito principal
autoenclavamiento 34
conexin de tres vas
(XOR) 34
conexin en paralelo 34
conexin serie 33
conmutador de
impulsin 33
contacto permanente 33
negacin 33
Circuito XOR 34
Comparador de valores
analgicos 29
Conectar el easy AC 7, 8
Conectar entradas 7, 8
Conectar salidas 7, 8
Configurar 19
Configurar da de la
semana 17
Contactor, funciones de 19
Contactos de
conmutacin, tipos 18
D
Dimensiones easy 37
E
easy vista general 5
Ejemplo de
circuitos principales 33
contactos y rels 20
rel de funcin 30
Encajar 19
Esquema de contactos
cargar 36
comprobar 22
contacto, introducir 20
ejemplos 20, 30, 33
elementos 11
funciones de las
teclas 15
guardar 35, 36
llamar pantalla 20
llamar pantalla de
parmetros 31
seleccionar bobina de
rel 21
seleccionar marcador 30
utilizar rels de
funcin 31
Estructura del men 12
G
Gestin de mens 9
H
Hora, configurar 17
Horario de invierno 17
Horario de verano 17
I
Idioma del men 16
39
ndice alfabtico
P
Pantalla de estado 10
Pantalla de parmetros
comparador de valores
analgicos 29
rel contador 27
rel de temporizacin 26
reloj programable 27
Pantalla del cursor 10
Potencial, diferencia 29
R
Reiniciar 19
Rel contador 27
Rel de impulsin 19
40
Rel de
temporizacin 2426
Rels de funcin
comparador de valores
analgicos 29
rel de temporizacin 24
reloj programable 28
tipos de rels 24
Rels, tipos de rels 18
Reloj programable 28
S
Seleccionar modo de
funcionamiento 17
T
Tablas lgicas 3334
Tarjeta de memoria 35
Teclas de funcin 9
M
Men especial 13
Montaje 6
Page 1
Qty.:
Type:
Voltage:
Power:
Load profile:
Cooling method:
Ambient temp.:
Enclosure:
Rel. humidity:
Dimensions:
Weight:
1
1562D-TJEY
4160V, 50/60Hz
500HP
Variable torque
Air
0-40C
NEMA Type 12
max. 95%, non condensing
(W)915 x (D)915 x (H)2315mm
636kg
Accessories included:
Motor Protection Relais Bulletin 825
with RTD input
Set of Lamps and push buttons
Set of Lamps and push buttons
Bulletin 1562D
... / 2
19.12.02
Blatt 2
Bulletin 1560 :
M
3~
Each controller shall be designed, manufactured and tested to meet or exceed the
requirements of the latest published standards of:
... / 3
Datenblatt Sach Nr.: 4200 595 (4)ev. 02
Blatt 1-3
19.12.02
Blatt 3
Standard Features :
Fixed mounted 400 amp "BYPASS" vacuum contactor
SMC Dialog Plus control module with four modes of starting: Soft Start with
selectable Kickstart, Current Limit, Dual Ramps or Full Voltage.
Programmable adjustments for setup.
Power SCRs with fiber optic isolated gate logic.
Viewing window in low voltage door to view the LCD display on the control
module.
Low voltage and power cell doors.
Metering (does not require additional CPT or PTs)
Electronic motor overload protection.
Bulletin 825-NCM-20 converter module(mounted in cabinet)
Built-in SCANport communications.
1 selector switch
local remote
1 push button color green
on local
1 push button color red
off local
1 push button color green
Resetl
1 potential-free contact on / off remote
1 potential-free contact UTS (soft start completed)
1 potential-free contact FAULT
1 potential-free contact Reset
1 lamp FAULT, in low-voltage unit, colour red
1 lamp UTS (soft start completed), in low-voltage unit, colour green
Colour of switch cabinet, standard colour RAL 7005
Motor- and power supply cables connected from top
Software for soft starter(DriveExplorer Lite) provided as CD-Rom including
connection cable 1203-SSS
Medium V
oltage
Voltage
Dialog Plus
Motor Controller
Bulletin 1503D, 1560D
and 1562D
User Manual
Because of the variety of uses for the products described in this publication,
those responsible for the application and use of this control equipment must
satisfy themselves that all necessary steps have been taken to assure that each
application and use meets all performance and safety requirements, including
any applicable laws, regulations, codes and standards.
The illustrations, charts, sample programs and layout examples shown in this
guide are intended solely for purposes of example. Since there are many
variables and requirements associated with any particular installation,
Rockwell Automation does not assume responsibility or liability (to include
intellectual property liability) for actual use based upon the examples shown
in this publication.
Rockwell Automation publication SGI-1.1, Safely Guidelines for the Application, Installation, and Maintenance of Solid-State Control (available from
your local Rockwell Automation office), describes some important differences between solid-state equipment and electromechanical devices that
should be taken into consideration when applying products such as those
described in this publication.
Reproduction of the contents of this copyrighted publication, in whole or in
part, without written permission of Rockwell International Corporation, is
prohibited.
Throughout this manual we use notes to make you aware of safety
considerations:
SMC Dialog Plus, SCANport, and Accu-Stop are trademarks of Rockwell Automation.
DeviceNet is a trademark of the Open DeviceNet Vendors Association (O.D.V.A.).
Table of Contents
Preface
Service Procedure
Product Overview
Chapter 1
Page
ii
Installation
Chapter 2
Page
Commissioning Procedure
Chapter 3
Preliminary Set-Up ............................................................................ 3-1
System Characteristics ...................................................................... 3-2
Preliminary Check ............................................................................. 3-3
Programming ..................................................................................... 3-3
Hi-Pot and Megger Test .................................................................... 3-4
Power Supply Tests ........................................................................... 3-6
Control Function Tests ...................................................................... 3-9
Resistance Checks ........................................................................... 3-10
Start-Up ........................................................................................... 3-10
Programming
Chapter 4
Overview ........................................................................................... 4-1
Keypad Description ........................................................................... 4-1
Programming Menu ........................................................................... 4-1
Password ............................................................................................ 4-5
Search ................................................................................................ 4-5
Parameter Management ..................................................................... 4-6
Parameter Modification ..................................................................... 4-8
Soft Start ............................................................................................ 4-9
Current Limit Start ............................................................................ 4-9
Dual Ramp Start .............................................................................. 4-10
Full Voltage Start ............................................................................ 4-10
Basic Setup ...................................................................................... 4-11
Advanced Setup ............................................................................... 4-12
Example Settings ............................................................................. 4-13
iii
Calibration
Chapter 5
Page
Metering
Chapter 6
Overview ........................................................................................... 6-1
Viewing Metering Data ..................................................................... 6-1
Options
Chapter 7
Overview ...........................................................................................
Human Interface Module...................................................................
Programming Parameters ..................................................................
Control Wiring for SCANport Control .............................................
Soft Stop Option ................................................................................
Pump Control Option ........................................................................
SMB Smart Motor Braking Option ...................................................
Preset Slow Speed Option .................................................................
Slow Speed with Braking Option ......................................................
Serial Communications
7-1
7-1
7-3
7-4
7-5
7-6
7-7
7-8
7-9
Chapter 8
Overview ........................................................................................... 8-1
Logic Control Data ............................................................................ 8-1
Control Wiring .................................................................................. 8-1
Control Enable................................................................................... 8-2
SMC Status Data ............................................................................... 8-3
Reference/Feedback .......................................................................... 8-3
Parameter Listing .............................................................................. 8-3
Scale Factor Conversion .................................................................... 8-3
Display Unit Equivalents .................................................................. 8-4
Datalinks/SLC Block Transfers ........................................................ 8-4
Interfacing ......................................................................................... 8-4
Processing Time ................................................................................ 8-4
Remote I/O Examples........................................................................ 8-5
Example #1 SLC 500 Controller without Block Transfer ....... 8-5
Example #2 SLC 500 Controller with Block Transfer .......... 8-10
Example #3 PLC 5/20, 5/40, 5/60 and 5/80 ........................... 8-20
DeviceNet Examples ....................................................................... 8-27
Example #1 SLC 500 Controller with Explicit Messaging ... 8-27
1203-GK5 Communication Module Switch Settings ............... 8-28
Explicit Messaging ................................................................... 8-33
iv
Diagnostics
Chapter 9
Page
Overview ...........................................................................................
Fault Display .....................................................................................
Clear Fault .........................................................................................
Fault Buffer .......................................................................................
Fault Auxiliary Contact .....................................................................
Fault Definitions ................................................................................
Troubleshooting
9-1
9-1
9-1
9-2
9-3
9-3
Chapter 10
General Notes and Warnings ........................................................... 10-1
Fault Identification .......................................................................... 10-2
Control Module Removal ................................................................ 10-7
Voltage Feedback Circuit Tests ...................................................... 10-8
Circuit Board Replacement ............................................................. 10-8
Power Circuit Troubleshooting ....................................................... 10-9
Thyristor Testing ...................................................................... 10-9
SCR Replacement Procedure .................................................. 10-10
Snubber and Resistor Circuit Testing ........................................... 10-24
Snubber Resistor Replacement ....................................................... 10-26
Maintenance
Chapter 11
Safety and Preventative ................................................................... 11-1
Periodic Inspection .......................................................................... 11-1
Appendix A
Appendix B
Appendix C
Figures
Page
Figure 1.1
Figure 1.2
Figure 1.3
Figure 1.4
Figure 1.5
Figure 1.6
Figure 1.7
Figure 1.8
Figure 1.9
Figure 1.10
Figure 1.11
Figure 1.12
Figure 1.13
Figure 1.14
Figure 1.15
Figure 1.16
Figure 1.17
Figure 1.18a
Figure 1.18b
Figure 1.18c
Figure 1.18d
Figure 1.19a
Figure 1.19b
Figure 2.1
Figure 2.2
Figure 2.3
Figure 2.4
Figure 2.5
Figure 2.6
Figure 2.7
Figure 2.8
Figure 2.9
vi
Figures (cont.)
Page
Figure 3.1
Figure 3.2
Figure 3.3
Figure 3.4a
Figure 3.4b
Figure 4.1
Figure 4.2
Figure 7.1
Figure 7.2
Figure 7.3
Figure 7.4
Figure 7.5
Figure 9.1
Figure 10.1
Figure 10.2
Figure 10.3
Figure 10.4
Figure 10.5
Figure 10.6
Figure 10.7
Figure 10.8
Figure 10.9
Figure 10.10
Figure 10.11
Figure 10.12
Figure 10.13
Figure 10.14
Figure 10.15
Figure 10.16
Figure 10.17
Figure 10.18
Figure 10.19
Figure 10.20
Figure 10.21
Low Voltage Panel & Power Cell Detail (1562D) .................................. 10-14
1000/1300/1500/2400 Volt Heatsink Assembly, 180/360 A ................... 10-15
Heatsink Clamp ........................................................................................ 10-15
Removal of SCR1 ..................................................................................... 10-16
Removal of SCR2 ..................................................................................... 10-16
3300/4160 Volt Heatsink Assembly, 180/360 A ..................................... 10-17
Heatsink Clamp ........................................................................................ 10-17
Removal of SCR1 ..................................................................................... 10-18
Removal of SCR1 or SCR2 ...................................................................... 10-18
6900V Module, 180/360 A ...................................................................... 10-19
6900V Module with Gate Driver Boards Removed, 180/360 A .............. 10-19
6900V Module with Boards and Frame Removed, 180/360 A ................ 10-20
6900V Heatsink Assembly, 180/360 A .................................................... 10-21
6900V SCR Replacement, 180/360 A ..................................................... 10-21
Removing and Replacing SCRs ............................................................... 10-22
2300V Heatsink Module, 800A ............................................................... 10-22
3300 and 4160V Heatsink Module, 800A ............................................... 10-23
6900V Heatsink Module, 800A ............................................................... 10-23
1500/2400V Module Wiring .................................................................... 10-27
3300/4160V Module Wiring .................................................................... 10-28
6900V Module Wiring ............................................................................. 10-29
Tables
vii
Page
Table 4.A
Table 5.A
Table 8.A
Table 8.B
Table 9.A
Table 10.A
Table 10.B
Table 10.C
Table 10.D
Table 10.E
Table A.1
Table A.2
Table B.1
Table B.2
Table B.3
Table B.4
Table B.5
Table B.6
Table B.7
Table B.8
Table B.9
Table B.10
Table C.1
viii
Preface
Service Procedure
For MV Dialog Plus technical support on start-up or existing installations, contact your Rockwell Automation
representative. You can also call 1-519-623-1810 for assistance Monday through Friday from 7:30 a.m.
to 5:15 p.m. (Eastern time zone).
Preface
Chapter
Product Overview
Manual Objectives
This manual is intended for use by personnel familiar with Medium Voltage and
solid-state power equipment. The manual contains material which will allow the
user to operate, maintain and troubleshoot the MV Dialog PlusTM controller.
Documentation
Description
1-2
Product Overview
Description (cont.)
The MV Dialog Plus product uses a modified version of the Bulletin 150 Pump Control Module. Do not use
a pump module for the low voltage product line in the medium voltage product. There is no difference for
the standard or soft stop modules.
"
These options utilize gating patterns which result in motor and line currents that produce noise and vibration
in the motor and/or distribution transformer. The factory should be consulted before applying these options.
Product Overview
Starting Modes
1-3
Soft Start
This mode has the most general application. The motor is given an initial
torque setting, which is user-adjustable from 0 to 90% of locked-rotor
torque. From the initial torque level, the output voltage to the motor is
steplessly increased during the acceleration ramp time. The acceleration
ramp time is user-adjustable from 0 to 30 seconds. Once the MV Dialog
Plus controller senses that the motor has reached the up-to-speed condition
during the voltage ramp operation, the output voltage automatically
switches to full voltage, and the bypass contactor is closed.
Figure 1.1
Soft Start
Percent
Voltage
100%
Initial
Torque
Start
Run
Time (seconds)
1-4
Product Overview
Selectable Kickstart !
Selectable kickstart provides a power boost at start-up that is 550% of
full-load current. The additional power helps motors generate higher
torque to overcome the resistive mechanical forces of some applications
when they are started. The selectable kickstart is user-adjustable from 0.0
to 2.0 seconds.
Figure 1.2
Selectable Kickstart
Percent
Voltage
Kickstart
100%
Initial
Torque
Start
Run
Time (seconds)
600%
50%
Start
Time (seconds)
!
"
Product Overview
1-5
Initial
Torque #2
Initial
Torque #1
Ramp #1
Start #1
Start #2
Run #1
Run #2
Time (seconds)
100%
Percent
Voltage
Time (seconds)
1-6
Product Overview
Overload
The MV Dialog Plus controller meets applicable requirements as a motor
overload protective device. Thermal memory provides added protection
and is maintained even when control power is removed. The built-in
overload algorithm controls the value stored in Parameter 11, Motor
Thermal Usage (see Chapter 4, Programming). An Overload Fault will
occur when this value reaches 100%. The programming parameters below
provide application flexibility and easy setup. See Note 3.
Parameter
Overload Class
Overload Reset
Motor FLC
Service Factor
Range
Off, 10, 15, 20, 30
Manual Auto
1.0 - 999.9 Amps
0.01 - 1.99
1-7
Product Overview
Figure 1.6
Overload Trip Curves
Class 10
Class 15
Class 20
Class 30
100.0
1000.0
1000.0
1000.0
10.0
1.0
0.1
1
5 6 7 8 9 10
Multiples of FLC
100.0
10.0
1.0
5 6 7 8 9 10
Multiples of FLC
10000.0
10000.0
10000.0
1000.0
100.0
10.0
1.0
100.0
10.0
1.0
1
5 6 7 8 9 10
Multiples of FLC
5 6 7 8 9 10
Multiples of FLC
Figure 1.7
Restart Trip Curves after Auto Reset
100000
1000
Seconds
100
Class 10
Class 15
Class 20
Class 30
10
Note:
Figures 1.6 and 1.7 provide
the overload trip curves for
the available trip classes.
0.1
0
100%
1000%
Load
Current
Setting
PerPercent
cent FullFull
Load
Current
Setting
1-8
Product Overview
Figure 1.9
Jam Detection !
Percent
Full
Load
Current
100%
Running
Jam
Time (seconds)
Product Overview
1-9
Open Gate
An open-gate fault indicates that improper SCR firing, typically caused by
an open SCR gate or driver system, has been detected on one of the power
poles. Before the controller shuts down, it will attempt to start the motor a
total of three times (or as programmed in Parameter 64).
Line Faults
The MV Dialog Plus controller continually monitors line conditions for
abnormal factors. Pre-start protection includes:
Underload $
If a sudden drop in current is detected, motor operation can be halted by
utilizing the underload protection of the MV Dialog Plus controller.
The MV Dialog Plus controller provides an adjustable underload trip
setting from 0 to 99% of the programmed motor full-load current rating.
Trip delay time can be adjusted from 0 to 99 seconds. The Bulletin 825
current converter module must be connected for this feature to be available.
!
"
$
Undervoltage, overvoltage, and voltage unbalance protection are disabled during braking operation.
Phase reversal protection is functional only at pre-start.
Underload protection is disabled during slow speed and braking operations.
1-10
Product Overview
Excessive Starts/Hour
The MV Dialog Plus module allows the user to program the desired
number of starts per hour (up to 99). This helps eliminate motor stress
caused by repeated starting over a short time period.
Note: The base rating of the MV Dialog Plus is two starts (thirty seconds
each max.) per hour. Applications requiring more frequent starts, or longer
duration starts, should be reviewed with the factory to avoid equipment damage.
Overtemperature
The power module temperature is monitored during starting and stopping
maneuvers by thermistors. The thermistor is connected to the gate driver
board where it is processed, and the status is transmitted by fibre-optic cable
through the interface board to the control module. When an overtemperature
condition exists, the control module trips and indicates a temperature fault.
An overtemperature condition could indicate high ambient temperature,
overloading or excessive cycling. After the power module temperature is
reduced to allowable levels, the fault can be cleared (see page 9-1 for
instructions).
Metering
Three-phase current
Three-phase voltage
Power in kW (see note 5 below)
Power usage in kWh (see note 5 below)
Power factor (see note 5 below)
Motor thermal capacity usage
Elapsed time
Notes:
1. The current sensing capability of the MV Dialog Plus controller requires
a Bulletin 825 converter module to maintain the three-phase current,
and motor thermal capacity measurements.
2. Current measurement is not available during the slow speed and/or
braking operations of the Preset Slow Speed, SMB Smart Motor Braking, and Slow Speed with Braking control options.
3. Voltage measurement is not available during the braking operation of
the SMB Smart Motor Braking, and Slow Speed with Braking control
options.
4. The elapsed time values are automatically saved to memory every 12
hours.
5. The current Series A SMC Dialog Plus module does not provide power
metering functions when used in the MV Dialog Plus Controller.
Product Overview
Communication
1-11
ESC.
SCANport
SEL.
Programming
Setup is easy with the built-in keypad and two-line, 16-character, backlit
LCD. Parameters are organized in a four-level menu structure, using a text
format for straightforward programming.
Figure 1.11
Built-in Keypad and LCD
ESC.
SEL.
1-12
Product Overview
Status Indication
Three programmable hard contact outputs are provided as standard. The first
two contacts are Form C and programmable for Normal or Up-to-speed. They
must be set for "Up-to-speed" to control the bypass contactor, and for operating
logic on the interface board. The third contact is programmable as Normal or
Fault. For Bulletin 1560D applications, it is set for "Fault" to signal the line
contactor to open in the user's starter feeding the MV Dialog controller. For
Bulletin 1562D applications, it is set for "Normal" to control the closing and
opening of the line contactor. The contact will open if there is a fault condition.
Control Options
The MV Dialog Plus controller offers the control options described below.
Important: The options listed in this section are mutually exclusive and
must be specified when ordering. An existing controller may be upgraded
to another control option by replacing the control module and possibly other
components. Consult your nearest Rockwell Automation sales office.
Option maneuvers count as a start when determining thermal capacity of the MV
Dialog Plus. i.e., a soft start followed by a soft stop counts as two starts, and the
unit must have the required rest period before another start. (See Note below).
100%
Kickstart
Coast-to-rest
Soft
Stop
Initial
Torque
Start
Run
Time (seconds)
Soft Stop
Product Overview
1-13
1-14
Product Overview
Pump Start
Run
Time (seconds)
Pump Stop
Product Overview
1-15
Forward
15% High
7% Low
Time (seconds)
Start
Run
10% Low
20% High
Reverse
Important: Slow speed running is not intended for continuous operation due
to reduced motor cooling. The two starts per hour limitation also applies to
slow speed operation. This option employs a cycle-skipping scheme which
produces limited torque. Applications should be checked with the factory.
100%
Smart Motor Braking
Motor
Speed
Coast-to-rest
Start
Run
Brake
Time (seconds)
Automatic Zero Speed
Shut-off
1560D-5.1 February 2000
1-16
Product Overview
100%
Coast-to-rest
Motor
Speed
7% or 15%
Braking
Slow
Speed
Start
Run
Stop
Time (seconds)
Product Overview
Hardware Description
1-17
Power Module
The controller consists of three power modules, one for each phase. Each
power module consists of incoming and outgoing terminals for cables, SCRs,
heatsink and clamp assembly. The SCRs are connected in inverse parallel
(and in series for 12- or 18-SCR assemblies) to form a three-phase, AC
line controller configuration.
Each power module includes a snubber circuit to limit the rate of rise in
voltage across each SCR pair. The module also includes gate driver
circuits which derive their power from the snubber circuit. A patent
application has been submitted for this process.
Voltage sharing resistors are connected across each SCR pair to provide
static voltage balance for series-connected SCRs. These resistors are
tapped to provide a reference for overvoltage protection circuitry on the
gate driver board.
A resistive voltage divider is used to reduce the line- and load-side voltages
to lower levels that can be handled by the SMC Dialog Plus control
module. The resistors for the top portion of the divider are located on the
Voltage Divider Resistor circuit board, and the bottom portion of the
divider is on the Voltage Feedback circuit board. The latter board provides
the resistor connection to ground, and power Zener diodes (with their own
ground connection) as a protection circuit to prevent high voltages from
entering the control module if a resistor or resistor ground were to open
circuit. The voltage feedback board provides the voltage reference signals
to the interface board for connection to the control module.
1-18
Product Overview
Interface Board
This circuit board takes line- and load-side voltage feedback signals from
the voltage feedback board and passes them via pins to the MV Dialog
Plus for processing. The control module produces gating signals for the
SCRs, which are received via pins on the interface board, and used to drive
fibre-optic transmitters. The gating signals are sent to the gate-driver
circuit board via fibre-optic cables. The interface board also receives
temperature feedback from the gate-driver board via fibre-optic cable(s).
If the heatsink temperature rises above a set value, a signal is sent to the
Dialog Plus to stop gating the SCRs and initiate a temperature fault.
For a detailed description of this circuit board, refer to Figure 3.1 on
page 3-5.
Product Overview
1-19
CONTROL COMMON
50/60 Hz
Figure 1.17
System Diagram
UTS N/O
1-20
Product Overview
Functional Description
Product Overview
1-21
1-22
Product Overview
Product Overview
1-23
Figure 1.18a
Bulletin 1562D Basic Control Circuit Standard Module
NO RMAL
*
* If supplied
1-24
Product Overview
Figure 1.18b
Bulletin 1562D Basic Control Circuit Soft Stop or Pump Control
NO RMAL
*
* If supplie
Product Overview
1-25
Figure 1.18c
Bulletin 1562D with SCANport Control Standard Module
NO RMAL
*
* If supplied
1-26
Product Overview
Figure 1.18d
Bulletin 1562D with SCANport Control Soft Stop or Pump Control
NORMAL
*
* If supplied
Product Overview
1-27
Figure 1.19a
Bulletin 1560D Basic Control Circuit Standard Module
FAULT
*
* If supplied
1-28
Product Overview
Figure 1.19b
Bulletin 1560D Basic Control Circuit Soft Stop or Pump Control
FAULT
*
* If supplied
Chapter
Installation
ATTENTION: Perform the installation duties correctly.
Errors may cause commissioning delays, equipment damage
or personal injury.
Important: For the 1503D, refer to applicable documentation from OEM
installation, grounding, interlocking and wiring. This manual should be
utilized in conjunction with the OEM supplied documentation, and is
suitable for commissioning, programming, calibration, metering, serial
communications, diagnostics, troubleshooting, and maintenance of a
standard solid-state controller.
Receiving
After unpacking the material, check the item(s) received against the bill of
lading to ensure that the nameplate description of each item agrees with
the material ordered. Inspect the equipment for physical damage, as stated
in the Rockwell Automation Conditions of Sale.
Remove all packing material, wedges, or braces from within the controller.
Operate the contactors and relays manually to ensure that they operate freely.
Store the equipment in a clean, dry place if it will not be installed immediately
after unpacking. The storage temperature must be between -20C and 75C
(-4F and 167F) with a maximum humidity of 95%, non-condensing, to
guard against damage to temperature sensitive components in the controller.
2-2
Installation
General Precautions
Installation
Installation Site
2-3
Mounting
The 1503D, 1560D and 1562D are designed to be mounted in the vertical
position. Standard cabinet drawings with certified dimension drawings can
be obtained by contacting your local Rockwell Automation Sales office for
the 1560D/1562D. Please refer to OEM documentation for the 1503D.
Refer to drawings for mounting requirements.
2-4
Installation
Grounding Practices
The purpose of grounding is to:
A. Provide safety for Personnel.
B. Limit dangerous voltages to ground on exposed parts.
C. Facilitate proper overcurrent device operation under ground fault
conditions.
D. Provide for electrical interference suppression.
Important: Generally, grounding should be in accordance with the
Canadian Electrical Code (CEC) or National Electrical Code (NEC) and
other local codes.
Each power feeder from the substation transformer to the controller must
be equipped with properly sized ground cables. Simply utilizing the
conduit or cable armour as a ground is not adequate. The conduit or cable
armour and ground wires should be bonded to ground at both ends. Each
enclosure and/or frame must be bonded to ground at a minimum of two
locations.
Each AC motor frame must be bonded to grounded building steel within 20
feet (6.1 m) of its location and tied to the controllers ground bus by ground
wires within the power cables and/or conduit. The conduit or cable armour
should be bonded to ground at both ends.
ATTENTION: Any instruments used for test or troubleshooting should have their case connected to ground for
safety. Failure to do so may result in damage to equipment
or personal injury.
Installation
Power Connections
2-5
Line Connections
Line Connections
Load Connections
Load Connections
Front View
RH Side View
Note: Bottom cable exit shown. Lugs may be oriented upwards for
cables exiting through the top of the cabinet.
Important: For 1503D, refer to applicable documentation from OEM for
installation, grounding, interlocking and wiring. This manual should be
utilized in conjunction with the OEM supplied documentation, and is
suitable for commissioning, programming, calibration, metering, serial
communications, diagnostics, troubleshooting, and maintenance of a
standard solid-state controller.
2-6
Installation
Figure 2.2
Power Connections 1560D 400 A, 6900 V (6.9 kV)
Phase 1 Module
Phase 1 Line Connection
Phase 1 Load Connection
Phase 2 Module
Phase 2 Line Connection
Phase 3 Module
Bypass Contactor
Installation
Phase 1 Module
2-7
Figure 2.3
Power Connections 1560D 800 A, 2400 V to 6900 V (6.9 kV)
Bypass Contactor
2-8
Installation
Power Wiring
Interlocking
Installation
Installation
2-9
Physical Location
The controller is designed for limited front access (components may have to
be removed) and should be installed with adequate and safe clearance to
allow for total door opening. The back of the unit may be placed against a
wall and several units may be set end to end. In special cases where floor
space is limited and the unit is not against a wall, certain cabinet sections
may be placed back to back. This requirement must be stated in the
specifications in order to mechanically alter the controller.
Fan
The controller may include a cooling fan which is used to cool the component.
It should be checked for free operation and no obstruction of the airflow.
Control Cables
Control cable entry/exit should be located near the terminal blocks; customers
connections are to be routed along the empty side of the terminals. Nylon
cable tie loops are provided at the left, front corner of the cabinet to route
control cables safely behind the low voltage panel hinges. Cables should
be routed so they do not interfere with the swing of the low-voltage panels.
Fibre-Optic Cables
The small, gray, fibre-optic cables are fragile and must be protected during
installation from sharp bends and impact.
2-10
Installation
Installation (cont.)
Installation
2-11
Figure 2.4
Typical One-Line Diagram Showing 2 Different Styles
of Power Factor Capacitor Connections
Power Bus
Isolation Switch
Isolation Switch
Fuse
Fuse
Contactor
Isolation Contactor
di/dt Inductor
di/dt Inductor
Capacitor
Contactor
PFCC
PFCC
(Power Factor
Correction Capacitor)
Bypass
Contactor
Motor
2-12
Installation
Motor and system inductance limits the rate at which the current can
change through the SMC. If capacitance is added at the motor, the
inductance is negated. The surge capacitors downstream of the SMC
represent a near zero impedance when presented with a step voltage
from the turn on of the SCRs near the line voltage peak. This causes a
high level of di/dt to occur, due to the fact that the motor cables are
generally short in length. There is very little impedance between the
capacitor and SCR to limit the di/dt of this capacitor charging current.
This can result in damage to the power semiconductors (SCRs) in the
SMC.
Installation
2-13
Emergency Bypass
In standard bypass configuration, the MV Dialog Plus controller relies on a
Bulletin 825 converter module to provide current feedback to the Dialog Plus
module in order to maintain thermal memory and power monitoring
capability. It is possible, however, to use traditional electromechanical or
solid-state overload relays for emergency bypass configurations in situations
where the Dialog Plus module does not initiate the start sequence, and the
MV Dialog Plus controller operates as a full-voltage starter.
Two-speed Motors
The MV Dialog Plus controller has overload protection available for single
speed motors. When the MV Dialog plus controller is applied to a two-speed
motor, the Overload Class parameter must be programmed to OFF, and
separate overload relays must be provided for each speed.
Multi-motor Protection
The MV Dialog Plus controller provides overload protection for only one
motor. When the MV Dialog Plus is controlling more than one motor, the
Overload Class Parameter must be programmed to OFF, and individual
overload protection is required for each motor.
2-14
Installation
The Bulletin 1201 human interface modules may be used to program and
control the SMC Dialog Plus controller. The human interface modules
have two sections: a display panel and a control panel. The display panel
duplicates the two-line, 16-character, backlit LCD display and programming
keypad on the front of the SMC Dialog Plus controller. Refer to Chapter 4
for a description of programming keys; refer to Appendix D for a listing
of human interface module catalog numbers that are compatible with the
controller.
The control panel provides the operator interface to the controller. The
keys that provide start and stop control are described below.
Start
The green start button begins motor operation.
Stop
The red stop button halts motor operation.
Jog
The jog button is active only when a control option is present.
Pressing the jog button will initiate the option maneuver
(for example: Pump Stop)
ATTENTION: The Bulletin 1201 human interface module's
stop push button is not intended to be used as an emergency
stop. Such usage may result in severe injury or death. Refer
to the applicable standards for emergency stop requirements.
All other controls available with the various human interface modules
are non-functional with the MV Dialog Plus controller.
Installation
2-15
Human Interface Module (cont.) Connecting the Human Interface Module to the Controller
Figure 2.5 shows the connection of the SMC Dialog Plus controller to a
human interface module. See Figure 1.18(c) on page 1-24 for the control
wiring diagram that enables start-stop control from a human interface
module.
Figure 2.5
SMC Dialog Plus Controller with Human Interface Module
11
12
21
L1
L2
L3
13 14
22
ESC.
15 16
17
23 24 25 26
18
27
19 20
28
Latching
Mechanism
Pull back moving part (connector body) to disconnect
cable from the SCANport connection.
Bulletin 1202
Cable
29 30
SEL.
2-16
Installation
Action
Display
STOPPED
0.0 AMPS
CHOOSE MODE
_____
CHOOSE MODE
PROGRAM
PROGRAM
_____
PROGRAM
LINEAR LIST
LOGIC MASK
0
LOGIC MASK
0
LOGIC MASK
4
LOGIC MASK
4
Note:
Installation
2-17
Action
Display
STOPPED
0.0 AMPS
CHOOSE MODE
_____
CHOOSE MODE
CONTROL STATUS
CONTROL LOGIC
DISABLE
CONTROL LOGIC
DISABLE
CONTROL LOGIC
ENABLE
CONTROL LOGIC
ENABLE
2-18
Installation
Communication Modules
The Bulletin 1203 communication module allows the user to connect the
SMC Dialog Plus controller to various networks and communication
protocols. The figure below shows how the controller and the communication module connect.
Figure 2.6
SMC Dialog Plus Controller with Communication Module
L2
3
L1
1
12
11
21
13
22
14
23
15
24
16
25
17
26
L3
5
19
18
27
28
20
29
Latching
Mechanism
2
SH
1
Re m I/O
Re m I/O STS
Re m I/O A ct
He a tl h
V+
VG
SCA Nb u sSTS
FA ULT
ES C . S EL.
Communication Module
Installation
Converter Modules
2-19
L1
L2
L3
Converter
Module !
T1
T2
T3
Cable (provided as
standard with the
converter module) "
150-NFS
Fanning Strip
21
!
"
22
23
24 25
26 27
28 29
30
The converter module rating must be programmed in the calibration group for proper current measurement
scaling.
Cable length is three meters. Only the cable provided with the converter module is compatible with the
SMC Dialog Plus controller. Use of any other cable may result in faulty controller operation.
2-20
Installation
L1
L2
L3
Converter Module #
T1
!
"
#
T2
T3
The current transformer (CT) ratio must be programmed in the calibration group for proper current
measurement scaling. See page 5-2 for instructions on programming this parameter.
Another current transformer connects L2 and T2, and another connects L3 and T3.
The converter module, Cat. No. 825-MCM20, must be used in these applications.
Installation
2-21
21
22
23
24
25
26
Terminal Number
19
18
17
16
15
14
13
12
11
27
28
20
29
30
Description
11
12
13
14
Logic Ground
15
16
Start Input !
17
Stop Input !
18
19
20
21
Not Used
22
Not Used
23
Not Used
24
Not Used
25
26
27
28
29
30
"
Do not connect any additional loads to these terminals. These parasitic loads may
cause problems with operation, which may result in false starting and stopping.
"
When control power is absent from terminals 11 and 12, this contact will be normally
open. Upon application of control power, the contact will take the state, normally open or
normally closed, as programmed. Refer to Fault Auxiliary Contact on page 9-3.
2-22
Installation
Chapter
Commissioning Procedure
Preliminary Set-Up
A. Ensure the work area is clean and tidy. Pathways to main disconnect
and emergency stop push-button must be clear and unobstructed.
B. The following test equipment is to be prepared for use:
Test power supply, supplied with each controller
Multimeters
Hi-Pot Tester (recommended) or Megger
Oscilloscope with memory (optional)
C. Complete drawing package and parts list.
D. Specification of project.
3-2
Commissioning Procedures
System Characteristics
Job Name: ______________________________
Fan ___Pump___Conveyor___Compressor___Mixer___
Other_________________________________________
Constant Torque_______ or Variable Torque _______
S.F.: _________
Commissioning Procedures
Preliminary Check
3-3
ATTENTION: Ensure that all sources of power are isolated and locked out before working on installed equipment.
Verify that all circuits are voltage free using a hot stick or
appropriate voltage measuring device. Failure to do so may
result in severe burns, injury or death.
A. Verify correct power cable phase sequencing, and that connections are
tight.
B. Verify power fuse ratings and condition.
C. Verify control fuse ratings and condition.
D. Check that power cable installation has not damaged components, and
that electrical spacings have not been reduced.
E. Check that fibre-optic cables are fully seated in their connectors.
F. Check that circuit board plug connectors are installed and fully
inserted in their sockets.
G. Check that the cooling fan (if supplied) is secured and the rotor is not
obstructed.
H. Verify integrity and operation of all interlocks.
I. In the case of the 1503D, verify wiring and perform all tests in
conjunction with OEM documentation.
Programming
3-4
Commissioning Procedures
Commissioning Procedures
3-5
Figure 3.1
Connection and Test Information for Interface Board
L
POWER
N
G
LINE
NEUTRAL
CONTROL POWER:
100-120 or 220-240 VAC
50 or 60 Hz
GROUND
Test Point 1
LED 3 (Yellow): Phase A.
ON when gate signal present.
Test Point 1
Test Point 1
LED 4 (Yellow) ON
when Phase B gate signal present
Test Point 1
LED 5 (Yellow) ON
when Phase C gate signal present
Temperature
feedback fibre
optic receivers.
One cable from a
gate driver board
in each phase.
Test Point 3: +5 V
Test Point 1
NOTES:
1. All test point voltages or signals are relative to TP1 (COM) except TP6 TEMP MODULE which is relative to TP19 TEMP COM only.
TP19 must not be connected to ground or TP1 COM. There are several TP1 locations on the board for convenience.
2. There are two versions of the circuit board: -51 and -53 have four fibre optic transmitters per phase (for <2700 volt operation, only two
per phase will be utilized); -52 and -54 have six fibre optic transmitters per phase for >5000 volt operation.
3. Part numbers 80187-131-51 and -52 are factory set for 100-120 VAC control power. 80187-131-53 and -54 are factory set for 220-240 VAC
control power. They can be changed in the field by moving the jumpers on the voltage selection plug (TB2) and changing the fuse (F1).
3-6
Commissioning Procedures
LED2
DIP1
Commissioning Procedures
3-7
5. Since the gate driver circuits normally receive power from the snubber
circuits when the SMC is operating, an alternate source must be used
for testing. Locate the Portable Test Power Supply that was included
with the equipment, and verify that the rating corresponds to the
available power system (i.e. 110/120 VAC or 220/240 VAC). Plug the
unit into the power source, and plug the green connector into TB1 on
each of the gate driver sections (See Figure 3.3).
Figure 3.3
Test Power Application
Yellow LED
Plug in test
power supply
(TB1)
TP7 (Gate)
TP1 (Com)
TP2 (+)
Yellow LED
Plug in test
power supply
(TB1)
TP7 (Gate)
TP1 (Com)
TP2 (+)
6. The yellow LED on the upper right-hand side of the energized gate
driver circuit should be lit (it may appear dim, depending on ambient
light conditions). This is normally sufficient to verify that the gate drive
system is functioning, however, a more detailed check can be made
utilizing steps 7 and 8.
3-8
Commissioning Procedures
14
14
12
12
10
10
Volts
Volts
Figure 3.4a
Gate Pulse Detail GEC (GPS) SCR
6
4
6
4
-2
-2
-2
-2
Microseconds
Microseconds
Figure 3.5
Gate Pulse Test Waveform
0.0
0.5
1.0
1.5
2.0
2.5
3.0
Milliseconds
9. If no pulse is observed, and the yellow LED is lit, check for a shorted
gate on the SCR by removing the green plug and connecting an
ohmmeter to the gate leads. If the LED is not lit, and the circuit
voltage is as specified in step 7 (above), pinch the tab on the fibre-optic
connector and carefully pull it straight out of the receiver. The end of
the connector should glow red to indicate the presence of a gate signal.
Commissioning Procedures
3-9
If it does not, remove the other end of the cable from the interface
board and check that the grey transmitter is emitting red light. If it is,
the fibre-optic cable must be replaced. If it isnt, the interface board
should be replaced.
10. When each gate driver circuit has been checked, disconnect the power
supply and remove it from the cabinet.
ATTENTION: The gate-drive circuits operate at high
voltage when the SMC is energized. Failure to remove the
portable test power supply will result in equipment damage
and may cause severe injury or death.
11. Open the switch DIP1 on the interface board (see Figure 3.2) before
returning the unit to service.
ATTENTION: If the DIP1 switch is not in the open
position when the SMC is energized, the motor will start in
an uncontrolled manner and may cause severe damage.
12. Check that all plugs and connectors are secure. Retrieve all hardware
and tools from the equipment. Replace and secure any barriers
removed during servicing and close all doors before applying power.
3-10
Commissioning Procedures
Resistance Checks
To ensure that resistors and connections have not been damaged during
shipment and installation, the following resistance tests should be performed
before energizing the starter.
1.
1000 V
1300 V
1500 V
2300 V
3300 V
4160 V
6900 V
Cathode to Cathode !
22K-30K
23K-31K
24K-32K
17K-23K
19K-25K
20K-27K
21K-29K
40K-53K
43K-57K
64K-84K #
Cathode to Gate
10-40 ohm
10-40 ohm
10-40 ohm
10-40 ohm
10-40 ohm
10-40 ohm
10-40 ohm
!
"
#
Measured between terminals Cathode on SPGD Boards, upper two or bottom two within a phase.
Measured between terminals Cathode on SPGD Boards, top to bottom within a phase.
Measured between line and load terminals within a phase.
3. If abnormal readings are obtained, refer to Power Circuit Troubleshooting on page 10-9.
Start-Up
Chapter
Programming
Overview
Keypad Description
The keys found on the front of the SMC Dialog Plus controller are
described below.
Escape
Select
Programming Menu
Up/Down
Arrows
Enter
4-2
Programming
Figure 4.1
Menu Structure Hierarchy
"
#$
"
The SMC Dialog Plus controller does not support EEPROM, Link, Process or Start-up modes.
"
Control Status and Search are only available when using a Series B Bulletin 1201 human interface module.
Password protected.
Programming
Linear
List
See page 4-4
Metering
See
Chapter 6
4-3
Basic Setup
Advanced Setup
Faults
Calibrate
See
Chapter 5
Language
"
4-4
Programming
Table 4.A
Parameter Linear List
Parameter No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
!
Description
Volts Phase AB
Volts Phase BC
Volts Phase CA
Current Phase A
Current Phase B
Current Phase C
Wattmeter !
Kilowatt Hours !
Elapsed Time
Power Factor !
Mtr. Therm Usage
Factory Use
Factory Use
SMC Option
ETM Reset
Factory Use
Parameter Mgmt.
Clear Fault
Fault Buffer #1
Fault Buffer #2
Fault Buffer #3
Fault Buffer #4
Fault Buffer #5
Factory Use
Factory Use
Factory Use
Factory Use
Starting Mode
Dual Ramp
Ramp Time #1
Initial Torque #1
Ramp Time #2
Initial Torque #2
Current Limit Level
Kickstart Time
Overload Class
Stall Delay
Energy Saver !
Aux. Contacts #1 & 2
Aux. Contact #3
Contact 3 Config.
Stop Time
Factory Use
Slow Speed Sel.
Parameter No.
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
Description
Slow Speed Dir.
Slow Accel Current
Slow Running Current
Braking Current
Factory Use
Factory Use
Stopping Current
Undervolt. Level
Undervolt. Delay
Overvolt. Level
Overvolt. Delay
Jam Level
Jam Delay
Unbalance Level
Rebalance !
Underload Level
Underload Delay
Phase Reversal
Starts per Hour
Restart Attempts
Restart Delay
Factory Use
Factory Use
Factory Use
Line Voltage
Motor FLC
Factory Use
Mtr. Code Letter
Factory Use
Converter Rating
CT Ratio
Calibration
Enter Calib. Amps
Language Select
Motor HP Rating
Motor kW Rating
LRC Ratio
Factory Use
Factory Use
Service Factor
Logic Mask
Unbalance Delay
S/W Version
Overload Reset
Programming
Password
4-5
Password protection lets the user limit access to the programming system
of the SMC Dialog Plus. This feature is disabled with a setting of 0
(factory set default). To modify the password or login after a password is
programmed, complete the procedure below.
Description
Action
Display
STOPPED
0.0 AMPS
CHOOSE MODE
DISPLAY
CHOOSE MODE
PASSWORD
PASSWORD
MODIFY
Options: Login, Modify,
Logout
ENTER PASSWORD
_____
ENTER PASSWORD
#####
CHOOSE MODE
PASSWORD
! After you have completed the programming process, re-enter the Password mode to logout. This will eliminate
unauthorized access to the programming system.
Note: If you lose or forget the password, contact your nearest Rockwell
Automation sales office. You can also call Rockwell Automation
Medium Voltage Headquarters at 1-519-623-1810 for assistance.
Search
The Search mode allows the user to view only those parameters that have
settings other than the factory default values. This mode is only available
when using Bulletin 1201 human interface module.
4-6
Programming
Parameter Management
EEPROM
RAM
ROM
Programming
Parameter Management
(cont.)
4-7
Action
Display
PARAMETER MGMT
STORE IN EE
PARAMETER MGMT
RECLL FRM EE
Recalling Defaults
After parameter values have been
modified and saved to EEPROM,
factory default settings can still be
re-initialized.
PARAMETER MGMT
DEFAULT INIT
4-8
Programming
Parameter Modification
All parameters are modified using the same method. The basic steps to
performing parameter modification are described below.
Note:
Action
Display
STOPPED
0.0 AMPS
CHOOSE MODE
DISPLAY
CHOOSE MODE
PROGRAM
PROGRAM
METERING
PROGRAM
BASIC SETUP
SMC OPTION
STANDARD
"
STARTING MODE
SOFT START
Options: Soft Start,
Current Limit
STARTING MODE
SOFT START
STARTING MODE
CURRENT LIMIT
STARTING MODE
CURRENT LIMIT $
RAMP TIME #1
10 SEC
PARAMETER MGMT
STORE IN EE
! If the Choose Mode menu does not provide the Program option, then you must enter your password.
" The first parameter displayed advises the user if any control option (i.e. Pump Control) is resident. This
parameter is factory set and cannot be modified by the user.
# The display will indicate that the second line is now active by flashing the first character. If the LCD display
does not provide a flashing cursor, then the controller is in the Display mode.
$ You will notice that the cursor has returned to flashing the first character of the first line.
Programming
Soft Start
4-9
The following parameters are specifically used to adjust the voltage ramp
supplied to the motor.
Parameter
Option
Starting Mode
This must be programmed for Soft Start.
Ramp Time #1 !
This programs the time period that the controller will ramp
the output voltage up to full voltage from the Initial Torque
level programmed.
0 to 30 seconds
Initial Torque #1
The initial reduced output voltage level for the voltage ramp
to the motor is established and adjusted with this parameter.
Kickstart Time
A boost of 550% full load current is provided to the motor for
the programmed time period.
! If the controller senses that the motor has reached full speed before completing the voltage ramp, it will
automatically switch to providing full voltage to the motor.
Parameter
Option
Starting Mode
This must be programmed for Current Limit.
Ramp Time #1 !
This programs the time period that the controller will hold
the fixed, reduced output voltage before switching to full
voltage.
0 to 30 seconds
Kickstart Time
A boost of 550% full load current is provided to the motor for
the programmed time period.
! If the controller senses that the motor has reached full speed before completing the current limit start, it
will automatically switch to providing full voltage to the motor.
4-10
Programming
The SMC Dialog Plus controller provides the user with the ability to
select between two Soft Start settings. The parameters below are available
in the Advanced Setup programming mode to obtain Dual Ramp control:
Parameter
Advanced Setup
The user must select the Advanced Setup programming
mode to obtain access to the Dual Ramp parameters.
Starting Mode
This must be programmed for Soft Start.
Dual Ramp !
This allows the user the option to choose between two Soft
Start profiles defined by:
1) Ramp Time #1/Initial Torque #1 and
2) Ramp Time #2/Initial Torque #2.
When this feature is turned on, the ramp time/initial torque
combination is determined by a hard contact input to
terminal 15. When this input signal is low, ramp time/initial
torque #1 are selected. When this input is high, ramp
time/initial torque #2 are selected.
Ramp Time #1
This programs the time period during which the controller
will ramp the output voltage up to full voltage for the first
Soft Start setup.
Initial Torque #1
This parameter establishes and adjusts the initial reduced
output voltage level for the first Soft Start setup.
Ramp Time #2
This programs the time period during which the controller
will ramp the output voltage up to full voltage for the second
Soft Start setup.
Initial Torque #2
The initial reduced output voltage level for the second Soft
Start setup is established and adjusted with this parameter.
Option
No, Yes
0 to 30 seconds
! The Dual Ramp feature is available only with the standard controller.
Option
Programming
Basic Setup
4-11
Option
Standard
Soft Start, Current Limit
0 to 30 seconds
0 to 90% locked rotor torque
50 to 600% full load current
0.0 to 2.0 seconds
0.0 to 10.0 seconds
Off (not used in MV Dialog
Plus)
Normal, Up-to-Speed
Normal, Fault
N.O., N.C.
Ready, Default Init., Recll
Frm EE, Store in EE
! Starting Mode must be programmed to Soft Start to obtain access to the Initial Torque parameter.
" Starting Mode must be programmed to Current Limit to obtain access to the Current Limit Level parameter.
# The new programmed parameter values will not be stored to the EEPROM without the users direction
in Parameter Management. Store in EE.
4-12
Programming
Advanced Setup
While the Basic Setup group allows the user to get started with a minimum
number of parameters to modify, the Advanced Setup group allows full
access to the SMC Dialog Plus controller's powerful parameter set.
Following is a listing of the additional setup parameters provided.
Note:
Dual Ramp !
Allows the user the option to choose between two Soft Start
profiles.
Ramp Time #2
Determines the soft start time for the second ramp of the
Dual Ramp feature.
Initial Torque #2
Provides the initial torque setting for the second ramp of the
Dual Ramp feature.
Undervoltage Level $
Determines the trip level as a percentage of line voltage.
Undervoltage Delay $
Provides a delay period prior to a trip occurrence.
Overvoltage Level
Determines the trip level as a percentage of line voltage.
Overvoltage Delay "
Provides a delay period prior to a trip occurrence.
Jam Level #
Determines the trip level as a percentage of the motors full
load current.
Jam Delay
Provides a delay period prior to a trip occurrence.
Unbalance Level
Allows the user to set the voltage unbalance trip level.
Unbalance Delay "
Provides a delay period prior to a trip occurrence
Rebalance
Underload Level "
Determines the trip level as a percentage of the motors full
load current.
Underload Delay
Provides a delay period prior to a trip occurrence.
Option
Off, On
0 to 30 seconds
0 to 90% locked rotor torque
0 to 99% (0 is the Off setting)
0 to 99 seconds
0 to 199% (0 is the Off setting)
0 to 999% (0 is the Off setting)
0 to 999% (0 is the Off setting)
0.0 to 10.0 seconds
0 to 25% (0 is the Off setting)
0 to 99 seconds
Off (not used in MV Dialog Plus)
0 to 99% (0 is the Off setting)
0 to 99 seconds
! The Dual Ramp feature is available only with the standard controller.
" The delay time must be set to a value greater than zero when Overvoltage or Unbalance are enabled.
# For Jam and Underload detection to function, the Motor FLC must be programmed in the Calibration
group. See Chapter 5 for instructions.
$ For Medium Voltage applications, the Undervoltage Level should be set to 80%, and the Undervoltage
Delay should be zero.
Programming
Parameter
Phase Reversal
Allows the user to enable phase reversal protection.
Starts Per Hour #
Allows the user to limit the number of starts during a one
hour period.
Restart Attempts !
Determines the number of attempts the controller will make
to automatically restart the motor after a fault.
Restart Delay !
Provides a delay period prior to a restart attempt.
ETM Reset
Allows the user to reset the accumulated value of the
elapsed time meter.
Parameter Management "
The newly programmed parameter values can be saved to
memory, or the factory defaults parameter values can be
recalled.
4-13
Option
Off, On
0-99 (0 is the Off setting)
0 to 5
0 to 60 seconds
Off, On
Ready, Default Init.,
Recll Frm EE, Store in EE
Example Settings
Undervoltage !
With Line Voltage programmed for 4160 V and the Undervoltage level
programmed for 80%, the trip value is 3328 V.
Overvoltage !
With Line Voltage programmed for 2400 V and the Overvoltage level
programmed for 115%, the trip value is 2760 V.
Jam "
With Motor FLC programmed for 150 Amps and the Jam level
programmed for 400%, the trip value is 600 Amps.
Underload "
With Motor FLC programmed for 90 Amps and the Underload level
programmed for 60%, the trip value is 54 Amps.
!
"
4-14
Programming
Chapter
Calibration
Overview
In the Program mode, enter the correct values into the Calibrate group:
Parameter
Option
Display
Overload Class
The factory default setting disables
overload protection. To enable it, enter
the desired trip class in this parameter.
See pages 1 -5 and 1 -6 for further
details and trip curves.
OVERLOAD CLASS
Overload Reset
Allows the user to select either a manual
or auto reset after an overload fault.
Manual, Auto
OVERLOAD RESET
MANUAL
0.0 6,533.5 hp
MOTOR HP RATING
#### HP
0.0 6,553.5 kW
MOTOR KW RATING
#### KW
1 9,999 V
LINE VOLTAGE
#### VOLTS
Motor FLC !
Enter the value from the motors
nameplate.
1.0 999.9 A
MOTOR FLC
###.# AMPS
Service Factor
Enter the value from the motors
nameplate
0.01 1.99
SERVICE FACTOR
#.##
Line Voltage !
Enter the system voltage in this
parameter. This must be done to
ensure optimum motor performance and
correct operation of undervoltage and
overvoltage protection.
Refer to the SMC Dialog Plus Controller nameplate for maximum ratings. Exceeding these
could result in damage to the controller.
"
The controllers programming system will not allow both HP and kW values to be programmed.
5-2
Calibration
Parameter
Option
Display
A V
LRC Ratio !
IEC motors do not provide a motor code
letter. Consult the motor manufacturer
for the motors locked rotor current/full
load current ratio.
0.0 19.9
LRC RATIO
##.#
Converter Rating
If a Bulletin 825 converter module will
provide current feedback to the
controller, enter the converters rating to
ensure proper current measurement
scaling.
None, 20
CONVERTER RATING
###
CT Ratio "
For controllers using external current
transformers with the 20A converter
module for current feedback, current
transformers with 5A secondaries are
required. Enter the current transformer
ratio in this parameter.
5 through 1200:5
CT RATIO
#### : 5
The controllers programming system will not allow both Motor Code Letter and LRC Ratio to
be programmed.
"
The Dialog module allows selection of most standard current transformer ratios. The only valid
ratio below 50:5 is 5:5. Motors with full load currents less than 30 amperes would normally use
a current transformer with a lower ratio (e.g. 30:5). This ratio cannot be selected on the dialog
module, so it is recommended that a valid ratio be used whenever possible. If an unlisted ratio
is used, the current can be read from the Dialog module by programming a different ratio, and
using an external correction factor. For example: If the motor FLC is 22 amperes, and a 30:5
current transformer is used, the Dialog module can be programmed for a 300:5 current
transformer. When the motor is drawing 22 amperes, the Dialog display will read 220 amperes.
The display value needs to be multiplied by 0.1 to obtain the actual motor current.
Table 5.A
Motor Codes
Letter Designation
kVA/hp #
Letter Designation
kVA/hp #
0 3.15
9.0 10.0
3.15 3.55
10.0 11.2
3.55 4.0
11.2 12.5
4.0 4.5
12.5 14.0
4.5 5.0
14.0 16.0
5.0 5.6
16.0 18.0
5.6 6.3
18.0 20.0
6.3 7.1
20.0 22.4
7.1 8.0
22.4 and up
8.0 9.0
Locked kVA per horsepower range includes the lower figure up to, but not including, the higher
figure. For example, 3.14 is designated by letter A, and 3.15 by letter B.
Chapter
Metering
Overview
While the SMC Dialog Plus controller operates your motor, it also
monitors several different parameters, providing a full function metering !
package.
Action
Display
AT SPEED
###.# AMPS
CHOOSE MODE
______
CHOOSE MODE
DISPLAY
CHOOSE GROUP
______
CHOOSE GROUP
METERING
6-2
Metering
Action
Display
VOLTS PHASE A-B
### VOLTS
VOLTS PHASE B-C
### VOLTS
VOLTS PHASE C-A
### VOLTS
CURRENT PHASE A
###.# AMPS
CURRENT PHASE B
###.# AMPS
CURRENT PHASE C
###.# AMPS
WATTMETER
##### kW
KILOWATT HOURS !
##### kWH
ELAPSED TIME
##### HOURS
POWER FACTOR
.##
MTR. THERM USAGE
## %
! Refer to page 1-10 for details on the metering functions.
Chapter
Options
Overview
The SMC Dialog Plus controller offers a variety of unique control options
that provide enhanced motor starting and stopping capabilities. (See
pages 1-12 to 1-15 for brief descriptions of each option.)
Note:
The control buttons available with the Bulletin 1201 human interface
modules are compatible with the SMC Dialog Plus controller's control
options. The following table details the function of each button with
respect to each option.
Notes:
Option
Action
Operation
The green start button, when pressed,
will commence motor acceleration to full
speed.
Soft Stop
Pump Control
7-2
Options
Action
Operation
The green start button, when pressed,
will commence motor acceleration to full
speed.
Preset Slow
Speed
Smart Motor
Braking
Options
Programming Parameters
7-3
Soft Stop
Pump
Control
!
Parameter
SMC Option
This parameter identifies the type of
control present and is not user
programmable.
Soft Stop
0-60 seconds !
SMC Option
This parameter identifies the type of
control present and is not user
programmable.
Pump Control
0120 seconds !
Starting Mode
Allows the user to program the SMC
Dialog Plus controller for the type of
starting that best fits the application.
SMC Option
This parameter identifies the type of
control present and is not user
programmable.
Preset Slow
Range
Forward, Reverse
Thermal capacity limits must not be exceeded. The base rating for MV Dialog units is 30 seconds
maximum. Consult factory if settings over thirty seconds are required. The base rating of the MV
Dialog Plus is two starts (or one start/stop combination per hour), thirty seconds maximum for each
operation. A stopping operation counts as a start for purposes of thermal capacity calculations.
"
Slow speed running is not intended for continuous operation due to reduced motor cooling. The two
starts per hour limitation also applies to slow speed operation.
7-4
Options
Programming Parameters
(cont.)
Option
SMB Smart
Motor Braking
Parameter
SMC Option
This parameter identifies the type of control
present and is not user programmable.
Braking Current #
Allows the user to program the intensity of
the braking current applied to the motor.
SMC Option
This parameter identifies the type of control
present and is not user programmable.
Slow Speed Select
Allows the user to set the slow speed that
best fits the application.
Slow Speed
with Braking
"
Range
SMB Braking
Braking Current !
Allows the user to program the intensity of
the braking current applied to the motor.
! All braking/stopping current settings in the range of 1100% will provide 100 % braking current to the
motor.
" Slow speed running is not intended for continuous operation due to reduced motor cooling. The two
starts per hour limitation also applies to slow speed operation.
Options
7-5
Figure 7.1
Soft Stop Option Sequence of Operation
100%
Coast-to-rest
Motor
Speed
Start
Push Buttons
Start
Stop
Soft Stop
Run
Soft Stop
Time (seconds)
Closed
Open
Closed
Open
Closed
Open
Auxiliary
Contacts
Soft Stop Operation
Normal
Coast-to-rest Operation
Up-to-speed
7-6
Options
Figure 7.2
Pump Control Option Sequence of Operation
Coast-to-rest
100%
Motor
Speed
Start
Run
Soft Stop
Time (seconds)
Push Buttons
Start
Closed
Open
Stop
Closed
Open
Pump Stop
Closed
Open
Auxiliary
Contacts
Pump Stop Operation
Normal
Coast-to-rest Operation
Up-to-speed
Options
7-7
Figure 7.3
SMB Smart Motor Braking Sequence of Operation
100%
Motor
Speed
Start
Push Buttons
Start
Stop
Soft Stop
Run
Brake
Time (seconds)
Closed
Open
Closed
Open
Closed
Open
Auxiliary
Contacts
Smart Motor Braking Operation
Normal
Coast-to-rest Operation
Up-to-speed
7-8
Options
Figure 7.4
Preset Slow Speed Option Sequence of Operation
100%
7 or 15%
Motor
Speed
Slow
Speed
Start
Run
Coast
Time (seconds)
Push Buttons
Start
Stop
Closed
Open
Closed
Open
Slow Speed
Closed
Open
Auxiliary
Contacts
Normal
Up-to-speed
Options
7-9
Figure 7.5
Slow Speed with Braking Option Sequence of Operation
100%
Braking
Motor
Speed
Slow
Speed
Push Buttons
Start
Run
Brake
Time (seconds)
Start
Stop
Closed
Open
Closed
Open
Slow Speed
Closed
Open
Auxiliary
Contacts
Normal
Up-to-speed
7-10
Options
Chapter
Serial Communications
Overview
The SMC Dialog Plus controller can be started, stopped, and programmed
through PLCs or SLCs using an optional Bulletin 1203 communication
module. Additionally, parameter data can be read to the logic controller
through block transfer. The amount of information that can be transferred
from the SMC Dialog Plus controller is determined by the DIP switch
settings on the communication module.
Note: Parameter values modified while the motor is operating are not
valid until the next start sequence begins.
The information in Table 8.A provides the logic control information that
can be sent to the SMC Dialog Plus controller through the logic controller's
output image table.
Table 8.A
Logic Control Data
Logic Bits !
15
14
13
12
11
10
Description
6
X
X
X
X
Definition
0
Stop "
Start "
Option Command
Clear Faults #
1
0
1
0
1
0
1
0
= Stop
= Not Stopped
= Start
= Not Start
= Option Init.
= Not Option Init.
= Clear Faults
= Not Clear Faults
"
The stop bit will take priority when more than one bit is asserted. Other bits will be ignored until the stop bit is reset.
Control Wiring
Refer to Figure 1.18(c) or 1.18(d) on pages 1-24 and 1-25 respectively for
the applicable wiring diagram to achieve start-stop control via the
SCANport.
8-2
Serial Communications
Control Enable
Description
Action
Display
STOPPED
0.0 AMPS
CHOOSE MODE
_____
CHOOSE MODE
PROGRAM
PROGRAM
_____
PROGRAM
LINEAR LIST
LOGIC MASK
0
85
LOGIC MASK
0
85
LOGIC MASK
4
85
LOGIC MASK
4
85
Note:
Serial Communications
8-3
The Information in Table 8.B provides the SMC Dialog Plus controller
status information that can be sent to the logic controller's input image table.
Table 8.B
SMC Status Data
Logic Bits
15
14
13
12
11
10
Description
6
X
X
Enabled !
Running
Not Used
Not Used
X
X
X
X
Definition
Starting
Stopping
Fault
At Speed
1 = Enabled
0 = Not Enabled
1 = Running
0 = Not Running
1 = Starting
0 = Not Starting
1 = Stopping
0 = Not Stopping
1 = Faulted
0 = Not Faulted
1 = At Speed
0 = Not At Speed
Reference/Feedback
The SMC Dialog Plus controller does not support the analog reference
feature of SCANport. However, the SCANport analog feedback feature is
supported. The feedback word will always be equal to Parameter
number 4, Current Phase A.
Parameter Listing
Refer to Appendix B, Table B.1 for a complete listing of the SMC Dialog
Plus controller's parameters and groups. In addition to the range of
adjustments, the parameters' units are provided.
The parameter values of the SMC Dialog Plus controller are stored as
unscaled numbers. When reading parameter data in the PLC/SLC's input
image table, divide this number by the scale factor shown in Appendix B,
Table B.1 to arrive at the proper value.
When writing from the PLC/SLC's output image table to the SMC Dialog
Plus controller, the scale factor must be taken into consideration to ensure
that the proper value is sent.
8-4
Serial Communications
Some parameter setting options use a text description when viewed from
the built-in LCD display or a human interface module. For example, the
parameter Starting Mode has the available settings of Soft Start and Current
Limit Start. Table B.2, found in Appendix B, provides the required display
unit decimal equivalent for use when sending a command from a logic
controller to the SMC Dialog Plus controller.
Datalinks/SLC Block
Transfers
The SMC Dialog Plus controller does not offer Datalinks. To communicate
with an SLC logic controller, use the 1747-SN (Series B) scanner. Refer to
the scanner user manual for instructions on block transferring data between
the SMC Dialog Plus controller and an SLC processor.
Interfacing
Processing Time
The typical time for the SMC Dialog Plus controller to process a single
parameter data request (i.e., block transfer) via the SCANport is approximately 100 milliseconds. Keep this value in mind when determining the
message length of multiple parameter value read or write operations.
Serial Communications
8-5
12
11
21
13
22
24
25
26
19
18
17
16
15
14
23
L3
5
L2
3
L1
1
27
1747-SN Scanner
28
20
29
30
2
SH
1
Rem I/O
Rem I/O STS
Rem I/O ACT
Health
V+
V- SCANbus STS
G
Note:
FAULT
1203-GD1
Communication Module
It is critical that during the system design phase that each device
on the Remote I/O link is allocated a unique segment of the
SLC's I/O image table. This is accomplished by coordination of
the device's rack address, rack size and starting group address.
8-6
Serial Communications
Switch Setting
02
Last Rack
No
Yes
Yes
Fault Controller
No
115 k
Block Transfer
No !
Logic Cmd/Status
Yes !
Reference/Feedback
Yes !
Datalinks
No !"
8 7 6 5 4 3 2 1
SW3
8 7 6 5 4 3 2 1
Not Used
Not Used
On
On
On
On
Off
On
SW2
8 7 6 5 4 3 2 1
SW1
Switch Settings
Block Transfer On
Logic Cmd/Sts On
Reference/Fdbk Off
Datalink A Off
Datalink B Off
Datalink C Off
Datalink D Off
Truncate Last Datalink Off
Serial Communications
8-7
G-File Configuration
The SLC system uses G-files to configure the R I/O link. G-files are
configured through the SLC programming software. The configuration is
based on the devices connected to the R I/O link. For this example, the
following G-file configuration map for the scanner's I/O image file of the
SMC Dialog Plus controller applies.
Address !
G1:0
G1:1
G1:2
15
xxxx
0000
0000
Data
xxxx
xxxx
0001 0000
0001 0000
0
xxxx
0000
0000
Description
Word 0 cannot be edited.
Logical device address (rack 2, start group 0)
Logical Image size (1/4 rack)
! Words 3 and 4 do not require configuration since the communication module does not support
Complimentary I/O.
I/O Addressing
The 1203-GD1 communication module uses
one-slot addressing.
Based on the module switch settings as described above, the discrete I/O
can be mapped to the PLC I/O Image as shown below.
SLC I/O Image Table Map
SLC I/O Group Number
Output Image
Input Image
Logic Command
Logic Status
Reference "
Feedback
" The output image word that maps to the Reference word (O: 1.17, in this example) must have the value 0
to ensure proper SMC Dialog Plus controller operation.
Addressing format
I : 1 0 / 12
I for input or O for output
Slot number
Word number
Input or output number
(bit identifier: 015)
8-8
Serial Communications
Slot "
Word #
Bit $
Address
Stop
16
00
O:1.16/00
Start
16
01
O:1.16/01
Option Command
16
02
O:1.16/02
Clear Fault
16
03
O:1.16/03
Bit Description
Slot "
Word #
Bit %
Address
Enabled
16
00
I:1.16/00
Running
16
01
I:1.16/01
Bit Description
Starting
16
04
I:1.16/04
Stopping
16
05
I:1.16/05
Fault
16
07
I:1.16/07
At Speed
16
08
I:1.16/08
I or O
Slot "
Word #
Address
17
I:1.17
The addresses shown are example-specific. Addresses for any given installation can be
determined, based upon the 1203-GD1 communication module switch settings for: rack
address, starting group number, block transfer, logic commands/status, and
reference/feedback by applying the I/O addressing format for SLC 500 controllers.
"
Based on the 1203-GD1 communication module switch settings (rack 2, starting group 0).
Refer to the 1747-SN User Manual, Publication 1747-6.6.
$
%
Serial Communications
8-9
SMC
START
Command
: 1.16
Second Rung: When the Machine STOP push button is pressed, the SLC sends a STOP command to the SMC Dialog Plus controller. (The stop
button is a normally closed contact in this example.) The branch provides a logic "latched" circuit which exerts the STOP command until the feedback
from the SMC Dialog Plus controller indicates that it has received the command and has responded appropriately.
SMC
STOP
Command
: 1.16
Machine
STOP
Push Button
: 1.8
1
SMC
STOP
Command
: 1.16
SMC
Running
Bit
: 1.16
0
1
Third Rung: The SMC Dialog Plus controller's Current Phase A value returned by the analog feedback word (I:1.17 in this example) is moved every
scan to integer file 7, element 2.
MOV
MOVE
Source:
I:1.17
Dest:
N7:2
8-10
Serial Communications
12
11
21
13
22
24
17
16
15
14
23
L3
5
L2
3
L1
1
25
26
19
18
27
1747-SN
B Scanner
1747-SNSeries
Scanner
28
20
29
30
2
SH
1
Rem I/O
Rem I/O STS
Rem I/O ACT
Health
V+
V- SCANbus STS
G
FAULT
1203-GD1
Communication Module
Serial Communications
8-11
Switch Setting
Last Rack
Yes
Yes
Yes
Fault Controller
Yes
57 k
Block Transfer
Yes
Logic Cmd/Status
Yes
Reference/Feedback
No
No !
Datalinks
Output Image
Input Image
Rack Size
Start at Group
Block Transfer
Block Transfer
1/4
0!
Logic Command
Logic Status
8 7 6 5 4 3 2 1
SW3
8 7 6 5 4 3 2 1
Not Used
Not Used
On
On
On
On
On
On
SW2
8 7 6 5 4 3 2 1
SW1
Switch Settings
Block Transfer On
Logic Cmd/Sts On
Reference/Fdbk Off
Datalink A Off
Datalink B Off
Datalink C Off
Datalink D Off
Truncate Last Datalink Off
8-12
Serial Communications
Setting the scanned input and scanned output words to less than 32 can reduce the
processor scan time by transferring only part of the input and output image that your
application requires. It is important that you do not set either of these values to 0.
2. [F7], G-FILE SIZE to specify the number of words required for the I/O
module, 3 for standard operation, 5 if using complementary I/O. (In
this application example, G-File size = 3.)
3. [F6], MODIFY G-FILE
Word 0 of the G-File is configured automatically by the processor
according to the particular specialty I/O module. Word 0 cannot be
edited.
Word 1, Primary/Normal Logical Device Address Specifies the
logical starting address of each primary/normal RIO link device. The
logical address consists of the logical rack number (0, 1, 2 or 3) and
starting logical group (0, 2, 4 or 6). Each bit in this word represents a
logical address. To specify an address (in binary mode), you enter a 1
at the bit corresponding to the starting logical address of each logical
device. (For this SMC Dialog example application, Word G1/16 = 1,
indicating logical rack 0, starting group 0.)
Serial Communications
8-13
BT
BTR
BTW
Block Transfer
Block Transfer Read
Block Transfer Write
8-14
Serial Communications
BT Control Buffer Layout The following table maps integer files starting at
N10:0 with the associated M0 file location as defined in the sample ladder
logic program that follows.
BT Control Datafile
Control Flags
BT Length
BT Logical Address !
Address
N10:0
"
64
Bulletin 1203 communication modules use full slot addressing. Refer to the 1747-SN scanner manual
for complete details to determine a BT logical address.
"
This word is set by the ladder logic program. Refer to the 1747-SN scanner manual for Control Flag
Definitions.
N10:10
1!
11
! This is a fixed value, associated with the "Continuous Parameter Value Read" function.
Serial Communications
8-15
Data Path for the BTW Rung 2:6 of the sample ladder-logic program that
follows executes a COP instruction to the M0 file to load the necessary
data for the BTW.
Address
0123456789
Address
N10:0
M0:1.100
N10:10
M0:1.110
N10:20
M0:1.120
N10:30
M0:1.130
N10:40
M0:1.140
N10:50
M0:1.150
N10:60
M0:1.160
N10:70
M0:1.170
0123456789
BTR Datafile Format A BTR Datafile must also be defined to accept the
data read during the BTR operation. For this example, the BTR Datafile
will begin at address N10:110.
BTR Datafile
Header Word
PLC Decimal Value
Number of Parameter Values to Read
Starting Parameter Number
Address
N10:110
15
11
#1
#2
#3
#4
#5
#6
N10:120
#7
#8
#9
#10
#11
Message OK:
Message Error:
Note:
1
-32767
The values of parameters 1-11 read from the SMC Dialog Plus
controller are loaded into addresses N10:114 through N10:124.
8-16
Serial Communications
Data Path for the BTR Rung 2:5 of the sample ladder logic program that
follows executes a COP instruction to copy the data obtained from the
BTR to program-defined integer file.
Address
0123456789
Address
M1:1.100
N10:100
M1:1.110
N10:110
M1:1.120
N10:120
M1:1.130
N10:130
M1:1.140
N10:140
M1:1.150
N10:150
M1:1.160
N10:160
M1:1.170
N10:170
0123456789
Serial Communications
8-17
First Scan
S:1
15
MOV
MOVEMOVE
Source
Source
0
Dest Dest
N10:0
128
N10:0
128
Rung 2:1
2:1
Rung
Copy the
the BT
BTStatus
StatusBits
Bitsfrom
fromthe
the1747-SN
1747-SNinto
into
Virtual
Status
Buffer.
Copy
thethe
Virtual
BTBT
Status
Buffer.
MOV
MOVE
MOVE
Source
M1:1.100
Source M1:1.100
*
Dest N10:100N10:100
Dest
0
0
Rung2:2
2:2
Rung
Thisrung
rungsets
setsupupthe
theBTBTbuffer
bufferforfor
a BTW.
This
a BTW.
User
Logic
BTR_Avail
BTW_Avail
Virtual
BT_Enable
Bit
Virtual
BTW = 0
BTR = 1
N10:0
B3:0
I:1.0
I:1.0
N10:0
10
13
15
7
Virtual
Virtual
BT_Enable
BT_Enable
Bit
Bit
N10:0
L
Rung2:3
2:3
Rung
This
rung
turnsoffoffthe
theVirtual
VirtualBT_Enable
BT_Enable
when
a BTW
completed.
This rung turns
when
a BTW
hashas
completed.
Virtual
BTW = 0
BTR = 1
Virtual
BT Done
Bit
N10:0
Virtual
BT_Enable
Bit
N10:100
U
15
13
15
8-18
Serial Communications
BTR_Avail
B3:0
Virtual
BTW = 0
BTR = 1
N10:0
I:1.0
L
7
Virtual
BT_Enable
Bit
N10:0
10
L
15
Rung 2:5
This rung copies the BTR data from the 1747-SN, clears the Virtual BT_Enable, and clears the User Logic Bit.
BTR_Avail
Virtual
Virtual
BTW = 0
BT Done
BTR = 1
Bit
I:1.0
N10:0
10
N10:100
7
COP
COPY FILE
Source #M1:1.100
Dest #N10:100
Length 74
13
Virtual
BT_Enable
Bit
N10:0
U
15
User
Logic
B3:0
U
1
Rung 2:6
This rung copies the BT information to the 1747-SN for execution.
COP
COPY FILE
Source #N10:0
Dest #M0:1.100
Length 74
Rung 2:7
2:7
Rung
END
END
Serial Communications
8-19
The information in the data table listed below was obtained from a 150 hp
motor, 1800 RPM rated at 480 volts. The motor was operating continuously
for a period of 72 hours.
Parameter
Description
Parameter
Number
Display
Value
470
Wattmeter
474
Current Phase A
Current Phase B
Current Phase C
!
Parameter
Description
Parameter
Number
Display
Value
7!
90.0
Kilowatt Hours
82
469
Elapsed Time
72
4!
120.0
Power Factor
10!
.92
5!
120.0
11
80
6!
120.0
Motor Thermal
Usage
Refer to Appendix B and apply the scale factor to above parameters in the data table below.
Address
Data
B3:0
Address
(Radix = BINARY)
0000
Data
0000
0000
0000
(Radix = DECIMAL)
N10:0
N10:10
N10:20
N10:30
N10:40
N10:50
N10:60
N10:70
N10:80
N10:90
N10:100
128
4
0
0
0
0
0
0
0
0
0
64
1
0
0
0
0
0
0
0
0
64
0
11
0
0
0
0
0
0
0
0
0
0
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
N10:110
N10:120
N10:130
N10:140
N10:150
N10:160
N10:170
N10:180
N10:190
N10:200
15
900
0
0
0
0
0
0
0
0
1
82
0
0
0
0
0
0
0
11
72
0
0
0
0
0
0
0
1
92
0
0
0
0
0
0
0
470
80
0
0
0
0
0
0
0
474
0
0
0
0
0
0
0
0
469
0
0
0
0
0
0
0
0
M0:1
M0:2
M0:3
M0:4
File Length:
File Length:
File Length:
File Length:
3300
0
0
0
M1:1
M1:2
M1:3
M1:4
File Length:
File Length:
File Length:
File Length:
3300
0
0
0
Address
G1:0
Data
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
(Radix = HEX)
2020
0001
000F
8-20
Serial Communications
12
11
21
13
22
24
25
26
19
18
17
16
15
14
23
L3
5
L2
3
L1
1
27
28
20
29
30
2
SH
1
Rem I/O
Rem I/O STS
Rem I/O ACT
V+
Health
V- SCANbus STS
G
FAULT
1203-GD1
Communication Module
Note: It is critical that, during the system design phase, each device on
the Remote I/O link is allocated a unique segment of the PLC's I/O
image table. This is accomplished by coordination of the device's
rack address, rack size and starting group address.
Serial Communications
8-21
Switch Setting
02
Last Rack
No
Yes
Yes
Fault Controller
No
115 k
Block Transfer
Yes !
Logic Cmd/Status
Yes!
Reference/Feedback
No !
No !"
Datalinks
8 7 6 5 4 3 2 1
SW3
8 7 6 5 4 3 2 1
Not Used
Not Used
On
On
On
On
Off
On
SW2
8 7 6 5 4 3 2 1
SW1
Switch Settings
Block Transfer On
Logic Cmd/Sts On
Reference/Fdbk Off
Datalink A Off
Datalink B Off
Datalink C Off
Datalink D Off
Truncate Last Datalink Of
8-22
Serial Communications
I/O Addressing
The 1203-GD1 communcation module uses one-slot addressing. Based on
the module switch settings as described above, the discrete I/O can be
mapped to the PLC I/O Image as shown below.
PLC I/O Group Number
Output Image
Input Image
Block Transfer
Block Transfer
Logic command
Logic Status
Addressing Format
I : 02
I for input or O for output
2-digit I/O rack number
I/O group number (0-7)
Input or output number
(octal bit address; 0-7, 10-17)
0 / 12
Serial Communications
8-23
Rack
Group
Bit "
Address
02
10
I:020/10
02
11
I:020/11
02
12
I:020/12
02
13
I:020/13
02
14
I:020/14
02
15
I:020/15
Bit Description
Rack
Group
Bit #
Address
Stop
02
00
O:021:00
Start
02
01
O:021/01
Option Command
02
02
O:021/02
Clear Fault
02
03
O:021:03
I or O
Rack
Group
Bit $
Address
Enabled
02
00
I:021/00
Running
02
01
I:021/01
Starting
02
04
I:021/04
Stopping
02
05
I:021/05
Fault
02
07
I:021/07
At Speed
02
10 %
I:021/10
Bit Description
! The addresses shown are example-specific. Addresses for any given installation can be determined,
based upon the 1203-GD1 communication module switch settings for: rack address, starting group
number, block transfer, logic command/status, and reference/feedback by applying the I/O addressing
format for PLC-5 controllers.
" Refer to Figure 3.1 of the Bulletin 1203 Remote I/O Communication Module.
# Refer to Table 8.A.
$ Refer to Table 8.B.
% This is the octal address representation for this bit.
8-24
Serial Communications
BTR
(EN)
(DN)
(ER)
It is critical that care is given to all file assignments to ensure that no overlapping or overwriting occurs.
Serial Communications
8-25
N10:10
769!
19
! This is a fixed value, associated with the Parameter Value Read function.
BTR Datafile:
Header Word 1
PLC Decimal Value
Parameter Number
Parameter Value
Address
N10:90
6!
"
19
"
Message OK:
Message Error:
If a message error occurs, the error code will be presented here. See Table 5.A of the Bulletin 1203
Remote I/O Communications Module Reference Manual, Publication 1203-5.0, for a listing of the error
codes and descriptions.
769
-31999
8-26
Serial Communications
First Rung: When the Machine START push button is pressed, the PLC sends a START command to the SMC Dialog Plus controller. The SMC Dialog
Plus controller will start if no STOP command is being issued by the PLC or any other control device. (The start button is a normally open contact in this
example.)
Machine
SMC
START
START
Push Button
Command
: 016
: 021
01
11
11
01
Second Rung: When the Machine STOP push button is pressed, the PLC sends an OPTION command ("pump stop" in this example) to the SMC
Dialog Plus controller. (The stop button is a normally closed contact in this example.) The branch provides a logic "latched" circuit which exerts the
OPTION command until the feedback from the SMC Dialog Plus controller indicates that it has returned to a "stopped" status (not running).
SMC
Machine
OPTION
STOP
Command
Push Button
: 021
: 016
12
SMC
OPTION
Command
: 021
02
SMC
Running
Bit
: 021
02
01
Third Rung: The SMC Fault Bit initiates a PLC block transfer write to the communication module, requesting a parameter value read (SMC
Dialog Plus controller Parameter 19, Fault Buffer #1, in this example).
BT
Read
Available
BTR_AVAIL
SMC
Fault
Bit
: 021
07
: 020
12
BT
Error
BT_ERROR
BT
Write
Available
BTW_AVAIL
: 020
15
BTW
BLOCK TRNSFR WRITE
Rack:
Group:
Module:
Control Block:
Data File:
Length:
Continuous:
(EN)
02
0
0
BT11:0
N10:10
3
N
(DN)
(ER)
: 020
14
Fourth Rung: A block transfer read occurs whenever the communication module's BT Read Available status bit is true, in this example, the
communication module responds to the PLC request (BTW in the third rung) by supplying the value stored in Parameter 19.
BT
Read
Available
BTR_AVAIL
: 020
12
BTR
BLOCK TRNSFR READ
Rack:
Group:
Module:
Control Block:
Data File:
Length:
Continuous:
(EN)
02
0
0
BT11:1
N10:90
4
N
(DN)
(ER)
Serial Communications
DeviceNet Examples
8-27
SLC 5/04
1747-SDN Scanner
DeviceNet Trunk
1203-GK5
Communication Module
SMC DialogPlus
Controller
Notes:
1) 1747-SDN scanner firmware revision 3.01 or later required.
2) 1203-GK5 module firmware revision 1.9 or later required.
8-28
Serial Communications
125k
No !
Yes
Yes
Yes
Switch Settings
13
Switch Settings
SW2, Switches 1, 3 & 4 (On)
Switches 2, 5 & 6 (Off)
SW2, Switches 7 & 8 (Off)
SW1, Switches 1 4 (Off)
Serial Communications
8-29
Output Data
Input Data
1
2
Logic Command
Reference !
Logic Status
Feedback "
! The SMC Dialog Plus Controller does not utilize this feature; a value of
zero should be given.
" The feedback word is the value of parameter 4, Current Phase A.
After you have your network "project" configured in the DeviceNet Manager
software, and perform a Network Who, the following screen will appear:
Notice that the SMC Dialog Plus controller is identified as node 13,
which was configured by setting the DIP switches on the 1203-GK5
communication module.
8-30
Serial Communications
Select the Edit Scan List option by clicking on the button; the following
screen will appear:
Notice that the SMC Dialog Plus controller (node 13) has an active
status. This means that it is active in the scan list and will communicate
with the 1747-SDN scanner on the network.
Serial Communications
8-31
You will also notice that Yes is listed twice under the Mapped column.
The left-side Yes indicates that input data is mapped from the SMC Dialog
Plus controller to the SLC-500. The right-side Yes indicates that output
data from the SLC-500 is mapped to the SMC Dialog Plus controller.
Configure the 1747-SDN if No is displayed.
To view the actual areas inside the SLC-500 processor where the device
data will be transferred to and from, select the Datatable Map by clicking
on the button; the following screen will appear:
This indicates that the SMC Dialog Plus controller's input data is mapped
to words 7 and 8.
By clicking the ratio button next to Output, the output data mapping can
be seen; the following screen will appear:
8-32
Serial Communications
This indicates that the SLC-500's output data associated with the SMC
Dialog Plus controller is mapped to words 7 and 8.
Given this data table mapping, following are the individual logic command
and status bit addresses for the SMC Dialog Plus controller:
SMC Dialog Plus Controller Logic Command Addresses !
Bit Description
Address
Stop
Start
Option Command
Clear Fault
O:1.7/00
O:1.7/01
O:1.7/02
O:1.7/03
Address
Enabled
Running
Starting
Stopping
Fault
At Speed
O:1.7/00
O:1.7/01
O:1.7/04
O:1.7/05
O:1.7/07
O:1.7/08
Serial Communications
8-33
Explicit Messaging
The 1747-SDN scanner module uses the M0 and M1 file areas for data
transfer. Words 224 through 256 must be used to execute the Explicit
Message Request and Response functions. The minimum data size for an
Explicit Message Request is 6 words and the maximum is 32 words.
Following is the data format to follow for a scattered parameter value read
(Get Attribute Multiple) as used in this example:
Explicit Message Request (Get Attribute Multiple)
15
0
TXID
PORT
SERVICE
Word 0
COMMAND
SIZE
MAC ID
CLASS
INSTANCE
ATTRIBUTE
PARAMETER
PATA PLACE HOLDER
Word 31
0
TXID
PORT
SERVICE
Word 0
STATUS
SIZE
MAC ID
PARAMETER
DATA
Word 31
8-34
Serial Communications
Service !
Class !
Instance !
0E
0F
Par.# "
10
0F
Par.# "
32
93
34
93
Attribute !
Serial Communications
8-35
Sequence of Events
Use the following sequence of events as a guide for establishing explicit
messages in your SLC ladder logic:
1. Put the Explicit Message Request data into an integer (N) file of the
SLC-500 processor.
2. Use the file copy instruction (COP) to copy the Explicit Message
Request data entered in step one to the M0 file, words 224 through 256.
3. Use the examine-if-closed instruction (XIC) to monitor bit 15 of the
scanners Module Status Register for an indication that it has received
a response from the 1203-GK5 communication module.
4. Copy the data from the M1 file, words 224 through 256, into a file in
the SLC-500 processor using the file copy instruction (COP).
5. Use the move instruction (MOV) to copy a one-word file from the
SLC-500 processor into word 224 of the M0 file. The upper byte of the
word should contain the TXID value for this transaction and the lower
byte should contain the value 4 which is the command for the scanner
to clear its response buffer. After the move is completed, bit 15 of the
scanners Module Status Register should go to a value of zero,
allowing the next explicit message to be executed.
8-36
Serial Communications
"
"
"
TXID
Command
Port
Size
Service
MAC ID
Class
Instance
Attribute
File
N11:0
0l 01
00 2E
32 0D
0093
0000
0000
0001
0001
0002
0001
Parameter Number
Data Place Holder
Parameter Number
Data Place Holder
Parameter Number
Data Place Holder
Parameter Number
Data Place Holder
Parameter Number
Data Place Holder
"
"
"
"
"
"
File
N11:10
0003
0001
0004
0001
0005
0001
0006
0001
0007
0001
Parameter Number
Data Place Holder
Parameter Number
Data Place Holder
Parameter Number
Data Place Holder
Parameter Number
Data Place Holder
Parameter Number
Data Place Holder
"
"
"
"
"
"
File
N11:20
0008
0001
0009
000A
000B
0001
Note:
There is no required value for the words identified as "Data Place Holder".
Serial Communications
8-37
8-38
Serial Communications
+D=FJAH
'
Diagnostics
Overview
Protection Programming
Many of the protective features available with the SMC Dialog Plus
controller can be enabled and adjusted through the programming parameters
provided. For further details on programming, refer to the Advanced Setup
section in Chapter 4, Programming.
Fault Display
The SMC Dialog Plus controller comes equipped with a built-in, two-line,
16-character LCD. The LCD displays the fault message on the first line
and the fault code on the second line.
Figure 9.1
Fault Display
OVERLOAD
F7
Note:
Clear Fault
Important: Resetting a fault will not correct the cause of the fault condition.
Corrective action must be taken before resetting the fault.
You can clear a fault using any of several methods:
Program the SMC Dialog Plus controller for a Clear Fault, which can
be found in the Faults and Linear List groups.
9-2
Diagnostics
Fault Buffer
The SMC Dialog Plus controller stores the five most recent faults in
memory. Display the fault buffer by selecting the Faults group and
scrolling through the fault buffer parameters. The information is stored
as fault codes. To determine what faults have occurred, use the fault
code cross-reference below.
Fault Codes
Table 9.A provides a complete cross-reference of the available fault codes
and corresponding fault descriptions.
Table 9.A
Fault Code Cross-Reference
Fault Description
Power loss A fault
Power loss B fault
Power loss C fault
Undervoltage fault
Overvoltage fault
Stall
Overload fault
Controller temp fault
Underload fault
Imbalance fault
Line A fault
Line B fault
Line C fault
Line fault
Phase reversal fault
Jam fault
Cur. Feedback loss
Comm fault
Start A firing fault
Start B firing fault
Start C firing fault
Line A fault
Line B fault
Line C fault
Line fault
Power loss A fault
Power loss B fault
Power loss C fault
Excess starts/Hr
System fault
COMM fault
MPU COMM fault
Fault Number
1
2
3
4
5
6
7
8
9
10
11
12
13
15
16
19
20
21
23
24
25
26
27
28
29#
30
31
32
64
128 140
Fault Type
Line
Line
Line
Line
Line
Line
Current
Hardware
Current
Current
Line
Line
Line
Line
Line
Current
Current
Hardware
Current
Current
Current
Current
Current
Current
Current
Current
Current
Current
Unexpected condition
SCANport disconnected
Internal COMM fault
Parameter Number
1/2/3
1/2/3
1/2/3
51 52
54 / 55
37
36 / 70 / 72 / 84 / 88
60 / 61
58
1/2/3
1/2/3
1/2/3
1/2/3
62
56 / 57
70
70
70
70
70
70
70
70
70
70
70
63
Diagnostics
9-3
The auxiliary contact is located at terminals 29 and 30. This contact can
be programmed as either Normal or Fault. Note that the state this contact
takes upon power-up (normally open or normally closed) can be programmed.
These parameters can be found in either Basic Setup, Advanced Setup, or
the Linear List groups when modifying parameters in the Program mode.
Fault Definitions
Power Loss K
Power loss indicates than an input power phase is not present. The controller's
LCD display will identify the missing phase.
Note: If all three phases are absent when a start command is issued, the
LCD will display "Starting" without motor rotation.
Line Fault L
Line fault, with the affected phase displayed, identifies three possible
pre-start conditions:
Line fault, with no phase indication, is displayed when one of the following
conditions occurs while the SMC Dialog Plus controller is in the run mode:
Phase loss
Load loss
Shorted SCR
Phase Reversal K
Phase reversal is indicated when the incoming power to the SMC Dialog
Plus controller is in any sequence other than ABC. This pre-start protective
feature can be disabled.
9-4
Diagnostics
Voltage Unbalance M
Voltage unbalance is detected by monitoring the three-phase supply voltages.
The formula used to calculate the percentage voltage unbalance is as follows:
Vu = 100 (Vd / Va)
Vu: Percent voltage unbalance
Vd: Maximum voltage deviation from the average voltage
Va: Average voltage
The controller will shut down when the calculated voltage unbalance
reaches the user-programmed trip percentages.
Stall Protection
Stall protection is enabled at the end of the programmed ramp time after a
motor has been started. If the controller senses that the motor is not up to
speed at the end of ramp, it will shut down after the user-selected delay
time has elapsed.
Jam Detection N
Jam detection operates when the SMC Dialog Plus controller status is "at
speed". The controller will shut down when the motor current reaches the
user-defined trip level, which is based on a percentage of the programmed
motor full-load current rating.
Overload Protection
Overload protection is enabled in the Calibration group by programming the:
Overload class
Overload reset
Motor FLC
Service factor
Underload MN
Underload protection is available for undercurrent monitoring. The controller will shut down when the motor current drops below the trip level.
This trip level, a percentage of the motor's full-load current rating, can be
programmed.
M
N
Diagnostics
9-5
Excess Starts/Hour
Controller Temp
Controller temp is an indication that a power pole's maximum rated
temperature has been reached. The controller's microprocessor monitors
the temperature of the SCRs by using internal thermistors. When the
controller detects an over-temperature condition, the microprocessor
turns off the SCRs and displays the appropriate fault code.
An overtemperature condition could indicate the presence of inadequate
ventilation, high ambient temperature, overloading, or excessive cycling.
If an overtemperature condition exists at start-up, the SCR gate signals will
be inhibited and the controller will trip and indicate the fault. The fault
can be immediately reset. However, the motor cannot be restarted until
after the controller temperature falls below trip levels.
The temperature signal line is also used as a control signal. A "Controller
Temp" trip may also indicate a problem with other hardware in the system.
Refer to Table 10.A.
Comm Fault
The SMC Dialog Plus controller disables control through the serial
communication port as the factory default. To enable control, the Logic
Mask parameter (#85) found in the Linear List programming group must
be set to "4". With Series B human interface modules, this can also be
accomplished by enabling control logic through the Control Status
programming group.
If a Bulletin 1201 human interface module or Bulletin 1203 communication
module is disconnected from the SMC Dialog Plus controller when control
is enabled, a Comm Fault will occur.
9-6
Diagnostics
Chapter
10
Troubleshooting
Note: The time required for the motor to come up to speed may be more or
less than the Start Time setting, and will vary depending on the
frictional load and inertial characteristics of the system.
Note: Depending on the application, the SMB Smart Motor Braking
and Slow Speed options may cause vibration and noise during the
operating cycle, and this may be minimized by lowering the current
setting. Consult the factory prior to applying these options.
For MV Dialog Plus technical support on start-up or existing installations, contact your
Rockwell Automation representative. You can also call 1-519-623-1810 for assistance
Monday through Friday from 7:30 a.m. to 5:15 p.m. (Eastern time zone).
10-2
Troubleshooting
Fault Identification
Troubleshooting
Fault Code
Power Loss !
(with phase indication)
F1, F2, F3
Line Fault !
(with phase indication)
F11
F12
F13
Table 10.A
Fault Display Explanation
Possible Causes
Possible Solutions
F26
F27
F28
F15
Undervolt
F4
the time delay is too short for the
application
Overvolt
F5
Stall
F6
Overload
F7
m otor overloaded
overload parameters are not
m atched to the motor
Controller
Temperature
F8
Underload
F9
F10
Voltage
Unbalance
10-3
10-4
Troubleshooting
Fault code
Phase reversal
F16
Jam
F19
F20
Comm Fault
F21
Open Gate
(with phase indication)
F23 - F25
!
"
Excess starts
per hour
F64
System Faults
F128
And above
Possible Causes
incoming supply voltage is not in
the expected ABC sequence
motor current has exceeded the
user-programmed jam level
Connection between Bul. 825
current module is lost
communication disconnection at
the serial port
open gate circuitry
Possible Solutions
Check power wiring.
Correct the source of the jam.
Check cable. Replace cable.
Check for a communication cable disconnection to the
SMC Dialog Plus module.
Check SCR gate resistance.
Check gate lead connections to gate driver boards.
Check gate drive system; gate driver board, fibre optics,
interface board, by performing power supply tests.
Replace divider board.
Wait an appropriate amount of time to restart.
Increase the number of starts per hour setting.
NOTE: The SMC is rated for only two starts per hour.
Contact the factory if the application requires more
frequent starts.
Replace control module.
Replace control module.
Troubleshooting
10-5
Table 10.B
Motor Will Not Start No Output Voltage to the Motor
Display
Fault displayed
Possible Cause
See fault description
Display is blank
Failed control module
Stopped
0.0 Amps
Starting
Possible Solutions
Pilot devices
SMC Enable input is open at
terminal 13
Terminal 15 is open on Soft
Stop, Pum p Control and SMB
Start-Stop control has not
been enabled for the hum an
interface module
Control voltage
Failed control module
Check wiring
Check wiring
Check wiring
Follow the instructions on pages
2-9 to 2-11 to enable control
capability
Check control voltage
Replace control module
Table 10.C
Motor Rotates (but does not accelerate to full speed)
Display
Fault displayed
Starting
Possible Cause
Possible Solutions
M echanical problems
Table 10.D
Motor Stops While Running
Display
Fault displayed
Possible Cause
See fault description
Display is blank
Failed control module
Stopped
0.0 Amps
Starting
Possible Solutions
Pilot devices
Failed control module
10-6
Troubleshooting
Table 10.E
Miscellaneous Situations
Display
Motor current and
voltage fluctuates with
steady load
Possible Cause
M otor
Erratic load
Possible Solutions
Verify type of motor as a standard
squirrel cage induction motor
Check load conditions
Loose connections
Starting time
Initial torque
Current limit setting
Kickstart
Starting time
Initial torque
Current limit setting
Kickstart
Erratic operation
Time setting
M isapplication
M isapplication
Duty cycle
Winding fault
Motor overheats
Note: For Pump Stop issues, refer to Application Considerations on page 1-13.
Troubleshooting
10-7
The control module is not intended for field repair. The entire module
must be replaced in the event of failure. The following procedure must be
followed before unplugging the control module.
1. Remove all power from the equipment.
ATTENTION: To avoid shock hazard, ensure the main
power has been disconnected before working on the
controller, motor or control devices. Verify that all
circuits are voltage free using a hot stick or appropriate
voltage measuring device. Failure to do so may result in
burns, injury or death.
2. Make sure that the wires are properly marked and that the program
parameters are recorded.
3. Disconnect all control wires to control module.
4. Loosen the six control module screws.
5. Unplug the control module from the interface board by pulling forward.
10-8
Troubleshooting
Feedback Voltage
(VLG)
System Voltage
(VLL)
Feedback Voltage
(VLG)
1000
210 230
4160
177 197
1300
210 230
4800
206 226
1500
171 - 191
6600
195 215
2400
191 211
6900
204 224
3300
205 225
If any voltage is well outside this range, there may be a problem either with
the system voltage, or with the voltage divider for the affected phase. Note
that the load side voltages (T1, T2, T3) will be very low, since the SCRs
are not turned on, and only a low leakage current flows to the motor.
If the motor will start and run, the line and load voltages should be the
same when the bypass contactor is closed.
Troubleshooting
10-9
Power Circuit
Troubleshooting
Thyristor Testing
If a power semiconductor is suspected of malfunctioning, it may be
checked as follows:
1. Remove all power from the equipment.
ATTENTION: To avoid shock hazard, ensure the main
power has been disconnected before working on the
controller, motor or control devices. Verify that all
circuits are voltage free using a hot stick or appropriate
voltage measuring device. Failure to do so may result in
burns, injury or death.
1000 V
1300 V
1500 V
2300 V
3300 V
4160 V
6900 V
Cathode to Cathode !
22K-30K
23K-31K
24K-32K
17K-23K
19K-25K
20K-27K
21K-29K
40K-53K
43K-57K
64K-84K #
Cathode to Gate
10-40
10-40
10-40
10-40
10-40
10-40
10-40
!
"
#
Measured between terminals Cathode on SPGD Boards, upper two or bottom two within a phase.
Measured between terminals Cathode on SPGD Boards, top to bottom within a phase.
Measured between line and load terminals within a phase.
10-10
Troubleshooting
Power Circuit
Troubleshooting (cont.)
Note: The actual resistance value depends on the ohmmeter used, the
particular brand/rating of thyristor, and external circuit influences.
It is impossible to accurately measure the condition of the thyristor
when it is unclamped!
3. If a short circuit is suspected, the thyristor must be isolated from all
surrounding circuitry (i.e. unplug gate and cathode leads, and remove
snubber and resistor circuit leads from the driver boards). Measure
resistance to confirm state of the thyristors. If the thyristors are not
shorted, proceed to snubber and resistor circuit testing, following this
procedure.
4. If a faulty device is found, the entire heatsink assembly must be
removed.
ATTENTION: For heatsink assemblies containing four or
more thyristors, the entire matched set shall be replaced.
Devices connected in series must have performance specifications matched for proper operation. Failure to use
matched sets may result in damage to the devices.
5. Complete heatsink assemblies with matched thyristors are available as
a renewal part (see Appendix C). In most cases, the assembly can be
dismantled to replace the SCRs.
Troubleshooting
Power Circuit
Troubleshooting (cont.)
10-11
10-12
Troubleshooting
Power Circuit
Troubleshooting (cont.)
Troubleshooting
Power Circuit
Troubleshooting (cont.)
10-13
10-14
Troubleshooting
Figure 10.1
Low Voltage Panel & Power Cell Detail (1562D) 400A, 2400 V to 4160 V
Voltage
Feedback
Board
Troubleshooting
10-15
Figure 10.2
1000/1300/1500/2400 Volt Heatsink Assembly, 180/360 A
Heatsink 2B
Heatsink 2A
Heatsink 1
Heatsink 3
SCR 1
SCR 2
Figure 10.3
Heatsink Clamp
Gap
Centre Nut
Locking Nut
Indicating Washer
10-16
Troubleshooting
Figure 10.4
Removal of SCR1
To Remove SCR1:
Remove shorting bar hardware
Pry Heatsinks 1 and 2A apart
Extract SCR
To Insert New SCR:
Apply thin film of electrical joint compound to surfaces of SCR
Install SCR so that it is seated in locating pin of heatsink (note
orientation of SCR).
Pry heatsinks to close gap, ensuring that SCR is seated properly
in both its locating pins.
Rotate SCR so that all leads have same direction.
Heatsink 1
Locating Pin
Figure 10.5
Removal of SCR2
Shorting Bar Hardware
SCR 2
Heatsink 3
Heatsink 2B
Locating Pin
Troubleshooting
10-17
Figure 10.6
3300/4160 Volt Heatsink Assembly, 180/360 A
Heatsink 4
Heatsink 5
Heatsink 3
Heatsink 2
Heatsink 1
To replace devices, place assembly on a flat
surface. Note that capacitor and board
assembly must overhang the edge of the flat
surface.
SCR1 and SCR3 are a matched pair.
SCR2 and SCR4 are a matched pair.
SCR 4
SCR 1
SCR 3
SCR 2
Figure 10.7
Heatsink Clamp
Gap
Centre Nut
Locking Nut
Indicating Washer
10-18
Troubleshooting
Figure 10.8
Removal of SCR4
To Remove SCR4:
Remove shorting bar hardware
Pry Heatsinks 4 and 5 apart
Extract SCR
To Insert New SCR:
Apply thin film of electrical joint compound to surfaces of SCR
Install SCR so that it is seated in locating pin of heatsink (note
orientation of SCR).
Pry heatsinks to close gap, ensuring that SCR is seated properly
in both its locating pins.
Rotate SCR so that all leads have same direction.
Proceed to replace SCR's matched pair (SCR2).
Locating Pin
Heatsink 5
Figure 10.9
Removal of SCR2
Shorting Bar Hardware
SCR 2
Locating Pin
Note: Similar procedure used to remove and replace SCR matched pair 1 and 3.
Troubleshooting
10-19
Figure 10.10
6900V Module, 180/360 A
Line connection
Load connection
Figure 10.11
6900V Module with Gate Driver Boards Removed, 180/360 A
Board mounting frame
Line connection
Load connection
10-20
Troubleshooting
Figure 10.12
6900V Module with Boards and Frame Removed, 180/360 A
Module retaining hardware locations (4)
Line connection
Load connection
Troubleshooting
10-21
Figure 10.13
6900V Heatsink Assembly, 180/360 A
Positioned on bench for SCR replacement
SCR4
SCR5
SCR6
SCR3
SCR2
SCR1
Heatsink 7
Heatsink 1
Heatsink 6
Heatsink 2
Heatsink 5
Heatsink 3
Heatsink 4
Figure 10.14
6900V SCR Replacement, 180/360 A
Do not loosen
Centre Nut
Locking Nut
(Do not adjust)
Indicating Washer
Do not loosen
Gap
1560D-5.1 February 2000
10-22
Troubleshooting
Figure 10.15
Removing and Replacing SCRs (SCR2 shown)
Extracted SCR
Locating pin
Figure 10.16
2300V Heatsink Module, 800A
Sharing Resistor
Snubber Capacitor
Snubber Resistors
Heatsink Assembly
Frame Assembly
Troubleshooting
10-23
Figure 10.17
3300 and 4160V, 800A Heatsink Module
Snubber Capacitor
Snubber Resistors
Snubber Capacitor
Heatsink Assembly
Sharing Resistors
Figure 10.18
6900V, 800A Heatsink Module
Snubber Capacitors
Snubber
Resistors
Gate Driver
Boards
Heatsink Assembly
Sharing Resistors
Snubber Capacitors
Frame Assembly
10-24
Troubleshooting
If the resistance checks from the Thyristor testing section were abnormal
and the thyristors checked out OK, there may be a problem in the snubber
or resistor circuits.
1. Remove all power from the equipment.
ATTENTION: To avoid shock hazard, ensure main power
has been disconnected before working on the controller,
motor or control devices. Verify that all circuits are voltage
free using a hot stick or appropriate voltage measuring
device. Failure to do so may result in burns, injury or death.
2. a) For units rated over 2000 volts:
Disconnect wires IL1, IT1, IL2, IT2, IL3, IT3 from the Voltage
Feedback board. On the 1562D, 400A, 2400V to 4160V, the voltage
feedback board is located on the back of the low voltage panel or
on the left side of the structure. Consult OEM documentation for
the location of the feedback board on the 1503D. Measure the
resistance from the end of each of these wires to the following
points on the gate-driver boards:
IL1 to Phase A cathode, top position
IT1 to Phase A cathode, bottom position
IL2 to Phase B cathode, top position
IT2 to Phase B cathode, bottom position
IL3 to Phase C cathode, top position
IT3 to Phase C cathode, bottom position
b) For units rated 1500 volts or less:
Disconnect wires 2L1, 2T1, 2L2, 2T2, 2L3, 2T3 from the Voltage
Feedback board. Measure resistors R7 to R12 and verify the
readings per the chart below.
The measured resistance based on the rated voltage of the MV
Dialog Plus should be per the chart below.
Rated Voltage
Resistance 2%
1000 V
20 K
1300 V
30 K
1500 V
50 K
2400 V
75 K
3300 V
100 K
4160 V
150 K
6900 V
224 K
Troubleshooting
10-25
The feedback voltages given are based on the stated system voltage. If the
actual system voltage is different, the feedback voltages will be scaled by
the actual system voltage divided by the value in the chart on page 10-8.
For example, if the actual system voltage is 2337 volts, the feedback
voltage should be (2337 / 2400) x (191 to 211), or 186 to 205 volts.
If these measurements are abnormal, the voltage divider resistor
board located behind the SCR/heatsink assemblies or next to the
left-hand sideplate, must be checked for proper connections or
replaced if necessary. See instructions for removing SCR stack
from unit on page 10-10.
3. Measure from each terminal (IL1, IT1, IL2, IT2, IL3, IT3) on the
Voltage Feedback board to RGND terminal (ground). Each reading
should be 12.5 kilohms to 12.9 kilohms. If measurements are abnormal,
remove the seven-pin, green connector from the lower edge of the
board and repeat the measurements. If still abnormal, replace the
Voltage Feedback board. If readings are normal, replace the seven-pin
connector, remove the Dialog Plus control module from the interface
board, and repeat the measurements. If still abnormal, replace the
Interface board. If readings are normal, replace the Dialog Plus control
module.
4. If no abnormal readings were found in points (2) and (3) above, check
the snubber components and sharing resistors by isolating them and
measuring values as follows (See Figures 10.19, 10.20 or 10.21):
RS 60 (200 & 400 A)
30 (800 A)
CS 0.5 or 0.68 F (200 & 400 A)
1.0 F (800 A)
RR 32.5 k total, taps at 2.5 k from each end.
Replace any out-of-spec components. See Renewal Parts listing in
Appendix B.
5. When repairs are complete, re-assemble all parts, check all fasteners,
and verify all connections are correct and tight. Make sure all barriers
and mechanical parts are in place and secured.
ATTENTION: Make sure ground wires from the Voltage
Feedback board are securely connected to the ground bar in
the low voltage panel. Failure to do so may result in severe
injury or equipment damage.
6.
10-26
Troubleshooting
When replacing the surface-mount style snubber resistor used in this product,
it is very important to apply a thin layer (approximately 0.02 inches or
0.5 mm) of electrical joint compound to both the resistor mounting surface
and the surface to which it is mounted. Some compound may already be
present from the old resistor, but it is best to wipe the area clean and apply
a fresh layer with your finger or a lint-free cloth. This will ensure a good
thermal interface between the two surfaces, which is essential for optimum
performance and life of the resistor. A small container of compound will
be supplied with the replacement resistor; however, if more is required, it
can be ordered from Rockwell Automation by part number RU-6052.
When installing the mounting screws, alternately tighten each screw
gradually to ensure uniform pressure distribution over the mounting
surface. Wipe off any excess compound that may have squeezed out while
tightening the mounting screws.
T
OV1
S1
C1
G1
C1
OV
Snub
G1
C1
GD1
C1
Cath
OV1
RS
HS2
Thermistor
RR1
CS
OV2
S2
C2
OV
Snub
Cath
Line
HS3
Figure 10.19
1500/2400 Volt Module Wiring
HS1
Thermistor
G2
C2
OV2
G2
C2
GD2
HS4
C2
Load
10-27
Troubleshooting
LEGEND:
10-28
Troubleshooting
C1
OV
Snub
G1
C1
GD1
C1
Cath
S2
C2
C2
OV
Snub
Thermistor
G2
C2
OV2
G2
C2
C2
GD2
Cath
HS3
CS1
C3
OV3
S3
C3
OV4
S4
C4
OV
Snub
G3
Load
C3
Cath
G3
C3
OV3
CS2
GD3
Line
OV1
RS1
RR1
OV2
HS2
RR2
HS4
OV4
C4
OV
Snub
Cath
G4
GD4
G4
C4
RS2
C4
HS5
LEGEND:
RR1 RR2 .............. Sharing Resistor
RS1 RS ................ Snubber Resistor
CS1 CS2 .............. Snubber Capacitor
HS1 HS5 .............. Heatsink
G1 G4 ................... Gate Lead (White)
C1 C4 ................... Cathode Lead (Red)
Figure 10.20
3300/4160 Volt Module Wiring
S1
G1
C1
C2
OV2
OV3
RR1
HS1
C3
C1
Cath
GD1
CS1
G1
Cath
C4
RS1
Snub
OV
GD4
G4
HS2
C1
OV1
OV1
C4
S4
OV4
OV4
G2
C2
RR2
HS3
C4
Line
Thermistor
SPGDB
Figure 10.21
6900 Volt Module Wiring
Snub
OV
C1
S1
G1
C1
G3
C3
HS4
T
RS2
CS2
0V2
S2
C2
OV3
S3
C3
G4
C4
0V
Snub
Cath
G2
GD2
HS5
C2
0V
Snub
Cath
G5
C5
G3
GD3
C3
HS6
C5
C5
Cath
GD5
Snub
OV
C6
Cath
RS3
GD6
G6
CS3
SPGDB
Snub
OV
C6
S6
OV6
G6
C6
C5
HS7
OV5
OV6
RR3
LEGEND:
C6
10-29
Troubleshooting
G5
S5
OV5
Load
10-30
Troubleshooting
Chapter
11
Maintenance
The Maintenance Technician should become familiar with the layout and
be aware of the basic system parameters. Only qualified technicians should
be allowed to work with this equipment under competent supervision.
General housekeeping is the key to maintaining power electronic and
electrical equipment. They are to be kept as dust free as possible. A
scheduled program of inspection will reduce the possibility of problems.
Periodic Inspection
Contamination
If inspection reveals that dust, moisture or other contamination has reached
the control equipment, the source must be eliminated. This could indicate
an incorrect or ineffective enclosure, unsealed enclosure openings (conduit
or other) or incorrect operating procedures. Dirty, wet or contaminated parts
must be replaced unless they can be cleaned effectively by vacuuming or
wiping.
11-2
Maintenance
Vacuum Bottles
The contacts in a vacuum bottle cannot be seen or examined directly.
They rely on the high vacuum to operate properly and to interrupt current.
Visually inspect the wear of the main contacts with the contacts closed.
When any part of the wear indicator, located on the front side of the hex
shaft, moves up into the bearing, replace all three vacuum bottles (see
Publication 1502-5.0).
The vacuum level should be tested periodically by applying high voltage
alternating current across the open bottle using a vacuum tester or Hi-Pot
equipment (see Publication 1502-5.0).
Terminals
Loose connections can cause overheating that can lead to equipment
malfunction or failure. Check the tightness of all terminals and bus bar
connections and securely tighten any loose connections. Replace any
parts or wiring damaged by overheating.
Coils
If a coil exhibits evidence of overheating (cracked, melted or burned insulation), it must be replaced. In that event, check for and correct overvoltage
or undervoltage conditions, which can cause coil failure. Be sure to clean
any residues of melted coil insulation from other parts of the device or
replace such parts.
Maintenance
11-3
Solid-State Devices
Solid-state devices require little more than a periodic visual inspection.
Printed circuit boards should be inspected to determine whether all cables
are properly seated in their connectors. Board locking tabs should also be in
place. Necessary replacements should be made only at the PC board or
plug-in component level. Solvents should not be used on printed circuit
boards. Where blowers are used, air filters, if supplied, should be cleaned
or changed periodically depending on the specific environmental conditions
encountered. For additional information see NEMA Standards Publication
No. ICS 1.1 - 1987 entitled "Safety Guidelines for the Application, Installation
and Maintenance of Solid State Control".
ATTENTION: Use of other than factory recommended test
equipment for solid-state controls may result in damage to
the control or test equipment, or unintended actuation of the
controlled equipment.
Static-Sensitive Items
While performing maintenance on the MV SMC, special precautions must
be observed in handling or touching certain static-sensitive components in the
cabinet. Most circuit cards and SCRs can be damaged by Electro-Static
Discharge (ESD). If personnel will make contact with an ESD-sensitive
component during maintenance, they must be grounded. Grounding should
be accomplished with a wrist strap which is connected to an approved
ground.
11-4
Maintenance
Power Components
Power components should be kept clean and free of dirt and obstructions.
This will avoid tracking and heat build-up, thereby increasing the life of
the device.
Fans
Physically rotating and observing the fans for noise or binding will
indicate if fan failure is evident.
Interlocks
Verify that interlocks function as intended, and have not been forced,
damaged or removed.
Barriers
Verify that all barriers are in place and securely fastened.
Appendix
Parameter Information
Table A.1
Parameter List
Group
Parameter Description
Voltage Phase A-B
Metering "
Faults
Basic Setup
Parameter
Number
Display
Units
Scale
Factor
Minimum
Maximum
Default
Setting
User
Setting
Volts
Volts
Volts
Current Phase A
Amps
10
Current Phase B
Amps
10
Current Phase C
Amps
10
Wattmeter !
kW
10
Kilowatt Hours !
kWh
Elapsed Time
Hours
Power Factor !
10
100
11
Clear Fault
18
No
19
20
21
22
23
14
Starting Mode
28
Ramp Time #1
30
Seconds
No, Yes
30
Soft Start
10
Initial Torque #1
31
% LRT
90
70
34
% FLC
50
600
50
Kickstart Time
35
Seconds
10
0.0
2.0
0.0 (Off)
Stall Delay
37
Seconds
10
0.0
10.0
0 (Off)
Energy Saver #
38
Off, On
39
Normal, Up-to-speed
Up-to-speed
Off
Aux. Contact 3
40
Normal, Fault
Fault (1560D)
Normal (1562D)
Contact 3 Configuration
41
N.O., N.C.
N.C. (1560D)
N.O. (1562D)
Parameter Mgmt.
17
Ready
"
Read-only capability.
The Series A SMC Dialog Plus module does not provide power functions when used in the MV Dialog Plus controller.
A-2
Parameter Information
Parameter Description
Parameter
Number
Display
Units
Scale
Factor
Minimum
Maximum
Default
Setting
60 "
Control Options
Soft Stop
Soft Stop Time
42
Seconds
Starting Mode
28
42
Seconds
44
Low, High
High
45
Reverse, Forward
Forward
46
% FLC
450
47
% FLC
450
48
% FLC
400
44
46
% FLC
450
47
% FLC
450
Braking Current
48
% FLC
400
Pump Control
Soft Start, Current Limit
and Pump Start
0
120 "
Soft Start
0
High
" Thermal capacity limits must not be exceeded. The base rating for MV Dialog units is 30 seconds max. Consult factory for higher settings.
User
Setting
Parameter Information
A-3
Advanced
Setup
Parameter
Number
Display Units
Scale
Factor
Dual Ramp
29
Ramp Time #2
32
Seconds
Initial Torque #2
33
% LRT
90
70
Undervoltage Level
52
% Line Voltage
0!
99
80
Undervoltage Delay
53
Seconds
99
Overvoltage Level
54
% Line Voltage
199
0 (Off)
Overvoltage Delay
55
Seconds
99
Jam Level
56
% FLC
999
0 (Off)
Jam Delay
57
Seconds
10
0.0
10.0
Parameter Description
Minimum
Maximum
No, Yes
0
Default
Setting
No
30
10
Unbalance Level
58
25
0 (Off)
Unbalance Delay
86
Seconds
99
Rebalance "
59
User
Setting
Off, On
Off
Underload Level
60
% FLC
99
0 (Off)
Underload Delay
61
Seconds
99
Phase Reversal
62
63
Restart Attempts
64
Restart Delay
65
Seconds
ETM Reset
15
Off, On
Off
Parameter Management
17
Ready
Off, On
Off
99
60
A-4
Parameter Information
Calibrate
Parameter
Number
Display Units
Scale
Factor
Overload Class
36
Off
Overload Reset
88
Manual Auto
Manual
Motor HP Rating
79
HP
10
0.0
6,553.5
0.0
Motor kW Rating
80
kW
10
0.0
6,553.5
0.0
Line Voltage
69
Volts
9999
350 #
Motor FLC
70
Amps
10
1.0
999.9
1.0
Service Factor
84
100
0.01
1.99
1.05
72
LRC Ratio
81
10
Converter Rating
74
Parameter Description
Minimum
Maximum
A,B,C,D,E,F,G,H,J,K,L,
M,N,P,R,S,T,U and V
0.0
0.0
20
5:5
Off
CT Ratio
75
Calibration
76
Off, Activate
77
Amps
Amps
10
17
19.9
Parameter Management
Default
Setting
0.01
999.9
0.0
Ready
"
Read-only capability.
The scale factor is 100 when Motor FLC, parameter 70, has a programmed value of up to 10.0 amps; above 10.0 amps, the scale factor is 10.
User
Setting
Parameter Information
A-5
Table A.2
Parameter Text/Display Unit Cross-Reference
Parameter Number
Description
14
SMC Option
15
ETM Reset
17
Parameter
Management
18
Clear Fault
28
Starting Mode
29
Dual Ramp #
36
Overload Class
38
39
40
Aux. Contact 3
41
Contact 3 Config.
44
45
59
Rebalance "
62
Phase Reversal
Setting Text
Display Unit
Standard
Soft Stop
Pump Control
Preset Slow Speed
Smart Motor Braking
Accu-Stop "
Slow Speed with Braking
Off
On
Ready
Default Init.
Recall From EE
Store in EE
No
Yes
Current Limit
Soft Start
Pump Start !
No
Yes
Off
10
15
20
30
Off
On
Normal
Up-to-speed
Normal
Fault
N.O.
N.C.
Low
High
Reverse
Forward
Off
On
Off
On
0
1
2
3
4
5
6
0
1
0
1
2
3
0
1
0
1
2
0
1
0
1
2
3
4
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
A-6
Parameter Information
Description
72
74
Converter Rating
75
CT Ratio
88
Overload Reset
Setting Text
Display Unit
A
B
C
D
E
F
G
H
J
K
M
N
P
R
S
T
U
V
None
20
180
630
5:5
50:5
75:5
100:5
150:5
200:5
250:5
300:5
400:5
500:5
600:5
700:5
800:5
1000:5
1200:5
Manual
Auto
0
1
2
3
4
5
6
7
8
9
11
12
13
14
15
16
17
18
0
1
2
3
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
0
1
Appendix
Spare Parts
Table B.1
Bulletin 1503D 1000-1500 Volt, 200/400 Amp, 6-device
Qty per controller
Description
Part Number
180 A
6
80173-005-01-R
80173-007-01-R
360 A
Common Components
3
1
1
1
3
3
3
3
9
9
1
80165-898-52
80165-938-51 or -52
80187-131-51
80187-131-53
80025-871-04
80025-812-01
80025-812-02
80025-753-01
80025-549-03
80025-549-01
80187-051-51
80187-245-51
! If desired, a complete factory assembled SCR/heatsink assembly with snubber resistor and capacitor can be purchased rather than
individual SCRs. See table below for part numbers :
Qty per controller
3
3
3
3
Description
180 Amp, 1000 Volt Controller
360 Amp, 1000 Volt Controller
180 Amp, 1300V and 1500V Controller
360 Amp, 1300V and 1500V Controller
Part Number
80157-863-55
80157-863-56
80157-863-54
80157-863-52
" Requires a thin film of electrical joint compound between base and mounting surface. Available with SCR replacement parts
or separately as Part Number 80025-783-51.
Note :
Reference only.
1503D For OEM products, refer to OEM-supplied documentation for specific spare parts list.
1560/1562D are Allen-Bradley manufactured starters. Refer to Service Manual for specific spare parts list.
B-2
Spare Parts
Table B.2
Bulletin 1503D, 1560D, 1562D 2300 Volt, 200/400 Amp, 6-device
Qty per controller
Description
Part Number
200 A
Individual SCR, DCR820 or 5STP03D6500 (matching not required)
!"
80173-006-01-R
400 A
Individual SCR, DCR1020 or 5STP03D6500 (matching not required)
!"
Common Components
3
Gate Driver Board (2 devices) Series B
1
Voltage Divider Resistor Board 2300 V
1
Voltage Feedback Circuit Board
1
MV SMC Interface Circuit Board Assembly (120 Volt)
1
MV SMC Interface Circuit Board Assembly (230 Volt) Series B
3
Snubber Resistor 60 ohm, 10%, 500 W
3
Snubber Capacitor 0.68 F, 4510 V peak
3
Sharing Resistor, 32.5 k, 225 W, Two 2.5 k Tap
9
Fiber-optic Cable, 2,5 m
9
Fiber-optic Cable, 5.0 m
2
Bridge Rectifier
120 V
2
MOV
240 V
120 V AC (North America)
1
Test Power Supply
Universal
1
LV Control Panel, 110/120 V AC #
1
LV Control Panel, 220/230 V AC
3
Power Fuses #
2
Primary Fuses #
1
LV Fuses
1
Holding Coil, 120 V DC
1
Holding Coil, 230 V DC
1
Closing Coil, 120 V DC
1
Closing Coil, 230 V DC
1
Vacuum Bottles (set of 3)
3
Heater Elements #
2
20 Amp Contact Cartridge #
3
1-pole Blade Assembly (400 Amp) #
Special Lubricant (for Blade Assembly, 400 Amp)
6
80173-007-01-R
80165-898-52
80165-878-51
80165-938-51
80187-131-51
80187-131-53
80025-871-04
80025-812-02
80025-753-01
80025-549-03
80025-549-01
24808-451-01
80145-581-02
80145-581-07
80187-051-51
80187-245-51
80154-991-59
80187-226-52
Consult Engineering Data
Consult Engineering Data
Consult Engineering Data
80153-575-51
80153-575-52
80153-576-51
80153-576-52
80157-496-52
Consult Engineering Data
700-CPM
80145-566-51
40025-198-01
! If desired, a complete factory assembled SCR/heatsink assembly can be purchased rather than individual SCRs.
See table below for part numbers :
Qty per controller
3
3
Description
180 Amp, 2400 Volt Controller
360 Amp, 2400 Volt Controller
Part Number
80157-863-51
80157-863-52
" Requires a thin film of electrical joint compound between base and mounting surface. Available with SCR replacement parts
or separately as Part Number 80025-783-51.
# 1562D only.
Note :
Reference only.
1503D For OEM products, refer to OEM-supplied documentation for specific spare parts list.
1560/1562D are Allen-Bradley manufactured starters. Refer to Service Manual for specific spare parts list.
Spare Parts
B-3
Table B.3
Bulletin 1503D, 1560D, 1562D 2300 Volt, 800 Amp, 6-Device
Qty per controller
3
Description
Part Number
80187-123-51
Note : Due to stringent torquing specifications in this application, it is MANDATORY that the entire heatsink assembly
be replaced. Contact the Rockwell Automation factory.
3
1
1
1
6
3
3
9
9
2
2
1
1
1
3
2
1
1
1
1
3
2
3
3
3
3
80165-898-52
80165-878-51
80165-938-51
80187-131-51
80187-131-53
80025-871-04
80025-812-01
80025-753-01
80025-549-03
80025-549-01
24808-451-01
80145-581-02
80145-581-07
80187-051-51
80187-245-51
80154-991-59
80187-226-54
Consult Engineering Data
Consult Engineering Data
Consult Engineering Data
80025-697-01
Not available
80157-496-56
Consult Engineering Data
700-CPM
80157-709-51
80157-710-51
Consult the Rockwell
Automation factory
Consult the Rockwell
Automation factory
40025-198-01
! 1562D only.
B-4
Spare Parts
Table B.4
Bulletin 1503D, 1560D, 1562D 3300 Volt, 200/400 Amp, 12-device
Qty per controller
Description
Part Number
180 A
SCR, DCR820 or 5STP03D6500 (matched set of 2) !"
80156-893-72-R
360 A
6
SCR, DCR1020 or 5STP03D6500 (matched set of 2) !"
Common Components
3
Gate Driver Board (4 devices) Series B
1
Voltage Divider Resistor Board 3300 V
1
Voltage Feedback Circuit Board
1
MV SMC Interface Circuit Board Assembly (120 Volt) Series B
1
MV SMC Interface Circuit Board Assembly (230 Volt) Series B
6
Snubber Resistor 60 ohm, 10%, 500 W
6
Snubber Capacitor 0.68 F, 4510 V peak
6
Sharing Resistor, 32.5 k, 225 W, Two 2.5 k Tap
15
Fiber-optic Cable, 2,5 m
15
Fiber-optic Cable, 5.0 m
2
Bridge Rectifier
120 V
2
MOV
230 V
120 V (North America)
1
Test Power Supply
Universal
1
LV Control Panel, 110/120 V AC #
1
LV Control Panel, 220/230 V AC
3
Power Fuses #
2
Primary Fuses #
2
LV Fuses
1
Holding Coil, 120 V DC
1
Closing Coil, 120 V DC
1
Vacuum Bottles (set of 3)
3
Heater Elements #
2
20 Amp Contact Cartridge #
3
1-pole Blade Assembly (400 Amp) #
Special Lubricant (for Blade Assembly, 400 Amp)
80156-894-72-R
80165-858-52
80165-878-52
80165-938-51
80187-131-51
80187-131-53
80025-871-04
80025-812-02
80025-753-01
80025-549-03
80025-549-01
24808-451-01
80145-581-02
80145-581-07
80187-051-51
80187-245-51
80154-991-59
80187-226-52
Consult Engineering Data
Consult Engineering Data
Consult Engineering Data
80153-575-51
80153-576-51
80157-496-52
Consult Engineering Data
700-CPM
80145-566-51
40025-198-01
" If desired, a complete factory assembled SCR/heatsink assembly can be purchased rather than individual SCRs.
See table below for part numbers :
Qty per controller
3
3
Description
180 Amp, 3300/4160 Volt Controller
360 Amp, 3300/4160 Volt Controller
Part Number
80157-864-51
80157-864-52
# Requires a thin film of electrical joint compound between base and mounting surface. Available with SCR replacement parts
or separately as Part Number 80025-783-51.
$ 1562D only.
Note :
Reference only.
1503D For OEM products, refer to OEM-supplied documentation for specific spare parts list.
1560/1562D are Allen-Bradley manufactured starters. Refer to Service Manual for specific spare parts list.
Spare Parts
B-5
Table B.5
Bulletin 1503D, 1560D, 1562D 3300 Volt, 800 Amp, 12-device
Qty per controller
3
Description
Part Number
80187-124-51
Note : Due to stringent torquing specifications in this application, it is MANDATORY that the entire heatsink assembly
be replaced. Contact the Rockwell Automation factory.
3
1
1
1
12
6
6
15
15
2
2
1
1
1
3
2
1
1
1
1
3
2
3
3
3
3
80165-858-52
80165-878-52
80165-938-51
80187-131-51
80187-131-53
80025-871-04
80025-812-01
80025-753-01
80025-549-03
80025-549-01
24808-451-01
80145-581-02
80145-581-07
80187-051-51
80187-245-51
80154-991-59
80187-226-54
Consult Engineering Data
Consult Engineering Data
Consult Engineering Data
80025-697-01
Not available
80157-496-56
Consult Engineering Data
700-CPM
80157-709-51
80157-710-51
Consult the Rockwell
Automation factory
Consult the Rockwell
Automation factory
40025-198-01
Note :
Reference only.
1503D For OEM products, refer to OEM-supplied documentation for specific spare parts list.
1560/1562D are Allen-Bradley manufactured starters. Refer to Service Manual for specific spare parts list.
B-6
Spare Parts
Table B.6
Bulletin 1503D, 1560D, 1562D 4160 Volt, 200/400 Amp, 12-device
Qty per controller
Description
Part Number
180 A
SCR, DCR820 (matched set of 2) !"
80156-893-72-R
6
SCR, DCR1020 (matched set of 2) !"
Common Components
3
Gate Driver Board (4 devices) Series B
1
Voltage Divider Resistor Board 4160 V
1
Voltage Feedback Circuit Board
1
MV SMC Interface Circuit Board Assembly (120 Volt) Series B
1
MV SMC Interface Circuit Board Assembly (230 Volt) Series B
6
Snubber Resistor 60 ohm, 10%, 500 W
6
Snubber Capacitor 0.68 F, 4510 V peak
6
Sharing Resistor, 32.5 k, 225 W, Two 2.5 k Tap
15
Fiber-optic Cable, 2,5 m
15
Fiber-optic Cable, 5.0 m
2
Bridge Rectifier
120 V
2
MOV
230 V
120 V (North America)
1
Test Power Supply
Universal
1
LV Control Panel, 110/120 V AC #
1
LV Control Panel, 220/230 V AC
3
Power Fuses #
2
Primary Fuses #
1
LV Fuses
1
Holding Coil, 120 V DC
1
Closing Coil, 120 V DC
1
Vacuum Bottles (set of 3)
3
Heater Elements #
2
20 Amp Contact Cartridge #
3
1-pole Blade Assembly (400 Amp) #
80156-894-72-R
6
360 A
80165-858-52
80165-878-53
80165-938-51
80187-131-51
80187-131-53
80025-871-04
80025-812-02
80025-753-01
80025-549-03
80025-549-01
24808-451-01
80145-581-02
80145-581-07
80187-051-51
80187-245-51
80154-991-59
80187-226-52
Consult Engineering Data
Consult Engineering Data
Consult Engineering Data
80153-575-51
80153-576-51
80157-496-52
Consult Engineering Data
700-CPM
80145-566-51
! If desired, a complete factory assembled SCR/heatsink assembly can be purchased rather than individual SCRs.
See table below for part numbers :
Qty per controller
3
3
Description
180 Amp, 3300/4160 Volt Controller
360 Amp, 3300/4160 Volt Controller
Part Number
80157-864-51
80157-864-52
" Requires a thin film of electrical joint compound between base and mounting surface. Available with SCR replacement parts
or separately as Part Number 80025-783-51.
# 1562D only.
Note :
Reference only.
1503D For OEM products, refer to OEM-supplied documentation for specific spare parts list.
1560/1562D are Allen-Bradley manufactured starters. Refer to Service Manual for specific spare parts list.
Spare Parts
B-7
Table B.7
Bulletin 1503D, 1560D, 1562D 4160 Volt, 800 Amp, 12-device
Qty per controller
3
Description
Part Number
80187-124-51
Note : Due to stringent torquing specifications in this application, it is MANDATORY that the entire heatsink assembly
be replaced. Contact the Rockwell Automation factory.
3
1
1
1
12
6
6
15
15
2
2
1
1
1
3
2
1
1
1
1
3
2
3
3
3
3
80165-858-52
80165-878-53
80165-938-51
80187-131-51
80187-131-53
80025-871-04
80025-812-01
80025-753-01
80025-549-03
80025-549-01
24808-451-01
80145-581-02
80145-581-07
80187-051-51
80187-245-51
80154-991-59
80187-226-54
Consult Engineering Data
Consult Engineering Data
Consult Engineering Data
80025-697-01
Not available
80157-496-56
Consult Engineering Data
700-CPM
80157-709-51
80157-710-51
Consult the Rockwell
Automation factory
Consult the Rockwell
Automation factory
40025-198-01
Note :
Reference only.
1503D For OEM products, refer to OEM-supplied documentation for specific spare parts list.
1560/1562D are Allen-Bradley manufactured starters. Refer to Service Manual for specific spare parts list.
B-8
Spare Parts
Table B.8
Bulletin 1503D, 1560D, 1562D 6900 Volt, 200/400 Amp, 18-device
Qty per controller
Description
Part Number
180 A
180A : Matched Set 3 SCRs DCR820 "
80156-893-73-R
360 A
3
360A : Matched Set 3 SCRs DCR1020 " #
Common Components
9
SCR Gate Driver Board (2 devices)
1
Voltage Divider Resistor Board 6900V
1
Voltage Feedback Circuit Board
MV SMC Interface Circuit Board Assembly (120V)
1
MV SMC Interface Circuit Board Assembly (230V)
9
Snubber Resistor 60 ohm
9
Snubber Capacitor 0.68 F
9
Sharing Resistor 32.5K, 225W
21
Fiber-optic Cable, 2,5 m
21
Fiber-optic Cable, 5.0 m
2
Bridge Rectifier
MOV 120V
2
MOV 230V
Test Power Supply 120V AC (North America)
1
Test Power Supply Universal
6
Voltage Divider Resistors, 74K 100W
1
LV Control Panel, 110/120 V AC "
1
LV Control Panel, 220/230 V AC
3
Power Fuses $
2
Primary Fuses $
1
LV Fuses
1
Holding Coil, 120 V DC
1
Closing Coil, 120 V DC
1
Vacuum Bottles (set of 3)
3
Heater Elements $
2
20 Amp Contact Cartridge $
3
1-pole Blade Assembly (400 Amp) $
Special Lubricant (for Blade Assembly, 400 Amp)
"
80156-894-73-R
80165-898-52
80165-878-53
80165-938-51
80187-131-52
80187-131-54
80025-871-04
80025-812-02
80025-753-01
80025-549-03
80025-549-01
24808-451-01
80145-581-02
80145-581-07
80187-051-51
80187-245-51
80025-588-05
80154-991-59
80187-226-52
Consult Engineering Data
Consult Engineering Data
Consult Engineering Data
80153-575-51
80153-576-51
80157-496-52
Consult Engineering Data
700-CPM
80145-566-51
40025-198-01
If desired, a complete factory assembled SCR/heatsink assembly can be purchased rather than individual SCRs.
See table below for part numbers :
Qty per controller
3
3
Description
180 Amp, 6900 Volt Controller
360 Amp, 6900 Volt Controller
Part Number
80187-140-51
80187-140-52
# Requires a thin film of electrical joint compound between base and mounting surface. Available with SCR replacement parts
or separately as Part Number 80025-783-51.
$ 1562D only.
Note :
Reference only.
1503D For OEM products, refer to OEM-supplied documentation for specific spare parts list.
1560/1562D are Allen-Bradley manufactured starters. Refer to Service Manual for specific spare parts list.
Spare Parts
B-9
Table B.9
Bulletin 1503D, 1560D, 1562D 6900 Volt, 800 Amp, 18-device
Qty per controller
3
Description
Part Number
80187-143-51
Note : Due to stringent torquing specifications in this application, it is MANDATORY that the entire heatsink assembly
be replaced. Contact the Rockwell Automation factory.
9
1
1
1
18
9
9
21
21
2
2
1
6
1
1
3
2
1
1
1
1
3
2
3
3
3
3
80165-898-52
80165-878-53
80165-938-51
80187-131-52
80187-131-54
80025-871-04
80025-812-01
80025-753-01
80025-549-03
80025-549-01
24808-451-01
80145-581-02
80145-581-07
80187-051-51
80187-245-51
80025-588-05
80154-991-59
80187-226-54
Consult Engineering Data
Consult Engineering Data
Consult Engineering Data
80025-697-01
Not available
80157-496-56
Consult Engineering Data
700-CPM
80157-709-51
80157-710-51
Consult the Rockwell
Automation factory
Consult the Rockwell
Automation factory
40025-198-01
Note :
Reference only.
1503D For OEM products, refer to OEM-supplied documentation for specific spare parts list.
1560/1562D are Allen-Bradley manufactured starters. Refer to Service Manual for specific spare parts list.
B-10
Spare Parts
Table B.10
Accessories
Qty per controller
Description
Part Number
80187-194-01
80187-194-02
80187-194-03
80187-194-04
80187-194-05
80187-194-06
Converter Module
825-MCM20
Fanning Strip
Fan (120 V) #
Fan (240 V) #
Fuse Extractor
150-NFS
80025-248-01
80025-248-02
80144-491-02
Note :
Reference only.
1503D For OEM products, refer to OEM-supplied documentation for specific spare parts list.
1560/1562D are Allen-Bradley manufactured starters. Refer to Service Manual for specific spare parts list.
Appendix
Accessories
Table C.1
Accessories
Description
Human Interface
Module
Communication
Module
Description/Used With
Catalog Number
1201-DMA
1201-HAP
1201-HJP
1201-HA1
1201-HA2
1201-HJ2
1203-CN1
1203-GD1
Flex I/O
Communication
Cables
Converter Modules
1203-GD2
1203-GK5
1203-GV6
1203-GK2
1203-FB1
1203-FM1
1201-SM1
1202-C03
1202-C10
1202-C30
1202-C90
825-MCM20
150-NFS
C-2
Accessories
Medium Voltage Business, 135 Dundas Street, Cambridge, ON N1R 5X1 Canada, Tel: (1) 519 623-1810, Fax: (1) 519 623-8930
Multifunctional
Motor Management
Thermal overload
High overload/stalling
Underload
Communications Options
Wye-Delta starting
Phase reversal
Short circuit
Damp Environments,
Mobile Equipment
Dusty Environments
High or Varying
Ambient Temperatures
Protective Functions
Fans, centrifuges
Crushers, mills,
Critical environmental
mixers, rollers
starting cycles
conditions
DeviceNet is a trademark of the Open DeviceNet Vendor Association (O.D.V.A.). SMM is a trademark of Rockwell Automation, a core business of Rockwell International Corporation.
Test Key
verifies correct operation
Reset Key
allows you to reset a trip
Simple Operation
Four keys and an LCD that displays text
allow you to quickly and easily:
program parameters and monitor motor
conditions
troubleshoot motor faults
Easy Startup
The Smart Motor Manager warns you about conditions that may cause
motor failureallowing you to take corrective action before damage
occurs.
Reduced Chance of
Unscheduled Downtime
The Smart Motor Manager models a thermal image of the motor. This
allows maximum use of equipment, even with:
a fluctuating load commonly found in compressor, crusher, mill,
mixer, conveyor, and crane applications
brief overloads
heavy duty startup
phase imbalance
Bulletin 825
Bulletin 825
0.52000 A Current
Range
Modular Construction
Built-in Keypad and LCD
Test and Reset Buttons
Alarm/Trip LED
NEMA 4 (IP65) Housing
Communication Options
Suitable for Low- and
Medium-Voltage
Applications
TABLE OF CONTENTS
Description
Page
Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Product Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Description
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Approximate Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Description
The Bulletin 825 SMM Smart Motor Manager provides the tools necessary to obtain
optimal utilization of motors that operate critical processes. The Smart Motor Manager
can minimize unplanned shutdowns with its comprehensive protective, monitoring,
warning, and diagnostic capabilities. Protective features include: thermal overload,
phase loss, phase reversal, phase imbalance, rapid trip/mechanical jam, ground
(earth) fault, short circuit, over-temperature (thermistor input), underload, stator and
bearing RTD monitoring, start time monitoring, stall during start, and multiple starts.
Some of these features require the installation of an option card.
Conformity to Standards:
Approvals:
IEC 947-4
CSA C22.2 No. 14
UL 508
CE
PTB
CSA Certified
UL Listed
Bulletin 825
Bulletin 825
Imbalance/Phase Loss
The Smart Motor Manager continuously monitors and calculates
the current imbalance of an operational motor. The measured
current imbalance is entered into the thermal image calculation
to simulate the resulting increased motor heating.
User-adjustable trip and warning settings for current imbalance
are available with a preset range of 580% of full-load current.
Phase loss, a severe form of imbalance, is one of the primary
causes of motor failure. A phase loss can occur as a result of a
blown fuse or a poor electrical connection. Under a phase loss
condition, the current draw of the remaining two powered
phases increases by as much as 1.73 times the normal
operating current. The Smart Motor Manager offers two options
for obtaining phase loss protection.
Basic Unit: With the basic unit, phase loss protection is gained
by using the current imbalance (asymmetry) settings.
Cat. No. 825-MLV: This option card provides terminals for
connection to the three-phase power system. With the
connection made before the motor-starting contactor, a phase
loss condition is recognized even while the motor is stopped.
The Smart Motor Managers phase loss protection provides a
preset delay of 2 s prior to a trip.
Underload
A sudden drop in motor current can signal conditions such as:
Pump cavitation
Tool breakage
Belt breakage
In these instances rapid fault detection can help minimize
damage and aid in reducing production downtime.
Additionally, monitoring for underload can provide enhanced
protection for motors that are cooled by the medium being
handled (e.g., submersible water pumps). Such motors can
become overheated despite being underloaded. This can result
from an absence or insufficient amount of the medium (due to
clogged filters, closed valves, etc.).
The adjustment range of the underload trip and warning settings
is 25100% of the motors full load current rating.
Short Circuit
In the event of a short circuit (phase-to-phase or
phase-to-ground), excessive currents, typically much greater
than a motors locked rotor current rating, are generated. Given
the magnitude of this current, it is generally preferable or
necessary to interrupt three-phase power to the motor through
the branch-protecting circuit breaker rather than the
motor-starting contactor due to the differences in the
short-circuit withstand rating.
In the event of a short circuit, the Smart Motor Manager trips
output relay #1 of the option card (Cat. No. 825-MST) regardless
of other protective functions, actuating the circuit breaker with
adequate breaking capacity. To prevent the contactor from
opening under short-circuit conditions, its main relay is blocked
from operating at currents greater than or equal to 12 times the
motors full-load current rating. Tripping is delayed by 50 ms.
Bulletin 825
Outputs
Output Relays
Control Functions
Contactor Operation
The Smart Motor Manager allows control relays #2 and #3 on
the Cat. No. 825-MST option card to be operated over an
automation network (e.g., DeviceNet via the Cat. No. 825-MDN
communication card). The relays will actuate the motor-starting
contactor(s).
Wye-Delta Control
With the Cat. No. 825-MLV option card installed, the Smart
Motor Manager can control the transition from wye to delta. The
command to transition is issued when the starting current has
dropped to the motors full-load current rating, thus minimizing
the associated current transients.
Emergency Restart
If a critical process requires the restart of the motor, the Smart
Motor Manager provides two terminals that, when bridged,
return the stored thermal capacity utilization to zero so that an
emergency restart can be initiated.
The basic unit provides a main relay and an alarm relay. The
main relay can be operated either as electrically held or
non-fail-safe. The Cat. No. 825-MST option card offers three
additional auxiliary relays. Two additional auxiliary relays are
available with the Cat. No. 825-MLV option card.
Isolated Analog Output
The Cat. No. 825-MST option card provides an isolated
420 mA analog output signal. This can be set to indicate one
of the following:
Motor current (as a percentage of the motors full-load current
rating)
Maximum RTD temperature measured
Thermal capacity utilization
Communications
The Smart Motor Manager provides a dedicated communication
expansion slot for connection to the following automation
networks:
DeviceNet
Modbus
Remote I/O
This can enhance process operation by allowing the user to do
the following via the network:
Control the motor starter
Modify settings
Access operational, diagnostic, and historical data
Bulletin 825
Basic
Bulletin 825
Features
Thermal Overload
Phase Imbalance (Asymmetry)
Jam (High Overload/Stalling)
Underload
Ground (Earth) Fault (Holmgreen)
Starting Time Monitor
Limited Starts Per Hour
Emergency Start
Short Circuit
Ground (Earth) Fault (Core Balance CT)
Stalling During Start
Thermistor Input (PTC)
Analog Output for Thermal Utilization
Two-Speed Motor Protection
Wye-Delta (Star-Delta) Starting
Phase Reversal (Sequence)
Phase Failure
Available
Option Cards
Cat. No. 825-MST
The features and protective functions provided by each option card can be monitored through the communication network with any of the
communication cards.
A single communication card (DeviceNet, Modbus or Remote I/O) can be used with any combination of option cards.
Available in shown combination.
Bulletin 825
Cat. No.
Basic Unit
Programmable electronic motor overload protection relay
with communication capability
Thermal Overload
Phase Imbalance
Jam (High Overload)
Underload
Ground (Earth) Fault
Starting Time Monitor
Limited Starts per Hour
825-M
The cat. no. as listed is incomplete. Select a control Voltage Suffix Code from the table below to complete the cat. no. Example: Cat. No. 825-M
for 120V power supply becomes Cat. No. 825-MD.
Voltage AC
24V
120220V
220240V
380415V
440V
Voltage DC
2448V
50/60 Hz
KD
AJ
GB
Code
Z48
Converter Module
Description
Converter Module
Connection to the Smart
Motor Manager is made by
a cable wire plug provided
as standard with the
converter module.
Cat. No.
0.52.5
825-MCM2
2.520
825-MCM20
20180
825-MCM180
IEC:160630
UL/CSA: 160434
825-MCM630
IEC:160630
UL/CSA: 160630
825-MCM630N
10
Current Ratio
Cat. No.
100:1
825-CBCT
Bulletin 825
Cat. No.
825-MST
825-MLV
825-MMV
Communication Card
DeviceNet DeviceNet Conformance Tested (Passed)
825-MDN
Modbus
3600-MB5
Remote I/O
3600-RIO
825-MVM
CAB6-HA1
CAB6-HA1
CAB6-HA2
CAB6-HA3
CAB6-HB2
CAB6-HB3
825-MTUM
11
Bulletin 825
Cat. No.
825-FPM
Connector Sets
Provided as Standard
with option card
825-MCA
825-MPS
825-CSB
825-CSST
825-CSMV
825-CSLV
12
Voltage AC
24V
120220V
220240V
380415V
440V
Voltage DC
2448V
50/60 Hz
KD
AJ
GB
Code
Z48
Bulletin 825
6
4
1
Values
Actual
Set
Recorded
Mode Selection
Display current operating data
Setting mode
(set, change, save, and store parameters)
Display recorded data
Reset
Reset trips
Single Line
(two lines of text are displayed alternately)
Select
LCD
Settings
Change
Enter
Entry
Enable entry
Save entry
Test
Test functions
(Alarm, trip, trip time)
Settings
The following parameters must be programmed for every application. The other parameters (e.g., high overload, asymmetry) have
factory-set values, which are correct for most applications.
Main Settings
Rated motor current or operating current Ie
Use of a primary current transformer
Current ratio of primary current transformer
Locked-rotor current
Locked-rotor time
Setting Range
Factory Setting
0.5...2000 A
No/Yes
1...2000
2.5...12 Ie
1...600 s
20 A
No
1
6 Ie
10 s
If, instead of the permissible locked-rotor time, the maximum starting time is known, the approximate locked-rotor time is calculated as follows:
Locked rotor time = Starting time 1.4
Special Settings
Connection of main relay (MR)
Connection of alarm relay (AL)
Reset of thermal trip
Reset at...% thermal utilization
Reset PTC trip
Cooling constant motor ON/OFF ratio
Motor insulation class
Communication
Setting Range
Factory Setting
Electrically held/non-fail-safe
Non-fail-safe/electrically held
Manual/automatic
10...100%
Manual/automatic
1...5
B/E/F
DeviceNet
Remote I/O
Modbus
Electrically held
Non-fail-safe
Manual
50%
Manual
2.5
B
13
Bulletin 825
Setting
Range
Tripping Delay
Factory
Setting
Relays
Range
Factory
Setting
Selection
Factory
Setting
Protective Functions
Bulletin 825-M basic unit
Thermal overload
Asymmetry/Phase loss
High overload/Stalling
Underload
Underload delay
Earth fault (Holmgreen)
Start time monitoring
Limited number of starts per hour
On
On
On
Off
On
On
Off
Off
5...80%
1...6 Ie
25...100%
10...100%
1...10
35%
2.4 Ie
75%
50%
1...5 s
0.5...25 s
1...60 s
0...240 s
0.1...5 s
1...240 s
2.5 s
0.5 s
10 s
0s
0.5 s
10 s
MR
All
All
All
All
All
All
MR
MR
MR
MR
MR
MR
MR
Option 825-MST
Short circuit
Earth fault (core balance transformer)
Stalling during start
PTC Thermistor input
Off
Off
Off
Off
4...12 Ie
5 mA...50 A
10 Ie
1A
20...990 ms
0.1...5 s
50 ms
0.5 s
800 ms
#1
All
All
All
#1
MR
MR
MR
Option 825-MLV
Phase sequence (motor supply)
Phase loss (motor supply)
Off
Off
1s
2s
All
All
MR
MR
Option 825-MMV
100 Platinum RTD inputs #1...#6 (stator, bearings)
100 Platinum RTD input #7
Off
Off
50...200C
50C
<8 s
MR, AL#1...3
MR
Alarm Functions
Bulletin 825-M basic unit
Thermal utilisation (% load)
Asymmetry (% Ie)
High overload (% IIe)
Underload
Off
Off
Off
Off
50...99%
5...80%
1...6 Ie
25...100%
75%
20%
2 Ie
75%
AL,#1...5
AL,#1...5
AL,#1...5
AL,#1...5
AL
AL
AL
AL
Option 825-MST
Earth fault (core balance transformer)
Off
5 mA...50 A
500 mA
AL,#1...5
AL
Option 825-MMV
100 Platinum RTD inputs #1...#6 (stator, bearings)
Off
50...200C
50C
AL,#1...5
AL
Via external speed switch (control input #1); output relays and time delay as with high overload.
Includes ambient temperature in the thermal image.
Only one relay can be selected per function; MR = main relay, AL = alarm relay, auxiliary relays #1...#5.
14
Bulletin 825
Setting Range
Tripping Delay
Factory
Setting
Relays
Range
Factory
Setting
Selection
Factory
Setting
70%
Y11Y12
4...60 min.
60 min.
0...100%
5...200C
0...200% Ie
Off
Off
Off
0...240 s
0...240 s
1s
2s
#2
#2
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
0.5...2000 A
20 A
0...240 s
0...240 s
1s
2s
#3
#3
Off
Off
Off
Off
Off
Off
Off
Off
Y-:
1.1 Ie
Y-:
1...240 s
10 s
Range
Control Functions
Bulletin 825-M basic unit
Warm start (% of cold trip)
Emergency start
Option 825-MST
Analog output
assigned to:
- Thermal utilisation
- PT100 max. Temperature
- I Motor
Control Auxiliary Relays #2, #3
via communication
Control Input #1: (24V AC/DC; 8 mA)
Alternatively, one of two functions may be selected:
Pick-up delay, relay #2
Drop-out delay, relay #2
Disabling of protective functions:
- Asymmetry/phase loss
- High overload/stalling
- Earth fault
- Short circuit
- Underload
- Limited starts per hour
- Thermistor PTC
- 100 Platinum RTD
Control Input #2: (24V AC/DC; 8 mA)
Alternatively, one of three functions can be selected:
Pick-up delay, relay #3
Drop-out delay, relay #3
Set 2nd rated current
Disabling protective functions:
- Asymmetry/phase loss
- High overload/stalling
- Earth fault
- Short circuit
- Underload
- Limited starts per hour
- Thermistor PTC
- 100 Platinum RTD
Option 825-MLV
Star-Delta starting
Off
Off
50...100%
Jumper
Terminals
On
4...20 mA
Off
Y: #4
: #5
Only one relay can be selected per function; MR = main relay, AL = alarm relay, relays #1...#5
15
Bulletin 825
5...+60C
40...+60C
40...+60C
Climatic Withstand
Damp heat IEC 68-2-3
Climatic cycling IEC 68-2-30
Protection Class
Bulletin 825, enclosed in panel
Terminals
IP65
IP20
Vibration Resistance
per IEC 68-2-6
Shock Resistance
per IEC 68-2-27
10...150 Hz, 3 G
30 G, shock duration 18 ms, half of a sin wave in x, y, z directions
Rated Voltage Ue
825-MCM2
825-MCM20
825-MCM630
825-MCM630N
825-MCM180
Motor Circuit
per IEC, SEV, VDE 0660
per CSA, UL
400V AC
240V AC
660V AC
600V AC
1,000V AC
600V AC
Control Circuit
Main relay (MR) 95...98, supply A1, A2
Phase-sequence protection L1, L2, L3
per IEC 947
per SEV
per CSA, UL
Alarm relay (AL) 13/14, Auxiliary Relays #1, #4, #5
per IEC 947
per SEV
per CSA, UL
Auxiliary Relays #2, #3
Control Inputs #1, #2
400V AC
380V AC
240V AC
400V AC
250V AC
240V AC
120V AC/30V DC
24V AC/DC
Electrical Ratings
Test Voltage
825-MCM2
825-MCM20
825-MCM630
825-MCM630N
825-MCM180
Motor Circuit
per IEC 947-4
Uimp 2.5 kV
Uimp 6 kV
Uimp 8 kV
Control Circuit
Control circuits against each other and against all other sets
Main relay (MR) 95...98, supply A1, A2
Phase sequence protection L1, L2, L3
Alarm relay (AL) 13/14, Auxiliary relays #1, #4, #5
per IEC 947-4
Core-balance transformer k, I
Auxiliary relays #2, #3
Control inputs #1, #2
per IEC 947-4
Uimp 4 kV
Uimp 2.5 kV
EMC Standard
Noise emission
Noise proof
Standards
Approvals
The measuring inputs PT100 and PTC, 4...20 mA analog output and the RS 485 communication interface are not isolated from one another.
Approved by the PTB (Physikalisch-Technische Bundesanstalt, Physical Testing Institute, Federal Republic of Germany) for the protection of
motors used in explosion hazard areas (EEx e).
Product Overview Page 6
Product Selection Page 10
Accessories Page 11
Approximate Dimensions Page 21
16
Bulletin 825
Relays
Contact Data of Output Relays, Main Relay (MR) 95...96
Contacts
[V]
[A]
24
110...125
220...250
380...440
AC-15
[A]
1.2
AC-15
[A]
30
30
12
DC-13
[A]
0.2
[A]
0.3
[A]
[V]
[A]
[A]
[VA/W]
[VA/W]
[V]
4 at 250V AC or 30V DC
2 at 250V AC or 30V DC
1250/150
500/60
240; 1 A pilot duty
[A]
[V]
48 AC, 30 DC
[W]
[W]
150
60
Terminals
Bulletin 825-M Plug-in Terminals
per UL
per VDE
[mm2]
[mm2]
[AWG No.]
Nominal gauge:
[mm2]
0.5...2.5, single-wire
0.5...1.5, double-wire
22...14
[mm2]
[AWG No.]
2 x 2.5/1 x 4
2 x 20...14/1 x 20...12
Range of gauges:
Main circuit
825-MCM2, 825-MCM20
Terminals:
825-MCM180
Aperture:
or bus bars:
Bus bars
825-MCM630(N)
[mm]
[mm]
[mm]
1.5
max. 19
20/16 x 4
25 x 8
17
Bulletin 825
[V]
[A]
[A]
[Hz]
Burden
Power consumption at maximum rated current
Continuous thermal current
Thermal current during 1 s
Rated frequency
[VA]
[A]
[A]
[Hz]
825-M + 825-MCM20
0.4 per Phase
24
600
50/60
No-load
Current transformer (P = Protection): 1% error at rated current (Ie)
5% error at rated overcurrent (10 Ie)
Rated thermal current = 120% Ie
For starting current 10 Ie: Class 5 P 20
The current transformer error is added to the Bulletin 825-M error.
2.5 A with Cat. No. 825-MCM2, 20 A with Cat. No. 825-MCM20
Kn =
[VA]
[VA]
[A]
[Hz]
0.4
0.5
25
50/60
Short-Circuit Protection
The line-side circuit breaker or fuse must ensure that the engine will
start, while still switching off short-circuit currents fast enough. Because
of the latter, the fuse selected should always be as small as
possible.
The lowest possible fuse rating depends on the starting current of the
motor and the tripping time set on the Bulletin 825-M.
The contactor receives its tripping signal when the Bulletin 825 trips and
must interrupt all currents up to the point of intersection of the time/
current characteristics of the Bulletin 825 and circuit breaker or fuse.
When starting large motors, the main contacts on the contactor are
subjected to high thermal loads so that if the motor starting time exceeds
a certain limit, the maximum permissible current has to be reduced.
The fuse or contactor rating must also allow for the prospective
short-circuit current. The Bulletin 825-MCM converter modules are
short-circuit proof. The contactor coordination diagrams are available
upon request.
18
Bulletin 825
Bulletin 825-MTUM Device for Indicating Thermal Utilisation, PT 100 max., Imotor
Display range
Utilisation
Wire
Front
Panel cutout
Mounting depth
[%]
[mm2]
[mm]
[mm]
[mm]
[Us]
[VA/W]
AC 0.85...1.1, DC 0.80...1.1
AC 13/DC 10
The power supply module is short-circuit proof
Weights
825-MPS
[g]
[g]
[g]
1000
710
290
Options
825-MPB
825-MST
825-MLV
825-MMV
[g]
[g]
[g]
[g]
125
90
90
90
Converter modules
825-MCM2
825-MCM20
825-MCM180
825-MCM630
825-MCM630N
[g]
[g]
[g]
[g]
[g]
570
570
860
3120
5460
825-CBCT
825-MTUM
825-FPM
825-VISU
825-PTS
825-PTL2
825-PTL4
825-PCB1
825-PCE
825-BC
825-CBC9
[g]
[g]
[g]
[g]
[g]
[g]
[g]
[g]
[g]
[g]
[g]
500
180
860
125
75
40
45
95
20
59/m
15
825-MVM
825-MVM2
[g]
[g]
230
230
19
Bulletin 825
Bulletin
825-MCM
825
Converter Module U1
825-MCM2
825-MCM20
Main current transformer U2...A/5 A or...A/1 A
See Specifications for selection
Core balance transformer U3
5 mA...50 A
Output to Bulletin 825-M: 5...500 mA
Control Circuit
825-M
QM
QA
K1
F1
S1
S0
Us
H1
H2
H3
MR
#1
20
Circuit breaker
Shunt trip coil
Contactor
825-M
ON button
OFF button
Control voltage
Indicator: contact closed
Indicator: Bulletin 825 tripped
(except for short-circuit protection)
Indicator: short-circuit trip
Main output relay
Auxiliary relay, short-circuit indicator
Bulletin 825
Surface Mounting
Bulletin 825-M devices can be installed on a mounting frame
(Cat. No. 825-FPM). The terminals can then be easily accessed
without unmounting the device.
138 + 1
-0
90
170
max. 6 mm
6.5
10
150
170
138 + 1
-0
144
170
144
165
Mounting Depth
Mounting position
22.5
22.5
90
22.5
21
Bulletin 825
e3
b1
d3
b
b2
d1
e2
c1
e2
d2
a
Dimensions
Cat. No.
c1
d1
d2
d3
e1
e2
38.5
825-MCM2
120
85
102
66
5.3
5.3
100
55
2 x 2.5
mm 2
825-MCM20
120
85
102
66
5.3
5.3
100
55
2 x 2.5
mm 2
38.5
825-MCM180
120
102
72
5.3
5.3
100
55
38.5
825-MCM630
155
145
156
118
6.3
6.3
135
88
11
M10
48
825-MCM630N
155
145
177
118
6.3
6.3
135
88
11
M10
48
b1
b2
75
/
100/118
Bus Bars
Terminal Dimensions
Cat. No.
Bottom
Top
825-MVM
M8
M8
22
Bulletin 825
Secondary
Winding
35
150
200
175
80
110
175
23
Bulletin 825
24
Application-Specific Options
The Smart Motor Manager Protection Relay offers the flexibility of different options
to fit your specific applications. (See the table on page 3 for protection options.)
Communication Options
With the appropriate card, your SMM Protection Relay can
communicate via: DeviceNet, Remote I/O, and Modbus.
Converter Module
ABB Oy
MV Induction Machines
Department/Author
Date of issue
Lang.
Rev. date
Our ref.
PIE/M. Ikonen
14.10.02
En
27.01.03
8908HD300
Customer ref.
Saving Ident
Rev./Changed by
Pages
Pipa Norte
8002644C
C/M. Ikonen
1/2
HXR 400LK6
Squirrel cage motor
Horizontal
TEFC
TEFC
Class F
1.15 temp. rise 100 C RTD
NEMA MG1
40 C
7217 ft.a.s.l.
Continuous
500 HP
4160 V
50 Hz
988 rpm
66 Amps
550 % Code F
130 %
200 %
24 Amps
2658 lb-ft
Load %
Current Amps
Efficiency % Power Factor
100
66
95,4
0,83
75
51
95,5
0,80
50
38
95,0
0,71
Connection of stator winding
Star
Direction of rotation
Bi-directional
Sound pressure level: (sinus supply, no load)
75 dB(A), tol. + 3 dB(A), 3 ft
Inertia rotor / load
441,6 lb-ft / 9848 lb-ft
Maximum stalling time
18 s (warm)
Starting time
12 s (U=Un)
21 s (U=0,85 Un)
Number of consec. starts
4 / 2 (cold/warm)
Maximum number of starts
1000 / year
This performance data is final and the motor will be manufactured accordingly.
ABB Oy
MV Induction
Machines
Visiting Address
Strmbergintie 1 B
HELSINKI
Postal Address
P.O.Box 186
FIN-00381 HELSINKI
Finland
Telephone
+358 10 222 000
Telefax
+358 10 222 3565
ABB Oy
MV Induction Machines
Department/Author
Date of issue
Lang.
Rev. date
Our ref.
PIE/M. Ikonen
14.10.02
En
27.01.03
8908HD300
Customer ref.
Saving Ident
Rev./Changed by
Pages
Pipa Norte
8002644C
C/M. Ikonen
2/2
500 HP
4160 V
50 Hz
988 rpm
66 Amps
Power Factor
Rated torque
Locked rotor Amps
Locked rotor torque
Breakdown torque
0,83
2658 lb-ft
550 %
130 %
200 %
600
300
500
250
400
200
300
150
200
100
100
50
0
0
10
20
30
40
50
60
70
80
% Torque
% Current
0
100
90
% Speed
A, V=100%
T, V=100%
A, V=95%
T, V=95%
A, V=90%
T, V=90%
A, V=85%
T, V=85%
A, V=80%
T, V=80%
Load Torque
ABB Oy
MV Induction
Machines
Visiting Address
Strmbergintie 1 B
HELSINKI
Postal Address
P.O.Box 186
FIN-00381 HELSINKI
Finland
Telephone
+358 10 222 000
Telefax
+358 10 222 3565
ABB Oy
MV Induction Machines
DATOS DE MOTOR
Department/Author
Date of issue
Lang.
Rev. date
Our ref.
PIE/M. Ikonen
14.10.02
Sp
27.01.03
8908HD300
Customer ref.
Saving Ident
Rev./Changed by
Pages
Pipa Norte
8002646C
C/M. Ikonen
1/2
HXR 400LK6
Jaula de Ardilla
Horizontal
TEFC
TEFC
Clase F
1.15 calentamiento 100 C RTD
NEMA MG1
40 C
7217 ft.s.n.m.
Continuo
500 HP
4160 V
50 Hz
988 rpm
66 Amps
550 % Code F
130 %
200 %
24 Amps
2658 lb-ft
Corriente
Rend. %
Factor Pot.
Amps
100
66
95,4
0,83
75
51
95,5
0,80
50
38
95,0
0,71
Conexin del bobinado del estator
Estrella
Sentido de rotacin
Bi-direccional
Nivel de ruido: (aliment. senoidal, en vaco)
75 dB(A), tol. + 3 dB(A), 3 ft
Inercia rotor / carga
441,6 lb-ft / 9848 lb-ft
Tiempo max. rotor bloqueado
18 s (Caliente)
Tiempo arranque
12 s (U=Un)
21 s (U=0,85 Un)
Nmero arranques consecutivos
4 / 2 (Fro/Caliente)
Max. nmero de arranques
1000 / ao
Estos datos son finales y el motor ser fabricado segn estos.
ABB Oy
MV Induction
Machines
Visiting Address
Strmbergintie 1 B
HELSINKI
Postal Address
P.O.Box 186
FIN-00381 HELSINKI
Finland
Telephone
+358 10 222 000
Telefax
+358 10 222 3565
ABB Oy
DATOS DE MOTOR
MV Induction Machines
Department/Author
Date of issue
Lang.
Rev. date
Our ref.
PIE/M. Ikonen
14.10.02
Sp
27.01.03
8908HD300
Customer ref.
Saving Ident
Rev./Changed by
Pages
Pipa Norte
8002646C
C/M. Ikonen
2/2
500 HP
4160 V
50 Hz
988 rpm
66 Amps
Factor Pot.
Par nominal
Corriente rotor bloqueado
Par rotor bloqueado
Par mximo
0,83
2658 lb-ft
550 %
130 %
200 %
% Corriente
300
500
250
400
200
300
150 % Par
200
100
100
50
0
0
10
20
30
40
50
60
70
80
90
0
100
% Velocidad
A, V=100%
T, V=100%
A, V=95%
T, V=95%
A, V=90%
T, V=90%
A, V=85%
T, V=85%
A, V=80%
T, V=80%
Par resistente
ABB Oy
MV Induction
Machines
Visiting Address
Strmbergintie 1 B
HELSINKI
Postal Address
P.O.Box 186
FIN-00381 HELSINKI
Finland
Telephone
+358 10 222 000
Telefax
+358 10 222 3565
ABB
TEST REPORT
Customer:
Project:
Order ref.:
Machine:
Work nr:
Serial nr:
HXR 400LK6
8908HD300
4572698
Date:
20.01.2003
Postal Address
P.O. Box 186
FIN-00381 HELSINKI
Finland
Telefax (Group)
+358 10 22 22330
Telefax (Test Floor)
+358 10 22 23692
ABB
TEST REPORT
Customer:
Machine:
Page:
HXR 400LK6
2/4
Order ref.:
Work nr:
Serial nr:
Revision
8908HD300
4572698
Project:
Approved:
Report rev:
Tarmo Juntunen
Ratings
Machine:
Standards
NEMA MG 1
Insulation class
Temperature class
Ambient temp. max
f [Hz]
Conn.
50,0
F
B
40,0 C
IM 1001
IP TEFC
P [H.P.]
U [V]
500
4160
I [A]
p.f.
Direction n [rpm]
66 0,83
<==>
Duty
988 Continuous
ABB
TEST REPORT
Customer:
Machine:
Page:
HXR 400LK6
3/4
Order ref.:
Work nr:
Serial nr:
Revision
8908HD300
4572698
Project:
Approved:
Report rev:
Tarmo Juntunen
1) Visual inspection
Version
Test bay
PIT 60
Notes:
Author:
OK
Tarmo Juntunen
R [Mohm]
39400
U [V]
1000
Temperature detectors
Stator
R [Mohm]
505000
U [V]
500
Ruv [ohm]
Ruw [ohm]
Rvw [ohm]
0,39350
0,39350
0,39340
== 21,1 C
Terminals
1- 2, 3
4- 5, 6
7- 8, 9
10-11,12
13-14,15
16-17,18
R [ohm]
107,9
108,1
108,2
108,1
108,2
108,2
Position
T3-phase
T2-phase
T1-phase
T3-phase
T2-phase
T1-phase
Detector
PYR PT100LG4/4EX
PYR PT100LG4/4EX
PYR PT100LG4/4EX
PYR PT100LG4/4EX
PYR PT100LG4/4EX
PYR PT100LG4/4EX
f [Hz]
50,0
U1 [V]
907,0
I1 [A]
66,0
P1 [kW]
p.f.
17,9 0,173
[C]
21,1
Ik [A]
302,53
6) Vibration measurement
Operating conditions
f = 50,0 Hz
U = 4160 V
Measured values
Bearing position Horizontal
D-END
0,625
ND-END
0,508
I = 24,4 A
Vertical
0,590
0,488
Axial
0,634
Mounting Rigid
Measuring equipment
Unit
Meas. device
mm/s PEAK
CSI 1910, PIT60
mm/s PEAK
CSI 1910, PIT60
Un [V]
4160
ABB
TEST REPORT
Customer:
Machine:
Page:
HXR 400LK6
4/4
Order ref.:
Work nr:
Serial nr:
Revision
8908HD300
4572698
Project:
Approved:
Report rev:
Tarmo Juntunen
7) No-load point
Conn.
Y
f [Hz]
50,0
U1 [V]
4160,0
I1 [A]
24,43
P1 [kW]
p.f.
6,9 0,039
[C]
31,1
Direction
CW
U [V]
10400
t [min]
1
U [V]
1500
t [min]
1
f [Hz]
50
R1 [Mohm]
16700
t1 [s]
60
U [V]
1000
Temperature detectors
Stator
No of pages:
End of report
R [Mohm]
505000
Printed:
U [V]
500
22.1.2003
Tarmo Juntunen
Safety Instructions
AMA, AMB, AMG, AMH, AMK, AML, AMS, AMZ, HS, HXR
General
Intended use
Electric machines have dangerous live and rotating parts and may
have hot surfaces. All operations serving transport, storage,
installation, connection, commissioning, operation and maintenance
shall be carried out by responsible skilled persons (in conformity
with EN 50 110-1 / DIN VDE 0105 / IEC 60364). Improper handling
may cause serious personal injury and damage to property. Danger!
These machines are intended for industrial and commercial
installations as components as defined in the Machinery Directive
(MD) 89/392/EEC. Commissioning is prohibited until conformity of
the end product with this directive has been established (follow
particular local safety and installation rules as e.g. EN 60204).
These machines comply with the harmonized series of standards
EN 60034 / DIN VDE 0530. Their use in hazardous areas is
prohibited unless they are expressly designed for such use (follow
additional instructions).
On no account, use degrees of protection IP 23 outdoors.
Air-cooled models are typically designed for ambient temperatures
of -20C up to +40C and altitudes of 1000 m above sea level.
Ambient temperature for air-/water-cooled models should be not
less than +5C (for sleeve-bearing machines, see manufacturer's
documentation). By all means, take note of deviating information on
the rating plate. Field conditions must conform to all rating plate
markings.
3
Transport, storage
Installation
Make sure of even support, solid foot or flange mounting and exact
alignment in case of direct coupling. Avoid resonances with
rotational frequency and double mains frequency as a result of
assembly. Turn rotor and listen for abnormal slip noises. Check
direction of rotation in uncoupled state.
Follow manufacturers instructions when mounting or removing
couplings or other drive elements and cover them with a touch
guard. For trial run without output elements, lock or remove the shaft
end key. Avoid excessive radial and axial bearing loads (note
manufacturer's documentation). The balance of the machine is
indicated as H = Half and F = Full key. With half-key models, the
coupling too, must be half-key balanced. In case of protruding,
visible part of the shaft end key, establish mechanical balance.
Electrical connection
De-energize!
Operation
ABB Industry Oy
2001-02-14
1(2)
Warning
Motors for hazardous areas are specially designed to comply with
official regulations concerning the risk of explosion. If improperly
used, badly connected, or alter, no matter how minor, their reliability
could be in doubt.
Standards relating to the connection and use of electrical apparatus
in hazardous areas must be taken into consideration, especially
national standards for installation. Only trained personnel familiar
with these standards should handle this type of apparatus.
IEC 60079-7;
IEC 60079-15;
IEC 1241-1-1
BS 5000:16;
ABB machines (valid only for group II) can be installed in areas
corresponding to following marking:
Zone (IEC) Category (EN)
Validity
These instructions are valid for the following ABB Industrys
electrical motor types, when the machine is used in explosive
atmospheres.
Reception check
-
Warning !
Disconnect and lock out before working on the machine or the
driven equipment. Ensure no explosive atmosphere is present while
the work is in progress.
Starting and Re-starting
-
Be sure that air gap between rotor and stator is measured after
any maintenance for the rotor or bearings. The air gap shall be
the same in any point between stator and rotor.
Centralise the fan to the centre of the fanhood or the air guide
after any maintenance. The clearance shall be at least 1% of
the maximum diameter of the fan and in accordance with
standards.
Conformity
As well as conforming to the standards relating to mechanical and
electrical characteristics, motors designed for explosive
atmospheres must also conform to the following IEC or CENELEC
standards:
IEC 60079-2;
EN 50016;
EN 50019;
EN 50021;
EN 50281-1-1
IEC 60079-0;
EN 50014;
Marking
Atmosphere (EN);
G explosive atmosphere caused by gases
D explosive atmosphere caused by dust
Declaration of Conformity
All ABB machines comply with:
All connections in main terminal boxes must be made with Exapproved connectors, which are delivered with the machine by
the manufacturer. In other cases ask an advice from ABB
Industry.
Note !
If there are any conflicts between this instruction and user manual,
this document is prevailing.
ABB Industry Oy
2001-02-14
2(2)
Instrucciones de seguridad
AMA, AMB, AMG, AMH, AMK, AMZ, HXR
1
Generales
Uso previsto
Transporte, almacenamiento
Instalacin
Desconectar los
anticondensacin)
auxiliares
ejemplo,
calefaccin
Las separaciones entre las piezas con corriente no aisladas y entre estas
piezas y tierra no deben ser inferiores a los siguientes valores: 8 mm
a UN 550 V, 10 mm a UN 725 V, 36 mm a UN 3,3 kV, 60 mm
a UN 6,6 kV y 100 mm a UN 11 kV.
En la caja de bornes no puede haber cuerpos extraos o polvo, ni permitirse
la condensacin de humedad. Cierre los orificios de entrada de cables que no
se utilicen de forma estanca y sin polvo. Fije la chaveta cuando la mquina
est funcionando sin acoplamiento. En el caso de los motores con
accesorios, compruebe su funcionamiento antes de poner en funcionamiento
el motor.
La correcta instalacin (por ejemplo, separacin de las lneas de alto voltaje y
de las de seales, cables apantallados, etc.) es responsabilidad del
instalador.
Funcionamiento
Mantenimiento y reparaciones
Convertidores de frecuencia.
U1
PE
V1
Platina
W1
Cables
3~M
> 150 mm
0.75 mm
(por
Conexin elctrica
Todas las operaciones deben ser realizadas por personal cualificado con el
motor parado. Antes de realizar cualquier tarea de este tipo, deben aplicarse
estrictamente las siguientes reglas de seguridad:
circuitos
Si se superan los valores lmite de la zona A en EN 60034-1 / DIN VDE 05301 - voltaje 5%, frecuencia 2%, forma de onda y simetra -, se puede
producir un aumento de la temperatura con efecto en la compatibilidad
electromagntica. Observe los marcados de las placas de caractersticas y el
diagrama de conexin de la caja de bornes.
Mquina accionada
70 mm
min 50 mm
2002-06-01
1(2)
IEC 60079-15;
IEC 1241-1-1
BS 5000:16;
Nota
Hay que seguir estas instrucciones para ofrecer una instalacin, un
funcionamiento y un mantenimiento correctos y seguros del motor.
Cualquiera que instale, opere o realice el mantenimiento de este
equipo debe tenerlas en cuenta. Ignorar estas instrucciones puede
invalidar la garanta.
Atencin
Los motores para reas peligrosas estn diseados especialmente
para satisfacer las normas oficiales referentes al riesgo de
explosin. Si se utilizan incorrectamente, si estn mal conectados o
sufren alguna modificacin, aunque sta sea menor, pueden perder
su fiabilidad.
Es necesario tener en cuenta las normas referentes a la conexin y
uso de aparatos elctricos en zonas peligrosas, especialmente las
normas nacionales sobre instalacin. nicamente personal
cualificado y familiarizado con dichas normas debera manejar este
tipo de mquinas.
Los motores de ABB (vlido slo para el grupo II) pueden instalarse
en zonas que correspondan a los siguientes marcados:
Zona (IEC) Categora (EN)
1
Marcado
EEx p, EEx pe ,EEx e
Ex p, Ex pe ,Ex e
Ex nA ,Ex N, EEx nA
Atmsfera (EN);
G atmsfera explosiva causada por gases
D atmsfera explosiva causada por polvo
Comprobacin de recepcin
-
Declaracin de conformidad
Todos los motores ABB deben cumplir:
Atencin
Arrancar y rearrancar
Validez
Estas instrucciones son vlidas para los siguientes tipos de
motores elctricos de ABB, cuando se utilizan en atmsferas
explosivas.
Antichispas Ex nA, Ex N, EEx nA
- Motores de induccin AMA, tamaos 315 a 500
- Motores de induccin AMB, tamaos 560 a 630
- Motores de induccin HXR, tamaos 315 a 560
- Motores sncronos AMZ, tamaos 710 a 2500
Conformidad
Accesorios
-
Nota
En caso de que estas instrucciones no coincidan con las del
manual del usuario, este documento tiene prioridad.
2002-06-01
2(2)
GB
ES
11
ABB Automation
ABB Motors
Machine instructions
Installation
Warning
These instructions must be followed to ensure safe
and proper installation, operation and maintenance
of the motor. They should be brought to the
attention of all the persons who install, operate or
maintain this equipment.
General information
ABB Motors are all fully factory tested and inspected before shipping. Damage during shipment and
storage can occur. Motors not correctly matched to
the power supply and/or the load will not operate
properly. These instructions are intended as a
guide to identify and eliminate these problems
before they are overlooked or cause further
damage.
Acceptance
Check carefully for any damage that may have
occured in transit. If any damage or shortage is
discovered, do not accept until an appropriate
notation on the freight bill is made. Any damage
discovered after receipt of equipment should be
immediately reported to the carrier.
Storage
A. Keep motors clean.
1. Store indoors.
2. Keep covered to eliminate airborne dust and
dirt.
3. Cover openings for ventilation, conduit
connections, etc. to prevent entry of rodents,
snakes, birds, and insects, etc.
B. Keep motors dry.
1. Store in a dry area indoors.
2. Temperature swings should be minimal to
prevent condensation.
3. Space heaters are recommended to prevent
condensation.
4. Treat unpainted flanges, shafts, and fittings
with a rust inhibitor.
5. Check insulation resistance before putting
motor into service.
C. Keep bearings lubricated.
1. Once per month, rotate shaft several turns to
distribute grease in bearings.
2. If unit has been stored more than one year,
add grease before start-up.
Transportation
Machines fitted with cylindrical-roller and/or angular
contact ball bearings shall be fitted with locking
devices during transport.
ABB Motors
Safety
Motors should be installed, protected and fused in
accordance with latest issue of National Electric
Code, NEMA Standard Publication No. MG 2 and
local codes.
Eyebolts or lifting lugs are intended for lifting the
motor only. These lifting devices should never be
used when lifting or handling the motor with other
equipment (i.e. pumps, gear boxes, fans or other
driven equipment) as a single unit. Be sure the
eyebolt is fully threaded and tight in its mounting
hole.
Eyebolt lifting capacity ratings is based on a lifting
alignment coincident with the eyebolt centerline.
Eyebolt capacity reduces as deviation from this
alignment increases. See NEMA MG 2.
Rotating parts such as pulleys, couplings, external
fans, and shaft extensions should be permanently
guarded.
Location
In selecting a location for the motor, consideration
should be given to environment and ventilation. A
motor with the proper enclosure for the expected
operating condition should be selected.
The ambient temperature of the air surrounding the
motor should not exceed 40C (104F) unless the
motor has been especially designed for high
ambient temperature applications. The free flow of
air around the motor should not be obstructed.
The motor should never be placed in a room with a
hazardous process, or where flammable gases or
combustible material may be present, unless it is
specifically designed for this type of service.
Electrical connections
Caution
Install and ground per local and national codes.
Consult qualified personnel with questions or if
repairs are required.
Floor mounting
Motors should be provided with a firm, rigid foundation, with the plane of four mounting pads flat
within .010 for 56 to 210 frame; .015 from 250
through 500 frame. This may be accomplished by
shims under the motor feet. For special isolation
mounting, contact ABB for assistance.
V-belt drive
1. Select proper belts and sheaves, do not over
belt. Excessive belt load will damage bearings.
Sheaves should be in accordance to NEMA
spec. MG-1 or as approved by the manufacturer
for a specific application.
2. Align sheaves carefully to avoid axial thrust on
motor bearing. The drive sheave on the motor
should be positioned toward the motor so it it as
close as possible to the bearing.
3. When adjusting belt tension, make sure the
motor is secured by all mounting bolts before
tightening belts.
4. Adjust belt tension to belt manufacturers recommendations. Excessive tension will decrease
bearing life.
Warning
1. Disconnect power before working on motor or
driven equipment. It is necessary to make sure
that the rotor of the motor can neither be
energized electrically nor start to rotate by any
other means.
2. Motors with automatic thermal protectors will
automatically restart when the protector
temperature drops sufficiently. Do not use
motors with automatic thermal protectors in
applications where automatic restart will be
hazardous to personnel or equipment.
3. Motors with manual thermal protectors may start
unexpectedly after protector trips. If manual
protector trips, disconnect motor from power line.
After protector cools (five minutes or more) it can
be reset and power may be applied to motor.
4. Discharge all capacitors before servicing motor.
5. Always keep hands and clothing away from
moving parts.
6. Never attempt to measure the temperature rise
of a motor by touch. Temperature rise must be
measured by thermometer, resistance, imbedded
detector, or thermocouple. The temperature of
the outlet of the motor may be hot to touch
during normal operation.
7. Electrical repairs should be performed by trained
and qualified personnel only.
8. Failure to follow instructions and safe electrical
procedures could result in serious injury or
death.
9. If safety guards are required, be sure the guards
are in use.
1. All wiring, fusing, and grounding must comply
with National Electrical Codes and local codes.
2. To determine proper wiring, rotation and voltage
connections, refer to the information and diagram
on the name plate, separate connection plate or
decal. If the plate or decal has been removed,
contact ABB for assistance.
3. Use the proper size of line current protection and
motor controls as required by the National
Electrical Code and local codes. Recommended
use is 125% of full amps as shown on the name
plate for motors with 40C ambient and a service
factor over 1.0. Recommended use is 115% of
full load amps as shown on the name plate for all
other motors. Do not use protection with larger
capacities than recommended. Three phase
motors must have all three phases protected.
ABB Motors
Warning
Windings should be discharged immediately after
measurement to avoid risk of electric shock.
Insulation resistance is halved for each 20C rise
in ambient temperature.
2. If the reference resistance value is not attained,
the winding is too damp and must be oven dried.
Oven temperature should be 90C (194F) for
12-16 hours followed by 105C (223F) for 6-8
hours.
Changing rotation
Operation
Warning
Disconnect and lock out before working on motor or
driven equipment.
Windings should be discharged immediately after
measurement to avoid risk of electric shock.
20 x U
1000 + 2P
ABB Motors
Cleanliness
Keep both the interior and exterior of the motor free
from dirt, water, oil and grease. Motors operating in
dirty places should be periodically disassembled
and thoroughly cleaned.
Lubrication
Motors with permanently greased bearings.
Motors up to frame size 210 are normally provided
with permanently greased bearings of 2Z type.
Bearing types are specified in the name plate and
the respective product catalogues. Motors provided
with Z-bearings can be regreased by dismantling
the motor, cleaning the bearings and bearing
housings, and filling these with new grease to 5070%.
Guidelines for regreasing intervals are:
1. 20,000 to 40,000 duty hours for 4 pole or greater
motor.
2. 10,000 to 20,000 duty hours for 2 pole motors.
The shorter times are valid for larger frame sizes.
Motors with grease nipples.
Lubricate the motor while running. If grease outlet
plug fitted, remove temporarily when lubricating, or
permanently with automatic lubrication.
Warning
Always keep hands and clothing away from moving
parts.
If the motor is provided with a lubrication information plate, follow the values given, otherwise use
values as follows:
Amount of grease
Service
Warning
Disconnect and lock out before working on motor or
driven equipment.
Caution
Overgreasing bearings can cause premature
bearing and/or motor failure. The amount of grease
added should be carefully controlled.
General inspection
1. Inspect the motor at regular intervals.
2. Keep the motor clean and ensure free ventilation
flow.
3. Check the condition of shaft seals (i.e. V-ring)
and replace if it is necessary.
4. Check the conditions of connections and mounting and assembly bolts.
Frame size
Drive-end
grams
80
120
160
200
400
500
600
250
280
320
360
40_
44_-50_
58_
ounces
3
4.5
6
7
15
18
22
Non-drive end
grams
ounces
50
2
75
3
100
4
145
5
400
15
400
15
500
18
Grams
250-280
320-360
40_-44_
50_
58_
20
25
35
50
60
r/min
3600 3000
1800
1500
1000
3200
1800
800
800
-
6000
5500
5000
4600
4000
7000
6500
6000
5500
5000
9000
8500
8000
7500
7000
4200
3100
2000
2000
1000
500900
10000
9000
8500
8000
8000
25
35
50
60
900
400
400
-
1500
1000
1000
-
4300
3300
2700
2200
5000
4500
3800
3200
6500
6300
6000
5500
ABB Motors
7000
6800
6500
6000
NOTE
For high speed motors (i.e. larger 2-pole motors),
check that the fn factor of the grease is sufficiently
high.
fn = Dm x n
Dm = average bearing diameter (mm)
n = rotational speed (rpm)
Warning
Many greases can cause skin irritation and eye
inflammation. Follow any precautions specified by
the manufacturer.
Spare parts
When ordering spare parts, the full type designation
and product code as stated on the name plate must
be specified.
If the machine is stamped with a serial
manufacturing number, this should also be given.
Typically a doubling of speed will require a reduction of lubrication intervals to approx. 50% of values
tabulated above.
Suitability of bearings for high speed operation
must also be checked.
Lubricants
When regreasing, use only special ball bearing
grease with the following properties:
1. Good quality lithium base or lithium complex
grease.
2. Base oil viscosity 100-140 cST at 40C (104F).
3. Consistency NI GI grade 2 or 3.
4. Temperature range -30C to +120C (-22F to
+248F), continuously.
Greases with the correct properties are available
from all the major lubricant manufacturers.
If the make of grease in changed and compatibility
is uncertain, lubricate several times at short intervals in order to displace the old grease.
Highly loaded and/or slowly rotating bearings
require EP-grease. If lubrication intervals are short
due to bearing temperatures of 80C (176F) or
above, use high temperature greases which
normally permit approximately 15 K higher bearing
temperatures.
If the ambient temperature is below 25C (-13F)
consult ABB Motors regarding the possible use of
low temperature grease.
ABB Motors
Troubleshooting
Warning
1. Disconnect power before working on motor or
driven equipment. It is necessary to make sure
that the rotor of the motor can neither be
energized electrically nor start to rotate by any
other means. Apply this also for the driven
equipment.
2. Motors with automatic thermal protectors will
automatically restart when the protector temperature drops sufficiently. Do not use motors with
automatic thermal protectors in applications
where automatic restart will be hazardous to
personnel or equipment.
3. Motors with manual thermal protectors may start
unexpectedly after protector trips. If manual
protector trips, disconnect motor from power line.
After protector cools (five minutes or more) it can
be reset and power may be applied to motor.
4. Discharge all capacitors before servicing motor.
5. Always keep hands and clothing away from
moving parts.
6. Never attempt to measure the temperature rise
of a motor by touch. Temperature rise must be
measured by thermometer, resistance, imbedded
detector, or thermocouple. The temperature of
the outlet of the motor may be hot to the touch
during normal operation.
7. Electrical repairs should be performed by trained
and qualified personnel only.
8. Failure to follow instructions and safe electrical
procedures could result in serious injury or
death.
9. If safety guards are required, be sure the guards
are in use.
ABB Motors
These instructions do not cover all details or variations in equipment nor provide for every possible condition
to be met in connection with installation, operation or maintenance. Should additional information be desired
for the purchasers purposes, the matter should be referred to the nearest ABB Sales Office.
CAUSE
WHAT TO DO
Blown fuses
Overload trips
Improper power supply
Mechanical failure
Short circuited stator
Poor stator coil connection
Rotor detective
Motor may be overloaded
Motor stalls
Power failure
Excessive load
Low voltage during start
Defective squirrel cage rotor
Applied voltage too low
Reduce load.
Check for high resistance. Adequate wire size.
Replace with new rotor.
Get power company to increase power tap.
Wrong rotation
Overload
Frame or bracket vents may be clogged
with dirt and prevent proper ventilation of
motor
Motor may have one phase open
Reduce load.
Open vent holes and check for a continuous
stream of air from the motor.
Grounded coil
Unbalanced terminal voltage
ABB Motors
TROUBLE
CAUSE
WHAT TO DO
Motor vibrates
Motor misaligned
Weak support
Coupling out of balance
Driven equipment unbalanced
Defective bearings
Bearings not in line
Balancing weights shifted
Polyphase motor running single phase
Excessive end play
Realign.
Strengthen base.
Balance coupling.
Rebalance driven equipment.
Replace bearings.
Line up properly.
Rebalance motor.
Check for open circuit.
Adjust bearing or add shim.
Scraping noise
Remove interference.
Clear fan.
Tighten holding bolts.
Noisy operation
Insufficient grease
Deterioration of grease or lubricant
contaminated
Excess lubricant
Overloaded bearing
Broken ball or rough races
10
ABB Motors
Instrucciones de puesta
en marcha
Advertencia
Se deben seguir estas instrucciones para asegurar
una instalacin correcta, segura y un funcionamiento y mantenimiento adecuados del motor. Se
debe asegurar de que el personal que lo instale, lo
ponga en marcha y efecte el mantenimiento, las
conozcan.
Informacin general
Todos los motores de ABB se prueban e
inspeccionan antes de su expedicin. Pueden
daarse durante la expedicin y almacenamiento.
Los motores que no se conectan adecuadamente a
la red y/o a la carga no funcionaran correctamente.
Estas instrucciones sirven como gua para
identifica y eliminar esos problemas antes de que
sea demasiado tarde y pueden causar daos.
Aceptacin
Comprobar cuidadosamente los daos posibles
que puedan haber ocurrido durante el transporte. Si
se descubre algn dao o deficiencia, no se debe
aceptar el motor sin antes hacer la correspondiente
notificacin al transportista.
Almacenamiento
A. Mantener los motores limpios.
1. Almacenarlos en lugares cubiertos.
2. Mantenerlos cubiertos para eliminar el polvo
y la suciedad
3. Tapar los canales de ventilacin y las
aberturas de las cajas de conexin, etc.
para prevenir la entrada de roedores,
serpientes, pjaros e insectos.
B. Mantener los motores secos.
1. Almacenarlos en lugares secos y cubiertos
2. Para prevenir condensaciones evitar
fluctuaciones de temperatura.
3. Se recomiendan resistencias calefactoras
para prevenir la condensacin
4. Tratar las partes no pintadas, ejes y otros
accesorios con inhibidor anticorrosivo.
5. Comprobar la resistencia de aislamiento
antes de ponerlos en servicio.
C. Mantener los rodamientos engrasados.
1. Una vez cada mes, hacer girar el eje varias
vueltas para repartir la grasa en el
rodamiento.
2. Si el motor ha estado almacenado ms de
un ao, engrasar antes de ponerlo en
marcha.
ABB Motors
Transporte
Los motores que lleven rodamientos de rodillos y/o
de contacto angular deben ser suministrados con
un dispositivo de bloqueo para el transporte.
Instalacin
Desempaque e inspeccin
Despus del desempaque, comprobar si se ha
daado el motor, debido a su manejo. El eje debe
girar libremente accionndolo con la mano.
Reparar o reponer las partes aflojadas o rotas
antes de poner en marcha el motor.
Comprobar que el motor no tenga polvo, suciedad
o humedad excesiva.
Medir la resistencia de aislamiento (ver funcionamiento). Limpiar y secar el bobinado si es
necesario.
Nunca poner en marcha el motor que se haya
mojado sin haberlo secado completamente.
Seguridad
Los motores se deben instalar con sus
protecciones y fusibles adecuados de acuerdo con
las normas de National Electric Code, normas
NEMA Publicacin No. MG2 y recomendaciones
locales.
Hay unos cncamos previstos solo para el movimiento del motor. No se deben utilizar estos
cncamos para el movimiento del motor con otros
equipos (bombas, reductores, ventiladores u otros
equipos) que formen una unidad. Asegurarse de
que los cncamos estn completamente atornillados en sus respectivos agujeros roscados.
La capacidad de carga de estos cncamos est
basada en el levantamiento alineado con su lnea
central. Su capacidad se reduce cuando hay
desviaciones de este alineamiento. Ver NEMA
MG2.
Las partes giratorias tales como poleas, acoplamientos, ventiladores externos, y segundas salidas
de eje deben estar permanentemente protegidas.
Lugar de funcionamiento
Al seleccionar el lugar de funcionamiento del motor,
se debe haber considerado el ambiente y la
ventilacin. Se debe seleccionar un motor con una
carcasa de proteccin apropiadas para las
condiciones de funcionamiento deseadas.
La temperatura ambiente no ser superior a 40C
(104F) a menos que ya se haya seleccionado el
motor para temperaturas ambientes superiores. Se
debe asegurar una ventilacin sin obstculos al
rededor del motor..
11
Cimentacin
Los motores se den instalar sobre una base firme y
rgida, en un plano, que tenga cuatro pernos de
anclaje, nivelado con .010 para carcasa de 56 a
210, y .015 para carcasas de 250 a 500. Se deben
colocar galgas debajo de las patas del motor para
que quede completamente alineado. Para
cimentaciones especiales consultar con ABB.
12
Conexiones elctricas
Precaucin
Siempre conectar a una tierra efectiva segn los
cdigos nacionales. Consultar con personal
cualificado por si son necesarias mejoras o
reparaciones en la instalacin.
Advertencia
1. Siempre desconectar el voltaje antes de
trabajar con un motor o equipo. Es necesario
asegurarse de que el rotor del motor nunca se
pueda poner a girar.
2. Los motores equipados con protectores trmicos pueden rearmarse automticamente
cuando la temperatura de dichos protector
disminuya. Nunca utilizar motores con
protectores trmicos automticos en aplicaciones donde un rearme automtico pueda ser
peligroso para el personal o el equipo.
3. Los motores con protectores trmicos manuales pueden rearmarse inesperadamente
despus de su disparo. Si el protector manual
dispara, desconectar el motor de la lnea
elctrica. Despus del enfriamiento del
protector (unos 5 minutos o ms) puede ser
rearmado y volver a conectar la lnea elctrica
del motor.
4. Descargar todos los capacitores antes de
manipular un motor.
5. Siempre mantener alejadas las manos y ropas
de la partes en movimiento.
6. Nunca intentar medir la temperatura de un
motor con el tacto. Las temperaturas deben
medirse con un termmetro, resistencia o
termopar. La temperatura en el conducto de
salida del aire de un motor puede estar muy
caliente para tocarla durante el funcionamiento
normal.
7. Las reparaciones elctricas debe ser efectuadas por personal cualificado.
8. De no seguirse las instrucciones y los procedimientos elctricos de seguridad pueden causar
accidentes y hasta la muerte.
9. Si se requieren protecciones de seguridad,
asegurarse de que no han caducado.
1. Los cableados, los fusibles y las tierras deben
cumplir con National Electrical Codes y normas
locales.
2. Para determinar las conexiones correctas,
sentido de giro y voltaje, ver la informacin de
la placa de caractersticas y placas adicionales.
Si la placa de caractersticas se ha perdido,
contactar con ABB para informacin.
3. Utilizar el calibre correcto de la proteccin de
lnea y controles del motor segn National
Electrical Codes y normas locales. Una
prctica recomendada es 125% de la corriente
nominal de la placa de caractersticas del
motor a 40C de temperatura ambiente y factor
de servicio 1.0. Utilizar 115% de la corriente
ABB Motors
Informacin de protectores
trmicos
Sobre pedido o como estandar los motores pueden
ser suministrados con protectores trmicos. Una
placa de caractersticas o una calcomana indicar
una de las modalidades siguientes:
1. Los motores tamaos 48 al 365 no llevan
proteccin trmica y por lo tanto no se indica
en la placa de caractersticas.
2. Los motores 404 y superiores llevan como
estandar 3 termistores PTC para 150C, en el
devanado del estator, conectados en serie.
Para los otros tamaos de motores sobre
demanda.
Si los motores llevan diagrama de conexiones
separado, seguir sus instrucciones.
ABB Motors
Funcionamiento
Advertencia
Desconectar y bloquear antes de trabajar con un
motor o equipo.
Los bobinados deben descargarse inmediatamente
despus de las mediciones para evitar choques
elctricos.
U = voltaje, P = potencia en kW
Advertencia
Los devanados deben descargarse
inmediatamente despus de las mediciones
pera evitar choques elctricos.
La resistencia de aislamiento se reduce a la
mitad para cada 20C de incremento de
temperatura ambiente.
2. Si no se alcanza la resistencia de referencia, el
devanado es demasiado hmedo y debe
secarse en un horno a la temperatura de 90C
(194F) durante 12-16 horas y seguidamente a
105C (223F) durante 6-8 horas. Se deben
quitar los tapones de drenaje durante el
calentamiento. Cuando haya entrado en los
bobinados, agua de mar, es necesario
rebobinar el motor.
3. Ver si voltaje y la frecuencia indicada en la
placa de caractersticas corresponde a los de
la lnea elctrica.
4. Comprobar las conexiones del motor y los elementos de control con el diagrama.
5. Asegurarse de que el rotor gira libremente al
desconectar la carga. Se debe quitar todo
objeto extrao en el entrehierro.
6. Dejar el motor desconectado de la carga al
ponerlo en marcha por primera vez; es mejor
dejar funcionando el motor durante 1 hora, sin
carga, para probar y localizar calentamiento en
los rodamientos y bobinados. Comprobar el
giro correcto. Comprobar si el voltaje es
correcto y balanceado. Comprobar la corriente
de vaco.
13
Mantenimiento
Advertencia
Desconectar y bloquear el motor antes de trabajar
con l o el equipo accionado.
Precaucin
Engrasar demasiado un rodamiento puede causar
averas prematuras. La cantidad de grasa debe ser
cuidadosamente controlada.
Limpieza
Mantener el interior y exterior del motor limpio de
suciedad, agua, aceite y grasa. Los otros que
deban funcionar en lugares sucios, deben
desmontarse peridicamente y limpiarse bien.
Tapones de drenaje
Todos los motores van equipados con tapones de
drenaje que pueden tapar los agujeros correspondientes. Estos tapones normalmente deben
estar abiertos. Al montar el motor, asegurarse de
que el tapn de drenaje est situado en la parte
ms baja. En caso de montaje vertical, el tapn
situado en la parte superior debe tapar completamente el agujero. En lugares muy polvorientos,
se deben tapar los dos agujeros.
14
Inspeccin General
1. Inspeccionar el motor a intervalos regulares.
2. Mantener el motor limpio y asegurar de que la
ventilacin es efectiva.
3. Comprobar el estado del sellado de los ejes (ej.
V-ring) y cambiarlo si es necesario.
4. Comprobar el estado de las conexiones y los
tornillos de montaje.
5. Comprobar el estado de los rodamientos
escuchando ruidos anormales, midiendo las
vibraciones, temperatura de los rodamientos,
inspeccionando la grasa sobrante o
controlando con el aparato SPM.
Cuando hay cambios en las condiciones de
funcionamiento, desmontar el motor, comprobar las
partes y cambiarlas si es necesario.
Lubricacin
Motores con lubricacin de por vida.
Los motores hasta el armazn 210 llevan rodamientos 2Z y estn normalmente lubricados de por
vida. Los tipos de rodamientos se indican en la
placa de caractersti8cas y en los catlogos. Los
motores con rodamientos del tipo Z pueden ser
lubricados desmontndolos, limpindolos as como
a su caja de rodamientos y llenndolos de grasa
hasta el 50-70%.
Los intervalos de lubricacin son:
1. De 20,000 a 40,000 horas de servicio para
motores de 4 polos y superiores
2. De 10,000 a 20,000 horas de servicio para
motores de 2 polos
Para armazones mayores los intervalos deben ser
menores.
Motores con engrasadores
Lubricar los motores en marcha. Si estos llevan
una proteccin de salida de grasa, quitarla temporalmente para lubricar, o permanentemente con
lubricacin automtica.
Advertencia
Siempre mantener las manos y la ropa alejados de
las partes mviles.
ABB Motors
Lubricantes
Al engrasar, utilizar solo grasa especial para rodamientos de bolas con las siguientes propiedades:
Cantitad de grasa
Armazn
tamao
250
280
320
360
40_
44_-50_
58_
Lado acople
gramos
onzas
80
3
120
4.5
160
6
200
7
400
15
500
18
600
22
Lado ventilador
gramos
onzas
50
2
75
3
100
4
145
5
400
15
400
15
500
18
Gramos
r/min
3600 3000
1800
1500
1000
250-280
320-360
40_-44_
50_
58_
20
25
35
50
60
3200
1800
800
800
-
6000
5500
5000
4600
4000
7000
6500
6000
5500
5000
9000
8500
8000
7500
7000
4200
3100
2000
2000
1000
500900
10000
9000
8500
8000
8000
25
35
50
60
900
400
400
-
1500
1000
1000
-
4300
3300
2700
2200
5000
4500
3800
3200
6500
6300
6000
5500
7000
6800
6500
6000
La tabla es vlida para motores en montaje horizontal. Los intervalos de lubricacin para motores
verticales se reducen a la mitad de dichos valores.
Como alternativa, cuando el motor lleva engrasadoras, se debe inyectar grasa fresca a la caja de
rodamientos hasta que la grasa vieja queda
totalmente reemplazada.
Advertencia
Mucha grasa pueden irritar la piel e inflamar los
ojos. Seguir las indicaciones del fabricante.
Los valores de la tabla estn basados en temperatura de rodamientos de 80C (176F). Los valores
se reducen a la mitad por cada 15 k (59R) de
aumento de temperatura en los rodamientos. Si la
temperatura mxima del rodamiento es 70C
(158F) los valores de la tabla pueden doblarse.
Advertencia
No se debe sobrepasar la temperatura mxima de
funcionamiento de la grasa ni del rodamiento.
Recambios
Si se pide recambios, se debe indicar la denominacin completa y el cdigo del producto indicado
en la placa de caractersticas.
Si el motor tiene un nmero de serie del fabricante,
se debe indicar tambin.
ABB Motors
15
Rastreo de averas
Advertencia
1. Desconectar la lnea antes de trabajar en el
motor o la carga. Es necesario asegurarse de
que el rotor nunca pueda ponerse en marcha ni
recibir corriente elctrica. Esto mismo aplica
para el equipo de carga.
2. Los motores equipados con protectores trmicos automticos se rearman automticamente
cuando la temperatura del protector se reduce
suficientemente. No utilizar motores con protectores trmicos automticos en aplicaciones
en donde un rearme automtico pueda ser
peligroso para el personal o el equipo.
3. Los motores con protectores trmicos manuales pueden rearmarse inesperadamente
despus del disparo. Si el protector manual
dispara, desconectar el motor de la lnea.
Despus de que se enfre el protector (5
minutos o ms) puede rearmarse y conectar
otra vez el motor a la lnea.
4. Descargar los capacitores antes de una
revisin del motor.
5. Siempre mantener las manos y la ropa lejos de
las partes mviles.
6. Nunca intentar medir la temperatura del motor
con las manos. sta siempre debe medirse con
un termmetro, resistencia, o termopar, La
temperatura del ducto de salida de un motor
puede estar muy caliente al tacto durante su
funcionamiento.
7. Las reparaciones elctricas debe ser efectuadas solo por personal capacitado y cualificado.
8. El no seguir con las instrucciones y
procedimientos de seguridad elctrica puede
ser causa de accidentes muy serios e incluso
la muerte.
9. Si se requiere protecciones de seguridad,
asegurarse de que no estn caducadas.
16
ABB Motors
ABB Motors
17
Estas instrucciones no cubren todas las situaciones que se pueden presentar en cuanto a instalacin,
funcionamiento y mantenimiento. En el caso de requerir ms informacin pueden contactar con las oficinas
de ventas de ABB.
Causa
Que hacer
Fusible fundido
Proteccin de sobrecarga
dispara
Lnea de suministro
incorrecta
Circuito abierto en el
bobinado o interruptor de
control
Avera mecnica
Avera en la lnea de
alimentacin
Aplicacin incorrecta
Voltaje demasiado bajo en
las terminales del motor
debido a cada de voltaje en
la lnea
Carga de arranque
demasiado alta
Barras del rotor rotas o rotor
que gira sobre el eje
Circuito primario abierto
Carga excesiva
Bajo voltaje al arranque
Barras del rotor defectuosas
Voltaje de lnea demasiado
bajo
Giro incorrecto
Secuencia de fases
equivocada
Sobrecarga
Carcasa o protector del
ventilador llenos de suciedad
que impidan la ventilacin
correcta
Fase abierta en el motor
Fase a tierra
Desequilibrio de voltaje
Reducir carga.
Limpiar el motor.
18
Comprobar conexiones.
Localizar y reparar.
Comprobar conexiones y transformador.
ABB Motors
Avera
Causa
Que hacer
El motor vibra
Desalineado
Soporte dbil
Acople desequilibrado
Equipo accionado
desequilibrado
Rodamientos defectuosos
Rodamientos desalineado
Pesos de equilibrado perdido
Funciona como monofasico
Excesivo juego axial
Alinear
Reforzar
Equilibrar
Equilibrar
Cambiarlos
Alinearlos
Equilibrar el rotor
Circuito abierto
Ajustar rodamiento
Desequilibrio en la corriente de
lnea en motores trifasicos durante
su funcionamiento
Ruido de rozaduras
Corregir anomala
Funcionamiento ruidoso
Entrehierro no es uniforme
Desequilibrio en el rotor
Eje doblado
Tiro excesivo en la polea
Polea muy separada del motor
Dimetro de la polea muy
pequeo
Mala alineacin
Calentamiento en rodamientos de
bolas
Lubricacin insuficiente
Deterioramiento de la grasa o
contaminada
Demasiada grasa
Rodamientos sobrecargado
Bolas rotas o pistas de
rodadura daada
ABB Motors
19
LV Motors
Manufacturing sites (*) and some of the biggest sales companies.
Australia
ABB Industrial Systems
Pty Limited
P.O.Box 126
Lilydale, VIC 3140
tel. +61 (0) 3 9735 7222
fax + 61 (0) 3 9735 7282
Austria
ABB Industrie
& Gebudesysteme GmbH
Wienerbergstrasse 11 B
A-1810 Wien
tel. +43 (0) 1 601 09 0
fax +43 (0) 1 601 09 8305
Belgium
Asea Brown Boveri S.A.-N.V.
Hoge Wei 27
B-1930 Zaventem
tel. +32 (0) 2 718 6311
fax +32 (0) 2 718 6657
Brazil
Asea Brown Boveri Ltda
P.O.Box 00975
06020-902 Osasco -SP
tel. +55 (0) 11 704 9111
fax +55 (0) 11 702 1991
Canada
Asea Brown Boveri, Inc.
200 Chisholm Dr.,
Milton, Ontario L9T 5E7
tel. +1 905 875 4500
fax +1 905 875 0077
China*
ABB Yuejin Motors (Shanghai)
Company Limited
8 Guang Xing Rd.,Rong Bei
Town, Songjiang County,
Shanghai 201613
tel. +86 21 5774 2188
fax +86 21 5774 2364
Chile
Asea Brown Boveri S.A.
P.O.Box 581-3
Santiago
tel. +56 (0) 2 5447 100
fax +56 (0) 2 5447 405
Denmark*
ABB Motors A/S
Petersmindevej 1
DK-5000 Odense C
tel. +45 66 147 096
fax +45 65 912 912
Finland*
ABB Motors Oy
P.O.Box 633
FIN-65101 Vaasa
tel. +358 (0) 10 22 4000
fax +358 (0) 10 22 47372
France
ABB Industrie
15, rue Sully
F-69153 Dcines Charpieu
Cedex
tel. +33 (0) 472 054 040
fax +33 (0) 472 020 345
Germany
ABB Elektromotoren GmbH
P.O.Box 10 03 46
D-68003 Mannheim
tel. +49 (0) 621 3810
fax +49 (0) 621 381 6820
Hong Kong
Asea Brown Boveri Ltd
3 Dai Hei Street
Tai Po Industrial Estate
Tai Po New Territories
Hong Kong
tel. +852 292 938 38
fax +852 292 935 05
India*
Asea Brown Boveri Ltd
P.O.Box 16
Faridabad 121 001
tel. +91 (0) 129 233 313
fax +91 (0) 129 234 288
Indonesia
P.T. Abdibangun Buana
P.O.Box 3781
Jakarta 10002
tel. +62 (0) 21 314 9115
fax +62 (0) 21 315 3963
Ireland
Asea Brown Boveri Ltd
Components Division
Belgard Road
Tallaght, Dublin 24
tel. +353 (0) 1 405 7300
fax +353 (0) 1 405 7327
Italy*
ABB Industria S.p.a.
Motor Division
Viale Edison 50
I-20099 Sesto S. Giovanni,
Milano
tel. +39 (0) 2 262 321
fax +39 (0) 2 262 32723
ABB Motors
Business Area Marketing Communications
P.O.Box 633
FIN-65101 Vaasa Finland
tel. +358 10 22 4000
fax +358 10 22 43575
www.abb.com/motors
Japan
ABB Industry K.K.
2-39, Akasaka 5-Chome
Minato-Ku
Tokyo 107
tel. +81 (0) 3 556 38605
fax +81 (0) 3 556 38615
Korea
ABB Industrial Systems Co.Ltd.
Oksan Bldg, 12 Fl,
157-33, Samsung-dong,
Kangnam-Ku, Seoul 135-090
tel. + 82 2 528 2327
fax.+ 82 2 528 3490
Mexico*
ABB Sistemas, S.A. de C.V.
P.O.Box M-2434
06000 Mexico D.F.
tel. +52 5 328 1400
fax +52 5 328 1694
The Netherlands
ABB Componenten B.V.
P.O.Box 532
NL-2900 AM Capelle a/d Ijssel
tel. +31 (0) 10 258 2250
fax +31 (0) 10 4586559
New Zealand
ABB Service Division
P.O.Box 22167
Otahuhu, Auckland
tel. + 64 (0) 9 276 6016
fax + 64 (0) 9 276 1303
Norway
ABB Industri AS
P.O.Box 6540 Rodelkka
N-0501 Oslo 5
tel. +47 22 872 000
fax +47 22 872 541
Singapore
Asea Brown Boveri Pte Ltd
P.O.Box 95
Pasir Panjang Post Office
Singapore 9111
tel. +65 775 3777
fax +65 778 0222
Sweden*
ABB Motors AB
S-721 70 Vsters
tel. +46 (0) 21 329 000
fax +46 (0) 21 124 103
Switzerland
ABB Normelec AG
Badenerstrasse 790
Postfach
CH-8048 Zrich
tel. +41 (0) 1 435 6666
fax +41 (0) 1 435 6603
Taiwan
Asea Brown Boveri Ltd
P.O.Box 81-54
Taipei
tel. +886 (0) 2 579 9340
fax + 886 (0) 2 577 9434
Thailand
Asea Brown Boveri Ltd
P.O.Box 2087
Bangkok 10501
tel. +66 (0) 2 249 4825
fax +66 (0) 2 249 8479
The United Kingdom
ABB Motors Ltd
South Point
Sutton Court Road
Sutton, Surrey SM1 4 TY
tel. +44 (0) 181 395 8585
fax +44 (0) 181 395 8991
USA
ABB Industrial Systems Inc.
Drive Products & Systems
P.O.Box 372
Milwaukee
WI 53201-0372
tel. +1 414 785 3416
fax +1 414 785 0397
Venezuela
Asea Brown Boveri S.A.
P.O.Box 6649
Carmelitas,
Caracas 1010A
tel. +58 (0) 2 238 2422
fax +58 (0) 2 239 6383
Spain*
ABB Motores S.A.
P.O.Box 81
E-08200 Sabadell
tel. +34 (9) 3 728 8500
fax +34 (9) 3 728 8554
Technical
Information
TI 189F/00/en
Ultrasonic Measurement
prosonic FDU 8086
Operating Instructions
015081-1007
Application
Prosonic FDU is a series of nine
ultrasonic sensors with different
measuring ranges for continuous, noncontact measurement of level and flow.
FDU 80, 80 F
Liquids: 5 m (16 ft)
Solids: 2 m (6.5 ft)
FDU 81, 81 F
Liquids: 10 m (32 ft)
Solids: 5 m (16 ft)
FDU 82
Liquids: 20 m (65 ft)
Solids: 10 m (32 ft)
FDU 83
Liquids: 25 m (82 ft)
Solids: 15 m (49 ft)
FDU 84
Solids: 25 m (82 ft)
FDU 85
Solids: 45 m (147 ft)
FDU 86
Solids: 70 m (230 ft)
Endress + Hauser
The Power of Know How
Measuring System
Measuring System
The complete measuring system
consists of
the Prosonic FDU 80, 80 F, 81, 81 F,
82, 83, 84, 85 or 86 ultrasonic sensor
the transmitter
Prosonic FMU 860: 1-channel version
for level measurement or
Prosonic FMU 861: 1-channel version
for flow measurement or level
measurement or
Prosonic FMU 862:
2-channel version.
Sensor FDU 86 can be selected and
operated by FMU 86x transmitters with
software version 2.2 upwards.
Sensor Accessories
The accessories (see pages 9 and 10)
ensure that the sensors can be adapted
to special process conditions:
Alignment unit FAU 40 for the sensor
All-weather protective cover
Mounting frame
Wall bracket
Sensor flanges (e.g. FAU 80)
External temperature sensor FMT 131
A separate power supply unit is
available for heated sensors.
FMU
FMU
FMU
FDU 80F with
flange FAU 80
FDU with
alignment unit
FAU 40
FDU
Max.
FDU
Blocking Distance
Due to the ringing time of the sensor,
there is a zone immediately below the
sensor in which returning echoes cannot
be detected. This so-called blocking
distance BD determines the minimum
distance between the sensor diaphragm
and the maximum level in the silo. If the
minimum distance is not maintained, the
level will not be measured correctly.
FMU
Operating principle of
FDU ultrasonic
sensors
BD Blocking distance
D Distance from sensor
to surface of material
L Height in silo
(Level)
F Maximum level
(100%, Full)
E Zero point of
measurement
(0%, Empty)
D =c t
2
BD
Function
Planning
Recommendations
Application Requirements
Optimum conditions in tanks or silos
are achieved if
the lower edge of the sensor is below
the silo roof
the detection zone does not include
any internal fixtures or the filling curtain
the surface of the solid is hard and
coarse-grained
the surface of the liquid is calm and no
vapour is formed
operation is under normal atmospheric
pressure
the vessel is not being filled during
measurement.
Less than optimum conditions reduce
the measuring range of the sensors.
Factors
Attenuation
(dB)
0
510
1020
2030
Filling curtain
outside detection zone
small amounts in detection zone
large amounts in detection zone
0
510
1040
Dust
none
low amounts
high amounts
0
5
520
Surface of solid
hard, coarse (e.g. grit)
soft
(e.g. peat, dust-covered clinker)
40
4060
Surface of liquid
calm
ripples
strong turbulence
(e.g. agitator blades)
0
510
1020
Foam
please contact Endress+Hauser
Measuring
range 70
m
FDU 86
Sensor installation
lower edge free in silo
on collar, lower edge slanted
depending on diameter/length ratio
on collar, lower edge horizontal
depending on diameter/length ratio
40
Dimensions
1 m = 3.28 ft
1 ft = 0.305 m
FDU 85
30
FDU 84
FDU 83
20
FDU 82
10
FDU 81, 81 F
FDU 80, 80 F
0
0
20
40
60
80
100
110
Attenuation dB
Echo attenuation as a
function of range for
various sensors (ideal
reflection and
atmospheric conditions)
0
1020
2040
Installation
Accuracy
A constant temperature and sound
velocity within the measuring path
enable a high degree of accuracy to
be achieved. The effects of large
temperature variations within the
measuring path and changing gas
mixtures must be calculated and the
Prosonic programmed accordingly.
With liquids having a high partial
pressure, the gas composition must
be determined to see if it remains
constant.
Operating Limits
The sensors may not be used to
measure aliphatic hydrocarbons
(not applicable to FDU 80 F / FDU 81 F).
r= tan
3 dB beam angle
L length of beam
(calculated from max.
measuring range of
sensor)
r radius of beam
FDU 80, 80 F
Liquids
FDU 81, 81 F
FDU 82
FDU 83
FDU 80
Solids
8
FDU 81
FDU 82
FDU 83
FDU 84
FDU 85
FDU 86
L
5m
(16 ft)
10 m
(32 ft)
20 m
65 ft)
25 m
(82 ft)
r
0.35 m
(1.1 ft)
0.69 m
(2.3 ft)
1.4 m
(4.6 ft)
0.87 m
(2.8 ft)
2m
(6.6 ft)
5m
(16 ft)
10 m
(32 ft)
15 m
(49 ft)
25 m
(82 ft)
45 m
(147 ft)
70 m
(230 ft)
0.14 m
(0.46 ft)
0.35 m
(1.1 ft)
0.7 m
(2.3 ft)
0,52 m
(1.7 ft)
1.1 m
(3.6 ft)
1.9 m
(6.2 ft)
3.6 m
(11.8 ft)
a)
b)
a) Correct installation
As far as possible from the silo wall, the material
inflow and internal fixtures.
The centre of the outflow funnel reflects an echo
which is received by the sensor even when the silo
is empty.
b) Incorrect installation
The detection zone includes the filling curtain.
The echo is reflected to one side when the silo is
empty.
Mounting in Vessels
Install the sensor so that its lower
edge projects into the vessel.
Position the sensor so that neither the
filling curtain nor any internal fittings,
e.g. an additional limit switch, are
within the detection zone.
The sensor must be positioned at the
centre of the outflow funnel so that an
echo is received when the silo is
empty.
Accurate positioning of the sensor
can be simplified using the FAU 40
alignment unit.
The cable of the prosonic sensor is
not designed as a supporting cable.
Do not use it as a suspension wire.
If the sensor is to be installed in tanks
containing very aggressive media,
check that the chemical and corrosion
resistance of the sensor materials
meet these requirements.
Mounting:
above: FDU 84 on girder or angle bracket
centre: FDU 84 with alignment unit FAU 40 near to
a service access
below: FDU 84 with a 1" sleeve welded to a grating
hazardous area
non-hazardous area
1" pipe
conduit seal
conduit seal
1" threaded
sleeve
81
d2
0,5 A
Order No.
d2
No. d2
Standard for
FAU 80 - CAP
20
200
18
160
DN 80 PN 16
(DIN 2527)
23.9
190.5
19.1
152.4
18
185
19
150
JIS 10 K 80
(JIS B 2210)
FAU 80 - CAJ
FAU 80 - AAP
FAU 80 - AAJ
FAU 80 - KAP
FAU 80 - KAJ
15
130
81
76
d2
D
Order No.
d2
No. d2
Standard for
FAU 80 - CHP
20
220
18
180
DN 100 PN 16
(DIN 2527)
23.9
228.6
19.1
190.5
18
210
19
175
JIS 10 K 100
(JIS B 2210)
FAU 80 - CHJ
FAU 80 - AHP
FAU 80 - AHJ
FAU 80 - KHP
FAU 80 - KHJ
Dimensions
1 mm = 0.039 in
1 in = 25.4 mm
FDU 8086
Heat
isolation
Inner edge
45 x 2 mm
Dimensions
1 mm = 0.039 in
1 in = 25.4 mm
97.5
Sensor
FDU 80, 81
FDU 80 F, 81 F
FDU 80 F, 81 F
FDU 82,
FDU 83,
FDU 84, 85
FDU 86
FDU 80 F,
FDU 81 F
Mounting with
FAU 80
flange DN 80
or DN 100
D / mm
80
80
100
150
200
250
300
L / mm
<250
<250
<300
<300
<400
<500
<600
Dimensions
1 mm = 0.039 in
1 in = 25.4 mm
Blocking distance BD
FDU 80:
min. 300 mm
1 x b0
Hmax.
Example:
Flow measurement with
Khafagi-Venturi flumes
Typ
b0 mm
be mm
QV 308
800
320
b0
Electrical Connection
Wire coding
BK
RD
YE
GNYE
BN
BU
Connecting
the sensors
above left :
FDU 80, 80F, 81, 81F,
82
above right:
FDU 80, 81 with
heating system
below right:
FDU 83, 84, 85
(ground via the
terminal box)
below left:
FDU 83, 84, 85, 86
(ground to FMU)
Screening
The screening acts as
feedback and must be
exhibit electrical
continuity between
sensor and transmitter.
0.5
(AWG 20)
0.75
(AWG 18)
1
(AWG 17)
max. length
m (ft)
150
(490.5)
250
(817.5)
300
(981)
black
red
yellow
green/yellow
brown
blue
Sensor extension
cable:
FDU 80, 80F, 81, 81F,
82:
Ord. No. 938278-0120
FDU 83, 84, 85
Ord. No. 938278-1021
FDU 86
Ord. No. 52000261
BK
YE
FDU 80/81
with heating
Screening
RD
BN BU BK YE RD
Use terminal
box for cables
up to 300 m
(981 ft)
Use terminal
box for cables
up to 300 m
(981 ft)
Screening
80
81 82
FMU
860/861/862
Channel 1
90
91 92
FMU 862
Channel 2
power
supply unit
80
81 82
FMU
860/861/862
Channel 1
90
91 92
FMU 862
Channel 2
GNYE BK YE RD
GNYE BK YE RD
Use terminal
box for cables
up to 300 m
(981 ft)
Use terminal
box for cables
up to 300 m
(981 ft)
Screening
Screening
80
81 82
FMU
860/861/862
Channel 1
80
81 82
FMU
860/861/862
Channel 1
90
91 92
FMU 862
Channel 2
90
91 92
FMU 862
Channel 2
13
Order number:
919791-0000
919791-0001
919791-0002
25
100
Mounting Frame
Material:
700 mm, galvanised steel
700 mm, 1.4301 (AISI 304)
1400 mm, galv. steel
1400 mm,
1.4301 (AISI 304)
Accessories
55
919791-0003
3.2
33.7
60
4
76
100
200
45
6.5
700/1400
20
100
150
130
919790-0003
A
25 50
100
20
20
C
Dimensions
1 mm = 0.039 in
1 in = 25.4 mm
Order number:
919790-0000
919790-0001
919790-0002
35
For separate
temperature sensor
M8
35
L
300
500
200
15
6.5
105
100
22
75
35
75
585
250
3.2
5
33.7
6.5
213
13
25
88
110
150
150
110
galvanised steel
919792-0000
1.4301 (AISI 304)
919792-0001
180
Wall Bracket
Material:
Order number:
Material:
Order number:
34
100
Accessories
All-weather protective
cover for FDU 80 and
FDU 81
98
Flanges
Version, similar to:
Order number:
DN 80 PN 16 in PPs
919789-0000
DN 100 PN 16 in PPs
919789-0002
DN 150 PN 16 in PPs
919789-0004
DN 200 PN 16 in PPs
919789-0006
The maximum operating pressure of the
sensor applies.
Other flanges on request.
Power Supply Unit for Sensor
Heating of FDU 80 and FDU 81
Power unit (24 V DC) for sensor heating
with IP 66 protective housing.
Material:
PT/ABS
Order No.:
215095-0002
Dimensions
1 m = 3.28 ft
1 ft = 0.305 m
Certificates
J
Cenelec EEx m II T5
Q FM Class I Div.1 Groups AD
R Standard
Cable Length
1
*
8
5m
other on request
m variable length
(630 m)
FMT 131 -
67
FMU 860 /
861 / 862 / 867
Pg 16
70
110
G 1/2 A
ISO 228
YEGN
EX
120
right:
electrical connection of
standard temperature
sensor FMT 131-R7
(FMT 131-J is delivered
with cable connected)
SW 27
25
left:
dimensions of
temperature sensor
FMT 131
71
BK YE
EX
BK YE YEGN
10
10
FMT 131
G 1/2
SW 27
12
Dimensions
1 mm = 0.039 in
1 in = 25.4 mm
21.8
110
Dimension of protective
sleeve for temperature
sensor
NPT
Pg 11
Hexagonal screw
AF 13 for lateral
adjustment
Two grub
screws for
height
adjustment
(4 mm
Allen key)
Seal here
Dimensions of
alignment unit FAU 40
O ring
G1A
St Ex Zone 10
11
left:
with G 1 thread and
Pg 11 cable gland
right:
with 1 NPT thread and
3
/4" cable gland for pipe
connection
~70
grounding
screw
Swivel
through 15
10
Accessories
1 NPT
Technical Data
General Information
Manufacturer
Endress+Hauser GmbH+Co.
Instrument
Ultrasonic sensor
Designation
Prosonic FDU 80, 80F, 81, 81F, 82, 83, 84, 85, 86
Technical documentation
Version
Technical data
TI 189F/00/en
06.99
according to DIN 19259
Application
Measuring principle
Modularity
Construction
Signal transmission
Analogue voltages
Measured variables
Input
Measuring ranges
FDU 80
FDU 80F
FDU 81
FDU 81F
FDU 82
FDU 83
FDU 84
FDU 85
FDU 86
FDU 80, 80F
FDU 81, 81F
FDU 82
FDU 83
FDU 84, 85
FDU 86
Operating frequency
(at 23C)
58 kHz
44 kHz
29 kHz
30 kHz
21 kHz
17 kHz
11 kHz
Pulse frequency
r= tan
FDU 80
FDU 81
FDU 82
FDU 83
FDU 84
FDU 85
FDU 86
Output
in solids
2 m (6.5 ft)
5 m (16 ft)
10 m (32 ft)
15 m (49 ft)
25 m (82 ft)
45 m (147 ft)
70 m (230 ft)
Blocking distance
=3 dB beam angle
L = length of beam (calculated from
max. measuring range of sensor)
r = radius of beam
in liquids
5 m (16 ft)
5 m (16 ft)
10 m (32 ft)
10 m (32 ft)
20 m (65 ft)
25 m (82 ft)
Transmitters
Liquids
8
8
8
4
Solids
8
8
8
4
5
5
6
L
L
5m
10 m
20 m
25 m
r
0.35 m
0.69 m
1.4 m
0.87 m
2m
5m
10 m
15 m
25 m
45 m
70 m
0.14 m
0.35 m
0.7 m
0.52 m
1.1 m
1.9 m
3.6 m
12
Process Conditions
Mounting conditions
Mounting position
Ambient conditions
Conversion factors
1 mm = 0.039 in
1 in = 25.4 mm
1 bar = 14.5 psi
1 psi = 0.068 bar
1 kg = 2.2 lbs
1 lb = 0.45 kg
x C = (1.8 x + 32) F
Ambient temperature
FDU 80:
FDU 80F
FDU 81:
FDU 81F:
FDU 82, 83, 84, 85:
FDU 86:
40+60C (40+140F)
40+95C (40+203F)
40+80C (40+176F)
40+95C (40+203F)
40+80C (40+176F)
40+150C (40+302F)
Relative humidity
Protection
Electromagnetic compatibility
FDU 80
FDU 80F*****
FDU 81****
FDU 81F*****
FDU 82
FDU 83
FDU 84
FDU 85
FDU 86
20+60C*
40+95C
20+80C
40+95C
20+80C
20+80C
20+80C
20+80C
40150C
Housings
122
132
20
119
3
80
FDU 82
Weight: 1.2 kg (2.6 lbs)
29.5
29.5
98
70
136 (153)
~ 139 (156)
189 (196)
FDU 85
Weight: 5.0 kg (10.9 lbs)
239 (244)
13
155
FDU 84
Weight: 4.7 kg (10.3 lbs)
30
FDU 83
Weight: 3.1 kg (6.8 lbs)
26.5
97
30
Mechanical Construction
244
ca. 450
30
FDU 86
Weight: 5.0 kg
198
Materials
Conversion factors
1 mm = 0.039 in
1 in = 25.4 mm
1 bar = 14.5 psi
1 psi = 0.068 bar
1 kg = 2.2 lbs
1 lb = 0.45 kg
Housing
PP-GF
ETFE
PA*
PA*
UP
UP
Thread
PP-GF
ETFE
1.4301 (AISI 304) or aluminium
1.4301 (AISI 304) or aluminium
UP
UP or 1.4301
Diaphragm
* 0.5 mm stainless steel 1.4571/SS 316Ti with a 4 mm
closed-pore PE cover facing the material
FDU 83
FDU 84
FDU 85
FDU 86
Diaphragm seal
FDU 80...85:
FDU 86:
EPDM
silicone
Connecting cable
Mounting accessories
Power Supply
Power supply
Ignition protection
CE mark
Order Code
Supplementary Documentation
14
PVC
Product Structure
Conversion factors
1 m = 3.28 ft
1 ft = 0.305 m
FDU
none
with heating, 24 V DC
Product designation
FDU
Product designation
15
Product Structure
Conversion factors
1 m = 3.28 ft
1 ft = 0.305 m
x C = (1.8 x + 32) F
Threaded connection G 1, UP
Threaded connection 1 NPT, UP
Threaded connection G 1, 1.4301 (AISI 304)
Threaded connection 1 NPT, 1.4301 (AISI 304)
Cable Length
1
2
3
4
5
6
8
FDU
86
Product designation
Endress+Hauser
GmbH+Co.
Instruments International
P.O. Box 2222
D-79574 Weil am Rhein
Germany
Tel. (0 76 21) 9 75-02
Tx 7 73 926
Fax (0 76 21) 9 75-3 45
http://www.endress.com
info@ii.endress.com
Endress + Hauser
The Power of Know How
08.99/MTM
TI 189F/00/en/08.02
015081-1007
HD/CV5
015081- 1007
Technical Information
TI 190F/00/en
Ultrasonic Measurement
Prosonic FMU 860...862
Level and flow measurements with ultrasonics
Simple to start up, easy to use, flexible
Field mounted ultrasonic transmitters
Applications
Prosonic FMU 860...862 ultrasonic transmitters are for use with the Prosonic FDU
80...86 family of sensors.
The transmitter determines levels in silos
and tanks and calculates the volume of
solids and liquids they contain.
With the Prosonic 860 ... 862 sensors can
be operated which are mounted in explosion hazardous areas according to FM /
CSA / ATEX.
When used for applications in fresh and
waste-water, Prosonic measures
flow rates in flumes and weirs
water levels
and can control screen cleaning and
pumps.
Measuring System
Measuring System
or
FMU 860
........
or
........
FMU 862
FMU 860
FDU
FDU
EX
ATEX
Zone 20
Ex Zone 1
Overspill protection
FMU 86
FDU
Max.
Endress+Hauser
Applications
Prosonic FMU 860
Level
FMU 860
FMU 860
L
FDU
FDU
Continuous level and volumetric measurement of liquids and solids in tanks and silos.
Pump control in up to 5 steps
Alternating pump control
Adjustable switch delay
Prosonic FMU 861
Endress+Hauser
Conveyor belts
Flow
FMU 861
Q
1 2 3 4 5 6
EX
FDU
Ex Zone 1
Differential
FMU 862
Dh
FDU
FDU
An ultrasonic pulse emitted from the sensor is reflected back by the surface of the material or
liquid and is received by the same sensor as an echo signal. The product height or water level is
then calculated from the run time of the ultrasonic signal (echo level determination).
Simple Start-Up
The time required for start-up is minimised by using preset operating parameter values. Selecting
just one parameter automatically sets the measuring line to one of five typical applications:
liquid
vessels with rapid changes of liquid
fine-grained bulk solids
coarse-grained bulk solids
conveyor belts
The Prosonic transmitter is based on state-of-the-art evaluation methods including fuzzy logic elements for intelligent echo analysis. No other special procedures are required as this method
enables the true level echo to be clearly distinguished from:
sporadic reflections (e.g. from agitator blades),
interference echoes and noise (e.g. from filling) or
multiple reflections (e.g. with closed tanks).
Even with almost unfavorable mounting points, the advantages of continuous, non-contact ultrasonic measurement can be used by activating a special fixed target suppression mode or filtering
factor.
Complete Functionality
Differential measurement:
Value1 Value2
Endress+Hauser
On-site operation
Keys and display on the
front cover
Full
Application Sensor
Measured Empty
calibration calibration
value
type
Relay
selection
Relay
function
Linearisation
Preset
height
Q/h char.
curve
Fixed
target
suppress.
Echo
S/N
attenuation factor
+
-
Level
Volume
Warning/
Fault
Output
with
fault
The keypad on the front panel is used to configure the transmitter and call up parameters, which
are shown on a 4 1/2 character display.
The input dialogue is based on the standard Endress+Hauser operating matrix in which every
input field is quickly and easily selected using the "V" (vertical) and "H" (horizontal) keys. Parameters are simply entered using the three keys , +, and are registered and stored once
the "E" key has been pressed.
I-- I+
45
DXR 275
Field
Control room
Communication
resistor
min. 250
DXR 275
4...20 mA
Operation
For devices with HART interface all values can be entered using a handheld terminal. The user
has comprehensive and detailed information on inputs both on-site and in the control room. The
measurement remains totally unaffected during the interactive input.
Electrical Connection
The handheld terminal is connected either
directly to current output 1 of the transmitter or
to a communications resistor.
In general: The handheld terminal can be connected anywhere in the signal circuit as long as
there is a resistance between its terminals which is larger than the minimum communications
resistor (250 ).
Screened cable is recommended, maximum capacitance 100 nF.
Endress+Hauser
Operation via
Commuwin II
optional
power pack
RS 232 C
4...20 mA
HART
Commubox
FXA 191
VH
Commuwin II
The Commubox FXA 191 connects HART transmitters to the RS 232 C serial interface of a personal computer. This enables the transmitter to be remotely operated with the Endress+Hauser
Commuwin II operating program.
PROFIBUS-DP interface
System integration
Personal Computer with
Profiboard or Proficard
and Commuwin II or ToF-Tool
PLC
PROFIBUS-DP
VH
other
field devices
Prosonic
The version with PROFIBUS-DP interface can be integrated as a slave into a PROFIBUS-DP segment. In order to connect a Personal Computer to the bus, PROFIBOARD or PROFICARD can be
used.
Operation
Endress+Hauser
RS-485 Interface
Connecting a
Personal Computer
Instruments with RS-485 interface can be connected to a Personal Computer in one of the following ways.
RS 485 card for PC (for the Fieldmanager and Commugraph programs)
Adapter RS 232 C/RS 485 (for the Fieldmanager and Commugraph programs)
Commubox FXA 192 (for the graphical program Commuwin II)
FXA 675 with a Gateway ZA 67x with serial interface
Connecting to Process
Control Systems
Personal computer
with display and
operating software
programmable
logic controller
Rackbus
VH
FXA 675
FXA 675
ZA 673
RACKBUS
PROFIBUS
max. 1200 m
Rackbus RS 485
Gateway:
ZA 673
PROFIBUS
ZA 674
FIP ZA 672
MODBUS
The Prosonic FMU 86... can be easily linked to existing process control systems via the RS-485
interface.
The FXA 675 interface card (or the Monorack II RS-485) connects two individual Rackbus RS-485
networks with up to 25 transmitters via the Rackbus. A second card (Gateway) serves as the bus
connection for standard networks such as PROFIBUS, FIP or MODBUS.
The Prosonic P level measurement system also enables a number of widely distributed ultrasonic
measuring points to be controlled by a personal computer.
Operating programs
Endress+Hauser
Housing Versions
Field housing
(Operation in the field)
Seperate transmitter
electronics
(Control room operation)
144
IP 40 plastic housing
21 TE
IP 10 mounting plate
With this version, the operating unit is separated from the transmitter electronics.The operating
unit is available for mounting in a control cabinet (144 mm x144 mm) or for mounting in an assembly rack (21 HP). The transmitter electronics are mounted in an IP 40 housing or else are on an
IP 10 mounting panel in the control cabinet.
Note!
The versions with separate electronics are not available together with the digital interfaces RS485 or PROFIBUS-DP.
Endress+Hauser
Dimensions
IP 66 field housing resp.
IP 40 plastic housing
292
10
min. 52
253
4,5
< 69
275,5
IP 10 mounting plate
255
200
170
9x20
10
90
280
6.4x19
6.4x38
10.5
25.5
9x40
230
operating unit
for rack
min .18
3 HE
63
144
21 TE
max. 105
max. 23
Endress+Hauser
Accessories
All-Weather Cover
Material: aluminium, blue lacquered
Order No. 919567-0000
Material: stainless steel 1.4301;
Order No. 919567-0001
Weight: approx. 1 kg
Mounting screws supplied
343
17
187,5
Post mounting
Material: galvanised steel, Order No.:
for 2"-Post: 919566-0000
for 1"-Post: 919566-1000
Material: stainless steel 1.4301; Order No:
for 2"-Post: 919566-0001
for 1"-Post: 919566-1001
Weight: approx. 1 kg
Mounting screws and nuts supplied
Order No.
94
DCE DTE
54
RS-232C
RS-485
15 V DC
154
BR 2
J5
100
BR 1
J1
J9
I
J2
HART-Communicator
DXR 275
Handheld for instruments with HART interface (siehe Operating Instructions 139F/00/en).
PC Interfaces
for PROFIBUS-DP
10
Endress+Hauser
Temperature sensor
Overvoltage protection in
IP 66 protective housing
Overvoltage protection
and power supply Unit for
Sensor heating in IP 66 Protective Cover
Power supply unit (24V DC)for sensor heating of up to 2 sensors with integrated overvoltage protection for power supply
Order No. 215095-0000
Power supply: 230 V (+15%/20%)
Dimensions: s. page 9 (IP 66 housing)
Endress+Hauser
11
Electrical Connection
Terminal Strip
L+ LL1 N
5
YE RD YE RD
24 VAC; 48VAC;
115 VAC; 230VAC
Sensor 2
RS-485 version
5
RS-485
11 12 13
31 32 33 41 42 43 51 52 53
DP
RS-485
RxD/TxD-N
GND
RxD/TxD-P
31 32 33 41 42 43 51 52 53
RxD/TxD-N
GND
RxD/TxD-P
11 12 13
Sensor 1
Profibus-DP version
DP
Temp.
0/4 20 mA
0/4 20 mA
L+
20 30 VDC LL1
N
PE
terminals fitted to
the version with
5 relays only
70 71 80 81 82 90 91 92
Sync. FMU
6 7 11 12 13 21 22 23 31 32 33 41 42 43 51 52 53 60 61 62 63 64
4 5
Liquiphant
Soliphant
1 2 3
The terminal strip for cable diameters up to 2.5 mm2 is in a separate connection chamber. The
cable entries are prestamped for easy removal.
underside 5 x Pg 16 und 4 x Pg 13.5 (M20x1,5)
rear 5 x Pg 16
The electrically isolated areas are separated by thick lines in the figure above.
Sensor Cable
Electrical Isolation
12
Connection is with the cable supplied or by using an extension via a terminal box with commercial, two-core screened cabling (also available from E+H). Maximum values: up to 6 per core,
maximum 60 nF.
mm2
0,5
0,75
max. length in m
150
250
300
Current output, relay outputs, power connection and sensor input are all electrically isolated from
one another.
With the FMU 862, the two current outputs are electrically connected to one another, as are the
two sensor inputs.
Endress+Hauser
Power Supply
Alternating voltage
180253 V
+10% / 15%
50/60 Hz
90132 V
+15% / 22%
50/60 Hz
3855 V
+15% / 20%
50/60 Hz
1928 V
+15% / 20%
50/60 Hz
64
FMU 86
63
64
FMU 86
63
max. 20units
64
In order to avoid cross-talk between parallel routed sensor lines connect the transmitters (max.
20) to a synchronisation line. The sensors are then scanned in sequence. If more devices are present, groups of 20 transmitters should be used. The cables within one group can be in parallel.
The cables of different groups must be separated. Common screened cable can be used.
Endress+Hauser
13
Technical Data
General Information
Manufacturer
Endress+Hauser GmbH+Co. KG
Instrument
Ultrasonic transmitter
Designation
Technical Documentation
Version
Technical Data
TI 190F/00/en
08.02
to DIN 19259
Application
Function and
System Design
Measuring principle
Modularity
Transmitter
Input
Measured variable
Measuring range
Ultrasonic sensors
Analogue output
Output signal
Output on error
020 mA:
10 % (2 mA), +110 % (22 mA), HOLD (last current value
is held)
420 mA:
10 % (2,4 mA, +110 % (21,6 mA), HOLD (last current
value is held)
Current limit
14
24 mA
Integration time
0300 s
Load
max. 600
Effect of load
negligible
Endress+Hauser
Relay output
Version
Functions
Accuracy
Ambient conditions
Materials/Weight
Accessories
Endress+Hauser
optional three or five independent relays each with one potentialfree change-contact
always three relays only with RS-485- or PROFIBUS-DP interface
limit value
alarm relay
trend
time pulses(FMU 861 and FMU 862 only)
max. counting frequency 2 Hz, pulse width200 ms
time pulses (FMU 861 only)
back-up (FMU 862 only)
switching power
Measured error
(sum of linearity, hysteresis and
reproducibility)
Max. resolution
1 mm for FDU 80
Effect of load
Ambient temperature
20+60 C
Storage temperature
40+80 C
Shock resistance
Climatic class
Ingress protection
DIN 40050:
Field housing: IP 66 with closed housing and cable entry of
identical protection
IP 40: plastic housing with cable entry of identical protection
IP 10: plate for mounting in control cabinet
IP 40: separate operating unit for control panel
IP 10: separate operating unit for rack
AC power supply:
Interference emmission to EN 61326 ; Electrical equipment
class B
Interference immunity to EN 61326 ; Annex A (Industrial)
DC power supply:
Interference emmission to EN 61326 ; Electrical equipment
class A
Interference immunity to EN 61326 ; Annex A (Industrial)
for PROFIBUS-DP instruments
Interference emmission to EN 61326, Electrical equipment
class A
Interference immunity to EN 61326
IP 40 plastic housing
PC/ABS
Weight: 1,0 kg
IP 10 mounting plate
Al/PS
Weight: 0,8 kg
PC/ABS
Weight: 0,3 kg
Post mounting
15
Communication Interfaces
Power supply
Supplementary
documentation
16
Display (LCD)
LEDs
Counter
Software counter
HART
RS 485
PROFIBUS-DP
Synchronizing connection
AC
DC
Power consumption
Ignition protection
CE Mark
Endress+Hauser
Ordering Information
Product Structure
FMU 86
Product designation
* Shipbuilding approvals:
GL; DNV, LR, ABS, BV, RINA on request
Scope of delivery
Endress+Hauser
17
18
Endress+Hauser
Endress+Hauser
19
Endress+Hauser GmbH+Co.
Instruments International
P.O. Box 2222
D-79574 Weil am Rhein
Germany
Tel. (07621) 975-02
Tx 773926
Fax (07621) 975 345
e-mail: info@ii.endress.com
Internet:
http://www.endress.com
11.01
TI 190F/00/en/02.03
FM+SGML 6.0
Prosonic
FMU 860
KA 017F/00/a6/05.00
016085-0000
Software 2.3
d Kurzanleitung Fllstandmessung
VH
FMU 860
FDU
Endress + Hauser
The Power of Know How
d Sicherheitshinweise
Qualifikation
Montage, elektrische Installation, Inbetriebnahme, Wartung und Bedienung des Gertes darf
nur durch ausgebildetes Fachpersonal erfolgen, das vom Anlagenbetreiber dazu
autorisiert wurde. Das Fachpersonal mu diese Kurzanleitung und die Betriebsanleitung
BA 100F gelesen und verstanden haben und die Anweisungen befolgen.
e Safety Instructions
Note
Mounting, electrical installation, start-up, maintenance and operation of the instrument are
only to be carried out by trained personnel authorised by the operator of the plant.
The personnel must read, understand and follow the instructions given in this quick reference
guide and the operating manual BA 100F.
Qualification
Le montage, linstallation lectrique, la mise en service, la maintenance et lutilisation de
lappareil ne doivent tre confis qu un personnel spcialis autoris par lutilisateur de
linstallation. Ce personnel devra lire les instructions contenues dans la prsente mise en
service condense ainsi que dans le manuel complet BA 100F et les appliquer
rigoureusement.
Conseils de scurit
d Gerte-Identifikation
ENDRESS+HAUSER
PROSONIC FMU 860
FMU860R1A1 1
U: XX V AC+XX / XX/XX HZ
P: 15 VA
IP 66
Typenschild
Nameplate
Plaque
signaltique
NEMA 4X
Ser.No.: XXXXXXXXXXX
Pat.
e Instrument Identification
FMU860-R1A1
Ohne Kommunikationsprotokoll /
No communication protocol /
Sans protocole de communication
Identification de lappareil
d Elektrischer Anschlu
e Electrical Connection
Switch off the power supply to the connecting strip before carrying out any work on the
instrument
Check that the power supply agrees with that stated on the nameplate
When installing the sensor cable ensure that:
Terminal boxes are used for cables up to 300 m
The screening is not grounded
The screening is continuous without any electrical breakage between the sensor and the
transmitter
FDU 83, 84, 85, 86: the potential compensation cable is not laid within the screening
Screening: metal strands max. 6
Cable specifications (per wire): max. 6 , max. 60 nF as total capacitance
When several Prosonics are connected together, the synchronisation connections must also
be made (see BA 100F).
Raccordement lectrique
L+ L-
l1+
L1 N
l2+
YE RD
Sensor
sensor
sonde
Relais
relays
relais
erden
grounding
barrette de terre
80 81 82
80 8182
70 71 80 81 82
Speisegert
power supply unit
alimentation
80 8182
80 8182
Abschirmung
screening
blindage
BK YE RD
FDU 80/80F/81/81F/82
GNYE BK YE RD
GNYE BK YE RD
FDU 83/84/85/86
FDU 83/84/85/86
Erdung am Klemmenkasten
grounding at the terminal box
mise la terre dans la boite de
jonction
Erdung am FMU
grounding at the FMU
mise la terre au FMU
BN BU BK YE RD
FDU 80/81
mit Heizung
with heating
avec chauffage
d Display
VH
e Display
Affichage
Kommunikationssignal
(nur bei Version mit
Kommunikationsprotokoll)
Communication signal
(only with versions having a
communications protokoll)
Parameter des
gewhlten Matrixfeldes
(blinkt bei der Bedienung)
Matrixfeld
Matrix field
Signalberlauf
Strom grer als 20 mA
Signal overrun
Current greater than 20 mA
Segmentanzeige des
Stroms
Signalunterlauf
Strom kleiner als 0/4 mA
Signal underrun
Current smaller than
0/4 mA
Symbole de
communication
(Seulement pour version
avec protocole de
communication)
Paramtre de la case
matricielle slectionne
(clignote lors de la
programmation)
Coordonnes matriciel
les slectionnes
Dpassement de signal
Courant suprieur 20 mA
Affichage bargraph
reprsentatif du signal
analogique
Dpassement de signal
Courant infrieur 0/4 mA
Symbole de dfaut
allum: dfaut
clignote: avertissement,
lappareil essaye de
poursuivre la mesure
d Bedienung
VH
e Operation
The FMU is operated using a 10x10-field
matrix (see page 18/19)
A function is assigned to every field of the
matrix.
,
Note: The decimal point moves one
position to the right when V and are
pressed simultaneously.
Confirm input with E
VH
Commande
E
7
d Parametrierung
Nach jedem Parametrierungsschritt knnen
die aktuellen Mewerte abgefragt werden.
Fr Funktionen, die nicht parametriert
werden, gelten die Werkseinstellungen.
Grundeinstellungen
Basic settings
Rglage de base
10
Mewertanzeige
Display of measured value
Affichage de la mesure
Abgleich
Calibration
Etalonnage
11
Eingabe Kundeneinheit
Entering technical units
Linarisation pour
afficage en unit technique
12
e Calibration
The actual measured values can be called
up after each calibration step.
Factory settings are used for those
functions not calibrated.
Analogausgang
Analogue output
Sortie analogique
13
Relais
Relay
Relais
15
Programmation
Fehlerdiagnose
Trouble-shooting
Recherche de dfauts
16
17
d Mewertanzeige
0.3 m
FDU 81/81F
0.5 m
FDU 82
0.8 m
FDU 83
1.0 m
FDU 84
0.8 m
FDU 85
0.8 m
FDU 86
1.6 m
BD
d Matrix verriegeln
100%
V0H8
V0H0
V0H9
0%
V0H0
Anzeige
Mewert (% oder
beliebiger Maeinheit)
Display
Meas. value (% or in
units selected)
Affichage
Valeur mesure
(% ou unit technique)
V0H8
Distanz D (m/ft)
Distance D (m/ft)
Distance D (m/ft)
V0H9
Fllhhe h (m/ft)
Height h (m/ft)
V9H6
Matrix verriegeln
Eingabe einer
beliebigen dreistelligen
Zahl
Hauteur de niveau H
(m/ft)
Verrouiller la matrice
Entre dun nombre
quelconque trois
chiffres
V9H6
Verriegelung aufheben
Unlocking the matrix
Eingabe von 519
Enter the number 519
Dverrouiller la matrice
Entre de 519
Affichage de la mesure
Verrouillage de la matrice
d Grundeinstellungen
VH
1
VH
VH
+
E
e Basic Settings
Carry out these settings on start-up or when
replacing the sensor.
Call up the matrix fields from the table in
the correct sequence and select the
parameter to be entered (bold type, e.g.
333 for general reset).
Register entry with E.
Note: Units of length should only be
changed immediately after a reset.
1.
V9H5
Eingabe
333: Grundreset
Entry
333: Reset
Rglages de base
10
2.
V8H3
3.
V8H0
4.
V0H4
Lngeneinheit whlen
0: m
1: ft
Betriebsart whlen
0: Fllstand Kanal 1
Sensortyp
80: FDU 80, 81: FDU 81
80F: FDU 80F
81F: FDU 81F
82: FDU 82, 83: FDU 83
84: FDU 84, 85: FDU 85
86: FDU 86
Technical units
0: m
1: ft
Operating mode
0: level channel 1
Sensor type
80: FDU 80, 81: FDU 81
80F: FDU 80F
81F: FDU 81F
82: FDU 82, 83: FDU 83
84: FDU 84, 85: FDU 85
86: FDU 86
Entre
333: Reset
apparait dans laffichage
Unit de longueur
0: m
1: ft
Mode de fonctionnement
0: Niveau voie 1
Type sonde
80: FDU 80, 81: FDU 81
80F: FDU 80F
81F: FDU 81F
82: FDU 82, 83: FDU 83
84: FDU 84, 85: FDU 85
86: FDU 86
BD
Fllstandanwendungen
Applications of level measurement
Types dapplications
V0H3
100%
0%
1.
V0H1
2.
V0H2
3.
V0H3
Eingabe
Leer E: Distanz
Sensormembran
0%-Punkt
Voll F: Distanz 0%Punkt 100 %-Punkt
Fllstandanwendung:
0: Flssigkeit
1: Schnelle Fllstandnderung
2: feine Feststoffe
3: Grobe Feststoffe
4: Bandbelegung
Fr das 0/420 mA
Signal gilt die
Werkseinstellung:
0 %: 0, 100 %: 100
Entry
Empty E: Distance
sensor diaphragm
0% point
Full F: Distance
0% point - 100% point
Entre
Vide E: distance entre la
sonde et le niveau 0%
d Abgleich
Grundlage fr alle Messungen sind die
Eingaben Leer und Voll
Leer E: Distanz Sensormembran0%-Punkt
Voll F: Distanz 0%-Punkt100%-Punkt
Angaben fr E und F nur in der
Lngeneinheit, die beim Grundabgleich
gewhlt wurde
Zuweisung 0/420 mA: Analogausgang
(S. 13) und Beispiel und (S.14)
e Adjustment
The basis for all measurements are the
entries Empty and Full
Empty E: Distance of the sensor
diaphragm...0% point
Full F: Distance of 0% point...100% point
Values for E and F are only given in the
units selected during the basic calibration
Allocating 0/4...20 mA: Analogue output
(Page 13) and Examples and
(Page 14)
Etalonnage
11
BD
100%
12
0%
5.
V2H7
6.
V2H0
Eingabe
(siehe auch Beispiel 1
Seite 14)
Volumen am 100%Punkt in Kundeneinheit
Linearisierungsart
0: linear
(m3, hl, )
Entry
(see also Example 1,
page 14)
Volume at 100% point in
technical units
Linearisation mode
0: linear
Entre
(Voir aussi exemple 1
page 14)
Volume V1 (100%)
en unit technique
Type de linarisation
0: linaire
d Analogausgang einstellen
20 mA
4 mA
0%
100 %
Mewert /
measured value /
valeur de mesure
110 %
20 mA
hold
V3H4
0: 10 %
1: +110 %
-2 mA
22 mA
-2,4 mA
21,6 mA
4 mA
V8H1
Eingabe
Entry
(siehe auch Beispiel 1
(see also Example 1
und 2, S.14)
and 2, Page 14)
Stromausgang whlen
Select current output
2.
V0H5
0: 020 mA
1: 420 mA
4 mA-Wert
0: 020 mA
1: 420 mA
4 mA value
3.
V0H6
4.
V3H4
20 mA-Wert
Anzeige bei Strung
0: -10 %
des Mebereichs
1: 110 %
des Mebereichs
2: letzten Mewert halten
20 mA value
Display on error
0: -10%
of measuring range
1: 110%
of measuring range
2: Hold last measured
value
1.
- 10 %
Entre
(voir ausi exemples 1
et 2, p. 14)
Slectionner sortie
courant
0: 0...20 mA
1: 4...20 mA
Valeur 4 mA
Valeur 20 mA
Affichage en cas de
derreur
0: -10% de la gamme
de mesure
1: 110% de la gamme
de mesure
2: maintenir la dernire
valeur
13
d Beispiel
e Example
100 %
350 hl
0%
15 hl
100 %
350 hl
1.
2.
Eingabe
350
0
V2H7
V2H0
Entry
350
0
V2H7
Entre
350
0
Exemple
14
350 hl
21,6 mA
20 mA
15 hl
4 mA
110 %
1.
2.
3.
4.
V8H1
V0H5
V0H6
V3H4
Eingabe
1
15
350
1
Entry
1
15
350
1
Entre
1
15
350
1
d Relaisfunktion Grenzwert
LED
r u a
LED
V1H3
r u a
LED
V1H3
fallend / falling /
descendant
V1H2
steigend / rising /
montant
fllt ab / de-energises /
retombe
BD
r u a
V1H2
Fllstand / level / niveau
Eingabe
Relais whlen
1: Relais 1
2: Relais 2
Relaisfunktion whlen
0: Grenzwert
Entry
Select relay
1: relay 1
2: relay 2
Select relay function
0: limit value
Entre
Choix relais
1: relais 1
2: relais 2
Fonction relais choisir
0: fonction seuil
V1H2
Einschaltpunkt
in Kundeneinheit
Switch on point
in customer units
Point denclenchement
unit technique
V1H3
Ausschaltpunkt
in Kundeneinheit
Point de
dclenchement
unit technique
1.
V1H0
2.
V1H1
3.
4.
15
e Response on Error
16
blinkt
flashes
clignote
normal
normal
normal
Strung
error
dfaut
1.
V9H0
Anzeige
Aktueller Fehlercode
Display
Current error code
Affichage
Code erreur actuel
2.
V9H1
Letzter Fehlercode
3.
V9H2
Vorletzter Fehlercode
E501
E613
E231
Diagnose / Manahme
Kein Sensortyp gewhlt
In V0H4 Sensortyp
eingeben
Gert in Betriebsart
Simulation;
in V8H0 Betriebsart 0
whlen
Kurzschlu interner
Temperaturfhler;
Sensoranschlu berprfen oder
E+H-Service rufen
E641
Ultraschallecho kann
nicht ausgewertet
werden; Fehler durch zu
hohe Dmpfung (Staub
oder Schaum);
bleibt Fehler lnger
bestehen
Sensoranschlu
berprfen oder
E+H-Service rufen
E661
Temperatur am Sensor
zu hoch;
Mestelle berprfen
E111
E112
E113
E114
E115
Elektronischer
Gertefehler.
E+H-Service rufen
Erreurs et remdes
Aucun type de sonde
slectionn en V0H4.
Entrer le type de sonde.
Appareil en mode
simulation. Choisir en
V8H0 un autre mode de
fonction.
Court-circuit de la sonde
de temprature interne.
Vrifier le raccordement
de sonde ou contacter
SAT E+H.
Echos ne peuvent tre
exploits. Error due un
amortissement trop
important (poussires
ou mousse); si lerreur
subsiste, vrifier le
raccordement de sonde
ou contacter le SAT E+H.
Vrifier le raccordement
de sonde ou contacter
SAT E+H.
Temprature la sonde
trop leve; vrifier le
point de mesure
Temperature at the
sensor too high.
Check measurement
point
Electronic instrument
Dfaut dlectronique;
error.
appeler le SAT E+H
Call E+H Service Centre
Erreurs et remdes
17
FMU 860
V0
d
e
f
Grundabgleich Mekanal 1
Calibration Channel 1
Etalonnage de base voie 1
H0
Mewert
Measured value
Valeur de mesure
H1
Abgleich Leer
Empty calibration
Etalonnage vide
H2
Abgleich Voll
Full calibration
Etalonnage plein
H3
Fllstandanwendung
Level application
Type dapplication
Relais
Auswahl Relais
Relaisfunktion
Einschaltpunkt
Ausschaltpunkt
e
f
Relays
Relais
Relay selection
Slection relais
Relay function
Fonction relais
Switch-On point
Point dencl.
Switch-Off point
Point de dcl.
d
e
f
Linearisierung Mekanal 1
Linearisation Channel 1
Linarisation voie 1
Linearisierung
Linearisation
Linarisation
d
e
Echoparameter Mekanal 1
Echo parameters Channel 1
Ist-Fllhhe
Actual level
Hauteur de remplissage relle
Echodmpfung
Echo attenuation
V1
V2
V3
Eingabe Fllhhe
Input level
Entre hauteur de
niveau relle
Wenn Echo fehlt
If no echo
Festzielausblendung
S/N-Verhltnis
Range for automatic
Signal/noise ratio
suppression
Paramtres chos voie 1
Suppression des
Attnuation de lcho Rapport signal/bruit
Perte dcho
chos fixes
Zeilen 4, 5 und 6 nur bei FMU 862 / Rows 4, 5 and 6 for FMU 862 only / Lignes 4, 5 et 6 uniquement pour FMU 862
Service
Service
Service
Service
Service
Service
Service
Service
Service
Service
Service
Service
Service
Service
Service
Betriebsparameter
Betriebsart
Stromausgnge
4 mA-Schwelle
Lngeneinheit
V7
d
e
f
d
V8
Operating status
Operating mode
Select current
4 mA-threshold
Paramtres de fonctionnement
Sorties courant
Seuil 4 mA
Unit de longueur
Mode de
fonctionnement
Aktueller Fehlercode
Letzter Fehlercode
Vorletzter Fehlercode
Diagnostic code
Service et simulation
Gerte und
Softwareversion
Instrument and
software version
Version appareil et
logiciel
V9
f
Anzeigefeld / Output fields / Zone daffichage
18
H4
Sensortyp
Type of sensor
Type sonde
H5
Wert fr 0/4 mA
Value for 0/4 mA
Valeur pour 0/4 mA
Alternierende
Pumpensteuerung
pump control
Commande de
pompe alterne
Eingabe Volumen
Input volume
Entre volume
Zeilennummer
Line number
Numro ligne
Hllkurvenstatistik
Envelope statistics
H6
Wert fr 20 mA
Value for 20 mA
Valeur pour 20 mA
H7
Integrationszeit
Output damping
Temps dintgration
H8
Distanz
Measured distance
Distance
H9
Fllhhe
Measured level
Hauteur de
niveau
Schaltverzgerung
Switch delay
Temporisation
Durchmesser Behlter
Diameter of vessel
Diamtre cuve cyl.
horiz.
Volumen Behlter
Volume of vessel
Volume cuve cyl.
horiz.
En cas dalarme
Service
Service
Service
Statistique de la
courbe enveloppe
Zeilen 4, 5 und 6 nur bei FMU 862 / Rows 4, 5 and 6 for FMU 862 only / Lignes 4, 5 et 6 uniquement pour FMU 862
Service
Service
Service
Service
Service
Service
Service
Service
Service
Service
Service
Service
Service
Service
Service
Externer
Grenzwertschalter
Temperaturfhler
Limit switch
External temperature
sensor
Dtecteurs externes
Sonde de temp.
externe
Verriegelung
Simulation Fllstand
Simulation Volumen
Simulation Strom
General Reset 333
Security locking
Simulation level
Simulation volume
Simulation current
Verrouillage
Simulation niveau
Simulation volume
Simulation courant
19
20
Prosonic
FMU 860
KA 017F/00/a6/05.00
016085-0000
Software 2.3
VH
FMU 860
Endress + Hauser
The Power of Know How
Atencin
El montaje, la instalacin elctrica, la puesta en marcha, el mantenimiento y la utilizacin del
instrumento debe realizarse nica y exclusivamente por personal cualificado, autorizado por
el operario de la planta. El personal deber leer y seguir atentamente las instrucciones
indicadas en el presente manual breve de instalacin, as como el manual de servicio
BA 100F.
Nota
Linstallazione, i collegamenti elettrici, la messa in esercizio, la manutenzione e lutilizzo
di questo strumento deve essere effettuata esclusivamente da personale qualificato.
Il personale dovr leggere attentamente, capire e seguire le istruzioni fornite da questo
manuale breve e dal manuale operativo BA 100F.
nl Veiligheidsinstructies
Kwalificatie
De montage, elektrische installatie, inbedrijfname, onderhoud en bediening van het
instrument alleen door gekwalificeerd personeel laten uitvoeren. Laat het personeel deze
verkorte handleiding en de inbedrijfnamevoorschriften BA 100F lezen en begrijpen en volg
alle instructies hierin vermeld.
ENDRESS+HAUSER
PROSONIC FMU 860
FMU860R1A1 1
U: XX V AC+XX / XX/XX HZ
P: 15 VA
IP 66
Placa de
identificacin
etichetta
typeplaatje
NEMA 4X
Ser.No.: XXXXXXXXXXX
Pat.
FMU860-R1A1
nl Identificatie instrument
es Conexin elctrica
Collegamenti elettrici
nl Elektrische aansluiting
Schakel altijd eerst de voedingsspanning uit voordat met werkzaamheden wordt begonnen.
Controleer of de voedingsspanning overeenkomt met die welke staat vermeld op het
typeplaatje.
Let bij het installeren van de sensorkabel op het volgende:
Gebruik bij kabellengten tot 300 m een klemmenkast
Aard de afscherming niet
Trek de afscherming zonder elektrische onderbreking van de sensor naar de meetversterker
FDU 83, 84, 85, 86: kabel voor potentiaalvereffening niet binnen de afscherming leggen
Afscherming: gevlochten metaal max. 6
Kabelspecificatie (per ader): max. 6 , max. 60 nF totale capaciteit
Bij de aansluiting van meerdere Prosonic-instrumenten moeten de synchronisatieaansluitingen verbonden worden (zie BA 100F).
L+ LL1 N
l1+
l2+
YE RD
salida analgica
corrente
stroom
toma de tierra
messa a terra
aarde
80 81 82
80 8182
70 71 80 81 82
sensor
sensore
sensor
rels
rel
relais
alimentacin
alimentatore
voedingseenheid
80 8182
80 8182
pantalla
schermatura
afscherming
BK YE RD
FDU 80/80F/81/81F/82
GNYE BK YE RD
GNYE BK YE RD
FDU 83/84/85/86
FDU 83/84/85/86
BN BU BK YE RD
FDU 80/81
con calefactor
con riscaldatore
met verwarming
es Indicador
VH
Seal de comunicacin
(slo en versiones con
protocolo de
comunicacin)
Segnale di comunicazione
(solo per versioni con
protocollo di
comunicazione)
Campo de matriz
Campo di matrice
Superacin de la seal
Corriente superior a 20 mA
Grfico de barras
representando la seal
analgica
Superacin de la seal
Corriente inferior a 0/4 mA
Smbolo de indicacin de
error
iluminado: fallo
intermitencia: advertencia,
el instrumento intenta
continuar la medicin
Simbolo dellindicazione
derrore.
acceso: errore
lampeggiante:
avvertimento,
lo strumento prova a
continuare il
funzionamento
nl Display
Display
Communicatiesignaal
(alleen bij uitvoering met
communicatieprotocol)
Matrixveld
Balkdisplay stroomuitgang
Signaaloverschrijding
stroom groter dan 20 mA
Signaalonderschrijding
stroom kleiner dan 0/4 mA
es Funcionamiento
VH
Funzionamento
VH
+
nl Bediening
es Programacin
Ajuste bsico
Impostazioni di base
Basisinstelligen
10
Calibracin
Taratura
Inregeling
11
Introduccin de valores
en unidades seleccionadas
Ingegneristiche
Invoer klanteenheid
12
Taratura
Salida analgica
Uscita analogica
Analoge uitgang
13
Rels
Rel
Relais
15
nl Parameters instellen
16
Deteccin da fallo
Ricerca guastia
Foutdiagnose
17
0.3 m
FDU 81/81F
0.5 m
FDU 82
0.8 m
FDU 83
1.0 m
FDU 84
0.8 m
FDU 85
0.8 m
FDU 86
1.6 m
BD
es Bloqueo de la matriz
100%
V0H8
V0H0
V0H9
0%
V0H0
Indicacin
Visualizzatore
Valor medido (% o en
Valore misurato (% o
unidades seleccionadas) nelle unit selezionate)
Display
Meetwaarde (% of
willekeurige eenheid)
V0H8
Distancia D (m/ft)
Distanza D (m/ft)
Afstand D (m/ft)
V0H9
Altura H (m/ft)
Altezza h (m/ft)
Niveauhoogte h (m/ft)
V9H6
Bloqueo de la matriz
Teclear cualquier
nmero de 3 cifras
Matrix vergrendelen
Invoer van een
willekeurig getal van
3 cijfers
V9H6
Desbloqueo de la
matriz
Teclear el nmero 519
Matrix vrijgeven
Invoer van 519
nl Meetwaarde-aanwijzing
nl Matrix vergrendelen
es Ajustes bsicos
VH
VH
Impostazioni di base
10
1.
2.
nl Basisinstellingen
VH
3.
4.
Entrada
333: Reset
Immissione
333: Reset
Invoer
333: Basisreset
BUSY Visualizado en el
indicador
V8H3 Unidades de altura
0: m
1: ft
V8H0 Modo de operacin
0: nivel del canal 1
V0H4 Tipo de sensor
80: FDU 80, 81: FDU 81
80F: FDU 80F
81F: FDU 81F
82: FDU 82, 83: FDU 83
84: FDU 84, 85: FDU 85
86: FDU 86
Unit ingegneristiche:
0: m
1: ft
Modalit operativa
0: livello, canale 1
Tipo di sensore
80: FDU 80, 81: FDU 81
80F: FDU 80F
81F: FDU 81F
82: FDU 82, 83: FDU 83
84: FDU 84, 85: FDU 85
86: FDU 86
Lengte-eenheid kiezen
0: m
1: ft
Bedrijfstype kiezen
0: niveau kanaal 1
Type sensor
80: FDU 80, 81: FDU 81
80F: FDU 80F
81F: FDU 81F
82: FDU 82, 83: FDU 83
84: FDU 84, 85: FDU 85
86: FDU 86
V9H5
BD
aplicaciones de nivel
applicazioni per la misura di livello
niveautoepassingen
V0H3
0
1
100%
es Ajuste
La base de toda medicin son las entradas
Vaco y Lleno
Vaco E: Distancia entre la membrana y el
nivel 0%
Lleno F: Distancia entre el nivel 0% y el
nivel 100%
Valores E y F dentro de las unidades de
altura seleccionadas durante el ajuste
bsico
Seleccin: 0/4...20 mA: salida analgica
(pg. 13) y ejemplos 1 y 2 (pg. 14)
0%
1.
V0H1
2.
V0H2
3.
V0H3
Programacin
Vaco E (m, ft):
Distancia entre la
membrana y el nivel 0%
Lleno F (m, ft):
Distancia entre el nivel
0% y el nivel 100%
Aplicaciones de nivel )
0: Liquidos
1: Cambios rpidos de
nivel
2: Slidos de grano fino
3: Slidos de grano
grueso
4: Cinta ransportadora
Immissione
Vuoto E: Distanza tra la
membrana del sensore
e il punto 0%
Pieno F: Distanza tra il
punto 0% e il punto
100%
Misura di livello
0: Liquidi
1: Liquidi con rapide
variazioni di livello
2: Solidi a granulometria
fine
3: Solidi a granulometria
grossa
4: Nastro trasportatore
El ajuste de fbrica para
Le impostazioni di
la senal 0/420 mA es de fabbrica per luscita
0 %: 0, 100 %: 100
0/4...20 mA sono: 0%:0,
100%: 100
invoer
Leeg E: afstand
sensormembraan 0%-punt
Vol F: afstand 0%-punt 100%-punt
Niveautoepassing:
0: vloeistof
1: snelle
niveauverandering
2: fijnkorrelige vaste stof
3: grofkorrelige vaste stof
4: belading
transportband
Voor het 0/4...20 mA
signaal geldt de
default-instelling 0%: 0,
100%: 100.
Regolazione
nl Inregeling
11
BD
0%
12
100%
(m3, hl, )
1.
V2H7
2.
V2H0
Entrada
(Ver tambin Ej. 1,
pg. 14)
Volumen V1 (100%) en
unidad seleccionada
Modo de linealizacin
0: lineal
Immissione
(Vds. anche Esempio 1
a pag. 14)
Altezza al punto di
100% nell unit di
lunghezza
Modalit di
linearizzazione
0: lineare
Invoer
(zie ook voorbeeld 1,
blz. 14)
Volume op 100%-punt in
klanteenheid
Type linearisatie
0: lineair
20 mA
4 mA
0%
100 %
Valor medido/
valore misurato /
meetwaarde
110 %
20 mA
V3H4
0: 10 %
1: +110 %
1.
V8H1
2.
V0H5
3.
V0H6
4.
V3H4
-2 mA
22 mA
-2,4 mA
21,6 mA
i
hold
4 mA
- 10 %
tiempo / tempo / tijd
Programacin
(Ver tambin ej.1 y 2,
pg. 14
Seleccin de la
corriente de salida
0: 0...20 mA
1: 4...20 mA
Valor 4 mA
Immissione
(Vds. anche Esempio 1
e 2 a pag. 14)
Scelta delluscita in
corrente
0: 0...20 mA
1: 4...20 mA
Valore 4 mA
Invoer
(zie ook voorbeeld 1 en
2 blz. 14)
Stroomuitgang kiezen
Valor 20 mA
Indicador con
interferencias
0: -10 % del rango de
medida
1: 110% del rango de
medida
2: Mantiene el ltimo
valor medido
Valore 20 mA
Uscita in caso di errore
0: -10% del campo di
misura
1: 110% del campo
misurato
2: Mantiene lultimo
valore misurato
20 mA-waarde
Aanwijzing bij storing
0: -10% van het
meetbereik
1: 110% van het
meetbereik
2: laatste meetwaarde
vasthouden
0: 0...20 mA
1: 4...20 mA
4 mA-waarde
Impostazione delluscita
analogica
13
es Ejemplo
Esempio
100 %
350 hl
0%
15 hl
100 %
350 hl
1.
2.
Entrada
350
0
V2H7
V2H0
Immissione
350
0
V2H7
Invoer
350
0
nl Voorbeeld
350 hl
21,6 mA
20 mA
15 hl
4 mA
14
110 %
1.
2.
3.
4.
V8H1
V0H5
V0H6
V3H4
Entrada
1
15
350
1
Immissione
1
15
350
1
Invoer
1
15
350
1
LED
r u a
LED
V1H3
r u a
LED
descenso /
decrescente / dalend
V1H3
conexin /
energizzato / komt op
V1H2
incremento / crescente /
toenemend
desconexin /
de-energizzato / valt af
BD
r u a
V1H2
nivel / livello / niveau
1.
V1H0
2.
V1H1
3.
V1H2
4.
V1H3
Entrada
Seleccinar rel
1: rel 1
2: rel 2
Seleccinar funcin rel
Invoer
relais kiezen
1: relais 1
2: relais 2
relaisfunctie kiezen
0: valor lmite
Punto de conexin
en unidades del cliente
Immissione
Scegliere rel
1: rel 1
2: rel 2
Scegliere la funzione del
rel
0: valore di soglia
Punto di attacco
nellunit ingegneristica
Punto de desconexin
en unidades del cliente
Punto di stacco
nellunit ingegneristica
Uitschakelpunt
in klanteenheid
0: grenswaarde
Inschakelpunt
in klanteenheid
nl Relaisfunctie grenswaarde
16
parpadea
lampeggia
knippert
normal
normale
normaal
fallo
errore
storing
1.
V9H0
Indicacin
Cdigo de fallo actual
Display
Codice derrore attuale
Display
momentele foutcode
2.
V9H1
laatste foutcode
3.
V9H2
E501
E613
E231
E641
E661
E111
E112
E113
E114
E115
Cdigos de error y su
correccin
No se ha especificado
el tipo de sensor;
entrar tipo de sensor en
V0H4
Instrumento en modo de
simulacin; seleccione
otra modalidad
operativa en V8H0
Cortocircuito en el
sensor de temperatura
interno; compruebe la
conexin del sensor o
bien contacte con el
servicio tcnico de E+H
El eco ultrasnico no
puede ser evaluado;
compruebe la conexin
del sensor o bien
contacte con el servicio
tcnico de E+H
Temperatura en el
sensor demasiado alta;
compruebe el punto de
medicin
Error electrnico en la
unidad; contacte con el
servicio tcnico de E+H
Errore e rimedio
Diagnose/maatregel
Geen sensortype
gekozen;
in V0H4 sensortype
invoeren.
Instrument in
simulatiefunctie;
in V8H0 functie 0 kiezen.
Kortsluiting interne
temperatuursensor;
sensoraansluiting
controleren of contact
opnemen met E+H
service-afdeling
Ultrasone echo kan niet
worden verwerkt; fout
door te hoge demping
(stof of schuim); blijft de
storing langer bestaan
controleer dan de
sensoraansluiting of
neem contact op met
E+H service-afdeling
Temperatuur aan de
sensor te hoog;
controleer de meting
Elektronische instrument
fout; contact opnemen
met E+H serviceafdeling
Errori e rimedi
nl Foutdiagnose en maatregelen
Wanneer een foutmelding optreedt die niet
is genoemd of kan de fout niet worden
opgeheven zie dan de
inbedrijfstellingsvoorschriften BA 100F of
neem contact op met de E+H serviceafdeling.
17
FMU 860
V0
es
i
nl
es
H0
Valor medido
Valore misurato
Meetwaarde
Seleccin de rel
H1
Calibrado en vaco
Taratura di vuoto
Inregeling leeg
Funcin de rel
H2
Calibrado en lleno
Taratura di pieno
Inregeling vol
Punto de conexin
H3
Aplicacin de nivel
Tipo di applicazione
Niveautoepassing
Punto de desconexin
Rel
Punto di attacco
Punto di stacco
nl
es
Relais
Linealizacin del Canal 1
Relaiskeuze
Linealizacin
Relaisfunctie
Nivel actual
Inschakelpunt
i
nl
es
Linearizzazione canale 1
Linearisatie kanaal 1
Parmetro de eco canal 1
Uitschakelpunt
Programacin de
volumen de llenado
Immissione livello
Invoer niveau
Si no hay eco
V1
V2
nl
es
Servicio y simulacin
Servizio e simulazione
nl
Service en simulatie
V3
nl
V7
es
i
nl
es
V8
V9
18
Penltimo cdigo de
diagnstico
Penultimo codice di
diagnosi
Voorlaatste foutcode
Equipo y versin de
software
Strumento e versione
software
Instrument en
software-versie
H4
Tipo de sensor
Tipo di sensore
Sensortype
Control alternativo de
bomba
Controllo delle pompe
Alternerende
pompsturing
Entrar volumen
H5
Valor para 0/4 mA
Valore per 0/4 mA
Waarde voor 0/4 mA
H6
Valor para 20 mA
Valore per 20 mA
Waarde voor 20 mA
H7
H8
Tiempo de integracin Distancia
Smorzamento uscita
Distanza misurata
Integratietijd
Afstand
Immissione volume
Invoer volume
Alarma seguridad
Allarme di sicurezza
H9
Nivel medido
Livello misurato
Niveau
Retraso conexin
Ritardi di intervento
Schakelvertraging
N lnea
Dimetro depsito
Volumen depsito
Servicio
Service
Service
Stoorechofilter
Filas 4,5 y 6 nicamente para FMU 862 / Righe 4, 5 e 6 solo per FMU 862 / Regels 4, 5 en 6 alleen bij FMU 862
Servicio
Servicio
Servicio
Servicio
Servicio
Service
Service
Service
Service
Service
Service
Service
Service
Service
Service
Sensor de
Interruptor lmite
temperatura externo
Contatto di soglia
Sensore esterno di
temperatura
GrenswaardeExterne
schakelaar
temperatuursensor
Reposcin general
Bloqueo de seguridad Simulacin nivel
Simulacin volumen
Simulacin corriente
333
Reset generale 333
Blocco di sicurezza
Simulazione di livello Simulazione del
Simulazione della
volume
corrente
Algemene reset 333
Vergrendeling
Simulatie niveau
Simulatie volume
Simulatie stroom
19
Austria
Endress+Hauser Ges.m.b.H.
Wien
Tel. (01) 8 80 56-0, Fax (01) 8 80 56-35
Hong Kong
Endress+Hauser (H.K.) Ltd.
Hong Kong
Tel. 25 28 31 20, Fax 28 65 41 71
Spain
Endress+Hauser S.A.
Sant Just Desvern
Tel. (93) 4 80 33 66, Fax (93) 4 73 38 39
Belgium / Luxembourg
Endress+Hauser N.V.
Brussels
Tel. (02) 2 48 06 00, Fax (02) 2 48 05 53
Italy
Endress+Hauser Italia S.p.A.
Cernusco s/N Milano
Tel. (02) 9 21 92 19 21, Fax (02) 92 10 71 53
Sweden
Endress+Hauser AB
Sollentuna
Tel. (08) 55 51 16 00, Fax (08) 55 51 16 55
Canada
Endress+Hauser Ltd.
Burlington, Ontario
Tel. (9 05) 6 81 92 92, Fax (9 05) 6 81 94 44
Japan
Sakura Endress Co., Ltd.
Tokyo
Tel. (04 22) 54 06 13, Fax (04 22) 55 02 75
Switzerland
Endress+Hauser AG
Reinach/BL 1
Tel. (0 61) 7 15 75 75, Fax (0 61) 7 11 16 50
Denmark
Endress+Hauser A/S
S@248borg
Tel. (70) 13 11 32, Fax (70) 13 21 33
Malaysia
Endress+Hauser (M) Sdn. Bhd.
Petaling Jaya, Selangor Darul Ehsan
Tel. (03) 7 33 48 48, Fax (03) 7 33 88 00
Thailand
Endress+Hauser Ltd.
Bangkok
Tel. (2) 9 96 78 11-20, Fax (2) 9 96 78 10
Finland
Endress+Hauser Oy
Espoo
Tel. (09) 8 67 67 40, Fax (09) 86 76 74 40
Netherland
Endress+Hauser B.V.
Naarden
Tel. (0 35) 6 95 86 11, Fax (0 35) 6 95 88 25
USA
Endress+Hauser Inc.
Greenwood, Indiana
Tel. (3 17) 5 35-71 38, Fax (3 17) 5 35-84 98
France
Endress+Hauser
Huningue
Tel. (3 89) 69 67 68, Fax (3 89) 69 48 02
Norway
Endress+Hauser A/S
Tranby
Tel. (0 32) 85 98 50, Fax (0 32) 85 98 51
Germany
Endress+Hauser Messtechnik GmbH+Co.
Weil am Rhein
Tel. (0 76 21) 9 75 01, Fax (0 76 21) 97 55 55
Singapore
Endress+Hauser (S.E.A.) Pte., Ltd.
Singapore
Tel. 5 66 82 22, Fax 5 66 68 48
International
Endress+Hauser GmbH+Co.
Instruments International
Weil am Rhein
Tel. (0 76 21) 9 75 02, Fax (0 76 21) 97 53 45
Great Britain
Endress+Hauser Ltd.
Manchester
Tel. (01 61) 2 86 50 00, Fax (01 61) 9 98 18 41
South Africa
Endress+Hauser Pty. Ltd.
Sandton
Tel. (0 11) 4 44 13 86, Fax (0 11) 4 44 19 77
http://www.endress.com
04.00/PTS-D
016085- 0000
6.1
Introduction
The automatic gap adjustment system is a unit that is capable of working
independent of the environment.
The system consists of the hydraulic power pack controlled by an on-board
control cabinet. The hydraulic cylinders, the measuring equipment and the
mechanical equipment are attached to the crusher. The control cabinet
accommodates the power supply equipment for the consumers (hydraulic
pump, valves) and their control systems. The control system is based on a
Mitsubishi microcontroller M16C.
The control system can be operated locally by pressing the appropriate
buttons on the front door of the control cabinet or from an external central
control room through remote control cables. The operation of the gap
adjustment system requires signals to be exchanged with the control system
of the crusher plant. The crushing gap can only be adjusted when the crusher
is at standstill or idling.
Caution!
6.2
11/2002
The front door also has two telltale lamps indicating the actual condition of
the system.
The telltale lamp ready shows that the system is ready for adjusting the
crushing gap (lamp is on continuously) and/or that the control system is
operating correctly and that the gap adjustment release from the higherranking control system is missing (lamp is flashing).
The telltale lamp fault indicates the collective message fault message
(lamp is on continuously) and/or the message warning (lamp is flashing).
2-443-20351-01e
6-1
The fault message can be reset locally as well as in the central control room
by pushing the reset button. The control cabinet has 5 coupling relays
optically indicating the exact assignment of the fault coded with a binary code
(in accordance with a list) and/or transmitting the message to the central
control room via potential-free contacts.
6.3
11/2002
Coupling relays are used for the potential-free exchange of signals in both
directions. A remote display of the gap width is possible through a signal
amplifier with potential isolation.
6-2
2-443-20351-01e
6.1
Introduccin
El regulador automtico de la rendija es una unidad que est en la condicin
de trabajar independientemente de las condiciones externas.
El dispositivo est compuesto de la unidad hidrulica, que est alimentada
elctricamente y tcnicamente controlada por un armario de distribucin incorporado. En el chancador se encuentran montados los cilindros hidrulicos con tcnicas de medicin as como con dispositivos mecnicos. El
armario de distribucin es responsable de la alimentacin de energa, por
ejemplo: bomba hidrulica, vlvulas, as como el control de las mismas. El
control se basa en un microcontrolador M16C de Mitsubishi.
La operacin del control se realiza in situ al presionar la tecla de la puerta
frontal del armario de distribucin as como desde una estacin de control
externa mediante una lnea piloto. Para el trabajo del dispositivo de regulacin es tambin necesario un intercambio de la seal con el control del sistema de chancado. La regulacin de la rendija slo es posible cuando el
chancador est parado y/o en marcha sin carga.
Atencin!
6.2
Durante el funcionamiento del chancador no est permitido realizar la regulacin del ancho de la rendija.
11/2002
2-443-20351-01sp
6-1
6.2.1
11/2002
6-2
2-443-20351-01sp
DALOG - Software
Manual
DALOG Diagnosesysteme GmbH
Augsburg
Version 2.47x, 2002
Index
Index
I
Indroduction
General Introduction
II
2.1
III
1.1
The Keyboard
1.2
1.3
1.3.1
Pointer forms
1.3.2
1.3.3
Mark
File
10
3.1
New
10
3.2
Open
10
3.3.
11
3.4
Printer set-up
11
Index
II
3.5
Base settings
12
3.6
Exit
14
Dalog
15
4.1
Open
15
4.1.1
15
4.1.2.
Modem
17
4.1.3
18
4.1.4
19
4.1.5
21
4.1.5.1
23
4.1.5.2
24
Templates
24
Window
25
Help
26
File
27
8.1
New...
27
8.2
Open...
27
8.3
Close
27
8.4
Save
27
8.5
Save as...
27
8.6
Save all
27
8.7
27
8.8
27
8.9
Base setting
27
8.10
Exit
27
Index
III
Edit
28
9.1
Undo
28
9.2
Redo
28
9.3
Cut
28
9.4
Copy
28
9.5
Paste
28
9.6
Delete
29
9.7
Mark all
29
9.8
Zoom
29
9.9
Monochrome
9.10
29
9.11
Set up
29
9.11.1
Memory card...
30
9.11.2
Base menus...
30
9.11.3
Passwords
30
9.11.4
Monitored plant...
30
9.12
New elements
31
9.12.1
Standard
32
9.12.2
Logic
32
9.12.3
Timers
33
9.12.4
Signal conditioning
34
9.12.5
Display
35
9.12.6
Analysis
35
10
Dalog
36
10.1
Open...
36
10.2
Connect...
36
10.2.1
37
10.3
Disconnect
37
10.4
38
29
Index
IV
10.5
38
10.6
38
10.7
Configure box
38
10.8
39
10.9
40
10.10
auto transfer
41
11
Window
41
12
Help
41
13
42
13.1
42
13.2
44
13.2.1
47
13.2.1.1
48
13.2.1.2
53
13.2.2
Sample rate
56
13.2.3
58
13.2.4
59
13.2.5
60
13.2.6
Data buffer
61
13.2.6.1
63
13.2.7
Logical AND
63
13.2.8
Logical OR
64
13.2.9
Logical NOT
64
13.2.10
JK flipflop
64
13.2.11
Pulse generator
64
13.2.12
Phone message
65
13.2.13
66
Index
67
13.2.14
Timer
67
13.2.15
Delay timer
68
13.2.16
Stop watch
70
71
13.2.17
Data vector
72
13.2.18
73
13.2.18.1 Arithmetic
76
77
78
13.2.18.4 Statistics
78
13.2.19
Derivation
80
13.2.20
82
13.2.21
85
13.2.22
Sum
86
13.2.23
Minimum
87
13.2.24
Maximum
88
13.2.25
Event
89
13.2.26
90
13.2.27
90
14
91
14.1
Setting up a configuration
91
14.2
93
14.2.1
93
14.2.2
94
14.2.3
94
14.2.4
94
14.2.5
94
Index
VI
15
Data analysis
95
15.1
95
15.2
102
15.3
105
15.4
107
15.4.1
107
15.4.2
110
15.4.3
112
16
Data-Upload
114
17
Online representation
116
17.1
116
17.2
119
17.3
121
18
125
18.1
Exporting data
125
18.2
Print Editor
125
19
126
IV
127
127
130
Index
VII
132
132
1.1
132
1.2
133
1.2.1
133
1.2.2
133
1.3
134
1.3.1
134
1.4
135
1.4.1
135
1.4.2
135
Chapter I:
Introduction
Introduction
The reference manual helps you to install the DALOG Software on your PC, specifies the
symbols of the DALOG Software and shows you some examples.
Chapter I
Chapter II
contains informations about the PC, the hardware and the software and
instructions for installation the DALOG Software.
Chapter III
deals with how to work with the DALOG - Software. It specifies the several
menu points and symbols and shows how a configuration could be built with
the DALOG - Software.
Chapter IV
shows how the user can convert the binary dates to ASCII dates or
DIA-PC dates.
Chapter V
Chapter VI
Chapter VII
Chapter I:
Introduction
General Introduction
Increasing demands for the availability and reliability of machines and plants as well as quality
considerations require more and more efficient, user friendly, electronical systems for a safe
storing of measuring data.
These systems have a high economical and precaution significance. Failure and defects of
machines and plants can be prevented with a continuous trend analysis of the actual conditions. With such a system irregularities of the machines can be detected early. The stops of a
plant and time for repair may be reduced and the quality standards will be increased.
The DALOG is an all-purpose, compact and self-supporting system for acquisition and storing of measuring data. It is especially developed for rough and severe operating conditions
(IP65). The DALOG allows an individual, customer specific adaptation of the sensors. Its robust housing, the high sample rates and the individual, customer specific adaptations of the
sensors allow universal applications.
The DALOG can continuously record over days, weeks, months or years. Each analog input
can be monitored with defined limit values and integrated directly into the system monitoring in
case of excess. It has its own real time clock so that the user will always know date and time
when something has happened.
The DALOG - Software is a comfortable, graphical software under Microsoft WINDOWS
and solves virtually any application problem. The enormous flexibility and manifold possibilities
of combinations will give you the best information on your measuring data. The software allows to configure the DALOG, to read the data out, and to represent them on screen in tabular form and graphics. With the DALOG - Software the user has the possibility to set up independently his own channel configuration. The user can create the block diagram of his own
measurement problem by easy-to- understand graphic symbols. You get a clearly arranged
presentation of your measuring problem.
The data can be reduced by efficient free eligible trigger conditions. The trigger conditions are
limit values, pre- and post-trigger, logical connections, timer, counter, stop-timer, events, etc..
The length and the timing of the measurement can be set by timer. The user has the possibility of a continuous data acquisition or an interval data acquisition. The channels can be configured in the specific physical units. Also the limit values can be fed in the physical units. The
storage allocation can be set separately for each channel. Thus you get an optimum of the
storage allocation. With the pretrigger and posttrigger modes, the DALOG can acquire data
before and after a trigger condition occurs. You can acquire a programmed number of samples before and after a trigger condition. Individual events including actual values, date and
time can be stored via event elements. The data and channels can be preprocessed by
mathematical operations. Data processing programs can be developed specifically to suit the
monitored device.The online display capacity of the system allows the user to view all measured data instantly on the screen at all times during the start-up and the operation of the plant.
The number of signal operations on screen can be selected with the DALOG - Software.
The configuration of the DALOG - System and the upload of the measured data can be accessed via RS 232 interface, modem, ethernet lan or by a memory card floppy.
The DALOG - Software can be installed on IBM compatible personal computer 80486 or
higher with 8mbyte memory under Microsoft WINDOWS with VGA graphics card and a colour
screen.
Chapter II:
II
Software
2.1
Chapter II:
Chapter II:
7. After finishing the installation, on the screen appears following menu item:
Chapter III:
III
1.1
The Keyboard
Working with the DALOG software, you can use key
combinations Alt, D means, that you should click and hold
the keys in the indicated sequence.
To select a command from the menu, you can use the
mouse or a key combination. The description which keys
should be used is always given at the end of the
corresponding command or menu.
For example:
Select the command Open from the
menu File (ALT,F,O).
Clicking on the small rectangular area activates the command.
Clicking on the small activated rectangular area the command will be deactivated.
Clicking on the menu item activates the command. An
altered representation will be displayed at the screen.
Clicking on the activated menu, item the menu item will be
deactivated.
Clicking on a menu item which has three dots after the command, one or more menu/menus will appear.
1.2
Show
Click
Double Click
Point to a function symbol and briefly press the left mouse button twice; an action will be initiated and/or a dialogue box will be
6
Chapter III:
opened.
Draw
Keep the mouse button pressed while you shift the mouse
pointer. This technique can be used to select function symbols
or to get a connection between determined function symbols.
1.3
1.3.1
Pointer Forms
Pointer is situated:
Function:
- in menus
- in a window
- on an icon
- select a menu
- click on an icon
- select an icon
in an active configuration window
(selected icons are flashing)
Pointer is situated:
- in a window-frame
Function:
pending
pointer
Pointer appears:
Function:
Pointer appears:
Pointer appears:
mouse
Function:
connections
- "connector symbol"
connect or disconnect the
between the icons.
Pointer appears:
Function:
- "insertion pointer
shows where the icon will be
inserted
Chapter III:
Pointer appears:
online or
hand appears.
Function:
to the
1.3.3
Pointer appears:
Function:
can be
are
1.3.2
Click
Double Click
Draw
Keep the left mouse button pressed and draw the mouse to the
requested position. Release the mouse button.
Mark
For a lot of commands the icons, parts of the configuration or
the configuration must be marked first
1. Mark single icons:
Click with the mouse pointer on the requested icon.
The icon is flashing and signalizes that it is marked. If several icons are to be marked, then the procedure must be
repeated as often as required.
Click with the mouse pointer on a marked icon, and the
selection will be undone.
2. Mark parts of the configuration or the entire configuration
Point on one corner of the configuration part which is to
be marked.
Push the left mouse button and draw the mouse pointer to
the diagonally opposite corner. All parts of the configuration
which will be touched will be also marked.
The whole marked part of the configuration is flashing.
Chapter III:
Topmost line:
Second line:
Third line:
Chapter III:
10
File
Click on the menu item File and the opposite pull-down menu
will be displayed.
3.1
New...
3.2
Open
opens the following window to call up already built configurations that are stored on the hard disk/floppy disk load configuration.
10
Chapter III:
Call-up of a configuration
11
3.3
Print...
3.4
Printer set-up...
The printer can be adjusted by the user. Click on the menu item
printer set-up... and the following window will open.
11
Chapter III:
3.5
12
Base settings...
Password:
Rights:
Password:
Rights:
12
Chapter III:
data analysis
13
The user can only have an online or offline look at the data,
which have been released for viewing by the master user.
The user can not configure.
He cannot add or erase online and offline windows.
He can only do an up-load of such buffers, which have been
released for inspection.
The user can only open Templates.
The user cannot see the configuration. He only can see a
blank background or a user-defined graphic background.
build templates
configure
He can configure, can view the data on-line and off-line and
can do data analysis.
He can assign rights to build templates or for to do data
analysis.
**master**
Rights::
13
Chapter III:
14
3.6
Modem
Advice:
All the inputs in the menu option base settings... will be stored
by so-called templates. When you start the DALOG program
the next time and call the file name of a template, all inputs will
be re-established. This means all inputs have to be made only
once.
Exit
With the menu option Exit you leave the DALOG program.
14
Chapter III:
15
Dalog
Click, the opposite pull-down menu appears.
4.1
4.1.1
Open...
Open...
Data source:
Click on the menu option DALOG data box, the following pulldown menu will appear.
15
Chapter III:
16
4. Getting a Connection
Click on the OK button, the connection to DALOG will be
done. If there is an incorrect connection between PC and
DALOG, the following failure report will appear at the
screen.
16
Chapter III:
17
4.1.2
Modem
17
Chapter III:
18
4.1.3
Connections:
Station:
Number:
18
Chapter III:
Initialization:
19
Here you can enter the initialization strings for the connection
between:
DALOG and modem Modem at box and
modem and PC Modem at PC
Click here to store the inputs.
When you click here the inputs will not be stored, you leave the
window without any changes.
4.1.4
Chapter III:
20
20
Chapter III:
21
You can see the status of the connection in the graphic at the
right bottom. In this case you have a PC modem modem DALOG E connection.
7. If there is no modem or an incorrect connection between
modem and PC, the following will be shown on the screen.
Note:
4.1.5
You can still click on Settings and enter the station name and
the telephone number of a modem connection to a DALOG.
Make sure to put the memory card correctly into the memory
card drive (see chapter VII 1).
Attention:
Chapter III:
22
Configuration and data upload are via the PCMCIA drive integrated in the PC.
1. Put the memory card into the internal PCMCIA drive.
2. Click on the menu option PCMCIA drive in the window
Connect.
The following will be shown on the screen.
Most PCMCIA drives have two slots, therefore one slot must be
selected.
3. Click on Slot0 in the field Interface, the following pull-down
menu will be shown.
22
Chapter III:
23
You can see the status of the connection in the bottom right. In
this case you have a PCMCIA - DALOG connection.
4.1.5.1
Click on the menu item Configure card. The memory card will
be configured with the configuration connected with the
PCMCIA drive.
On the other hand, a configuration stored on the memory card
may be uploaded from the card via the menu item Load config.
from card.
23
Chapter III:
4.1.5.2
24
Templates
Template
Save
Save as...
Delete
Close
24
Chapter III:
Window
25
With the menu option Window you can configure the layout of
the configuration windows on the screen as well as fade in or
fade out the symbolbars, the footbar and the quick info.
Click on the menu option Window, and the following pull-down
menu will appear on the screen:
Cascade
Tile
Arrange
The minimized configuration windows (symbol size) will be arranged at the lower border of the DALOG window.
Symbolbar
The Symbolbar can fade in or fade out. The faded-in Symbolbar is indicated by a check mark ( Symbolbar).
Footbar
Quick info
The Quick info can fade in or fade out. The faded-in Quick
info is indicated by a check mark ( Quick info).
File name of the configura- The Quick info indicates the file names of the opened configution
ration windows. When you click on a file name, this configuration window will become the active one.
Note:
The pull-down menu options Cascade and Tile are only active
when one or more configuration windows are open.
Help
With the menu option Help you can activate the WINDOWS
help of the DALOG software. The menu option Help will assist
25
Chapter III:
26
you when you use the DALOG software and will give you general information on DALOG.
Click on the menu option Help, and the following pull-down
menu will appear.
Content
Search...
Help on Help...
About DALOG...
26
Chapter III:
27
File
8.1
New...
8.2
Open...
8.3
Close
8.4
Save
8.5
Save as...
8.6
Save all
8.7
Print...
8.8
8.9
Base settings...
8.10
Exit
Edit
Click on the menu option Edit all functions and all edit com27
Chapter III:
28
9.1
9.2
9.3
Undo
Note:
Redo
Note:
Cut
9.4
Copy
9.5
Paste
9.6
Delete
Chapter III:
29
Should you have deleted the wrong parts with the command
Delete by mistake, select the command Undo at once. The
previous state will be re-established.
You can paste in the deleted parts with the command Paste.
9.7
Mark all
The entire configuration will be marked. All parts of the configuration are flashing.
The entire configuration can be deleted, copied or cut out in this
way.
9.8
Zoom
9.9
Monochrome
9.10
Attention:
9.11
Set up...
Chapter III:
30
9.11.1
Memory card...
9.11.2
Base menus...
9.11.3
Passwords...
9.11.4
Monitored plant...
Here you can put in machine specific data. The data must be
written in text files. The extension of this files is *.TXT. These
text files are stored on the memory card.
30
Chapter III:
31
Input of the file name with the machine data, e.g. madata.txt
Clicking on Import the file with the machine data will be imported and connected to the configuration.
The imported data will be shown on the screen. The data can
be shown and edited.
Clicking OK the window will be closed.
9.12
New elements...
Standard...
Logic...
Timer...
function modules for trigger operations and for timing the measuring.
Signal conditioning...
Display...
function modules for online and offline presentation at the display (only DALOG-D)
Analysis...
Note:
31
Chapter III:
9.12.1
Standard...
32
Standard...
9.12.2
Sample rate
Filter
Limit above
Limit below
Buffer
Logic...
The icon
The AND icon connects two trigger conditions, i.e. only if two
conditions are fulfilled at the same time, a triggering will be
done.
OR
The icon
Chapter III:
33
The icon
The symbol
The symbol
The symbol
The phone message is used for making a call to the user, initiated by a trigger condition..
9.12.3
Digital output..
Timers...
In the Timer... pull-down menu you will find the function modules for the time control and triggering of the measurement.
Interval timer
The symbol
The symbol
With the Delay timer the pre- and/or the post trigger time is set.
Stop watch
The symbol
The Stop watch measures the length of a time interval, e.g. the
period of an off-limit condition or the accumulated number of
individual time intervals.
9.12.4
Signal conditioning...
33
Chapter III:
34
The symbol
displayed.
Sum
The symbol
The sum is used to count trigger events, e.g. the number of offlimit conditions.
Minimum
The symbol
The symbol
for the Maximum will be displayed.
The Maximum determines the highest value within a fixed time
base.
Derivation
Event
The symbol
The symbol
34
Chapter III:
9.12.5
Display...
35
Here you will find the function modules for configuring the display functions.
Note:
Text
The symbol
The symbol
The Key is used for configuring the soft keys at the display.
Data
The symbol
for the Data will be displayed.
The symbol Data is used to indicate the online and offline data
at the display.
9.12.6
Analysis...
Online
Note:
Offline
The symbol
for the Online Function will be displayed.
Data will be indicated online at the screen.
The online function module is only available in connection with
the function "Connect DALOG.".
The symbol
for the offline function will be displayed.
Data will be indicated offline at the screen.
35
Chapter III:
36
10
Dalog
10.1
Open...
10.2
Connect...
With this menu item you can set up the following connections
when a configuration has already been opened (e.g. to configure DALOG with the configuration displayed in the active window):
With the menu item Connect... the online screen can be called
without a direct connection to DALOG. With this quasi connection, the individual online windows and online connections can
be configured. The following status indication will be faded in at
the right bottom edge of the screen.
At the bottom right edge the status of the connection, in this
case a modem - ? connection is faded in. The question mark
symbolizes that no active DALOG has been recognized at the
interface.
(Also see chapter III 4.1.1 and the following).
36
Chapter III:
10.2.1
37
3. Click on the Reset COM button. The interface will be reinitialized now.
4. When a proper connection has been set up, the symbol to
the left will be displayed at the bottom right edge of the
screen.
5. When a proper connection has not been set up, the symbol
to the left will be displayed at the bottom right edge of the
screen.
If the latter is the case, check the following:
Serial connection between PC and DALOG
Supply voltage of DALOG
10.3
Disconnect
When you click here, the program will return from the online
mode to the configuration mode.
This menu item is only active when the program is in the online
mode.
10.4
Chapter III:
38
10.5
About monitored plant After clicking here you will get general information on the moni-
10.6
When you click here, the configuration stored in the box will be
loaded, provided there is a connection between PC and
DALOG. This menu item is only active when the program is in
the online mode.
10.7
Configure box
Short name of configura- contains the default name of the configuration. This name can
tion
be changed if required.
Note:
38
Chapter III:
User's name
39
is not filled in as default. The user may enter his name here.
This name will also be indicated in the Info Menu of DALOG.
Filling in this field is not absolutely necessary.
you will exit the window configure box by clicking here The
window system time of the data box below will be displayed.
will always indicate the current date and the time of the real
time clock of DALOG .
The user may alter the real time clock here. Thus the real time
clock may be adapted to the local time. Date and time correspond to the PC-clock.
When you click on the Yes button, the real time clock will be
reinitialized together with the reconfiguration of the box.
When you click on the No button, the time of the real time clock
will not be altered when the box is reconfigured.
10.8
Chapter III:
40
10.9
Note:
File name
Directories:
OK
10.10
auto transfer
By means of the auto transfer, the measurement data are continuously transferred in the ASCII format via the serial interface
(see chapter III 14.2).
40
Chapter III:
11
Window
41
12
Help
41
Chapter III:
13
42
The bottom icon bar contains all functions required for setting
up the configuration.
13.1
Open box
Connects DALOG to a PC via the serial interface (RS232),
modem or mains
Open configuration
Opens an already existing configuration on the hard disk or
floppy disk
Store configuration
To store a new and/or changed configuration on the hard disk
or floppy disk
42
Chapter III:
43
Undo
To undo the last change to an existing configuration
Cut
To cut marked icon blocks and connections by the mouse
(marked parts are flashing on the screen)
Copy
To copy marked blocks and connections by the mouse (marked
parts are flashing on the screen)
Insert
To insert previously cut or copied parts of a configuration
Delete
To delete previously marked parts of a configuration
Larger/smaller
To increase or reduce a configuration currently displayed at the
screen
Erect a connection
To connect a DALOG to a PC
43
Chapter III:
13.2
44
Sample rate
Sample rate elements
Data buffer
Data buffer to determine the memory size for the channel concerned.
Logical AND
Logical linking of channels by an AND condition
Logical OR
Logical linking of channels by an OR condition
44
Chapter III:
45
Logical NOT
Logical linking of channels by a NOT condition
JK flipflop
Logical linking of channels by storing a logical state by a JK
flipflop
Pulse generator
Triggers an action by an adjustable number of pulses
Message calls
DALOG will report automatically e.g. when a limit is exceeded
Timer generator
To initiate trigger conditions at exactly defined times
Delay timer
To determine a defined period for data recording
Stopwatch
To establish the retention time, e.g. the duration of a limit value
violation or operating hours
Data vector
To establish data vectors in order to prepare statistical characteristics, FFTs etc.
Calculations
To calculate channels and physical units and to draw up complex logical conditions
Derivation
To initiate a trigger pulse at rising or falling edge
Classification
Classification of the data as per Rainflow
45
Chapter III:
46
Sum
Counter to form the accumulated number of individual events
e.g. limit value limitations
Minimum
Records the minimum that occurred
Maximum
Records the maximum that occurred
Event
Records an event, e.g. limit value violation
46
Chapter III:
13.2.1
47
Analog
12 bit inputs
Total number
In use
Selection
Chapter III:
48
Input pin:
AD converter:
Measuring point:
Signal:
Here you can select the type of the sensor connected and the
signal.
Type:
Only analog sensor can be selected as standard. Customerspecific sensor signal pre-analysing may be stored here.
Name.:
log. resolution:
48
Chapter III:
Symbol:
49
High pressure
Signal:
0-600-bar
Name:
49
Chapter III:
Logical resolution:
50
Linearisation
Physical
resolution:
Binary value:
Here you can enter any binary value within the given resolution.
Resolution:
Signal
12 bit 0 - 4095
10 bit 0 - 1023
8 bit 0 - 255
Sensor adjustment
50
Chapter III:
51
Signal
Name:
Indicates the Name for the physical conversion table that has
been entered in the menu window Sensor adjustment, e.g.
vibration.
51
Chapter III:
Symbol:
52
You can select a suitable symbol for the physical unit via the
arrows.
Physical unit
Unit:
Definition:
Internal conversion
Logical resolution
Sample range:
Defining signal
52
Chapter III:
53
All the inputs and/or changes will be stored, and you will exit the
menu.
Inputs and/or changes will not be stored, and you will exit the
menu.
Input pin:
Measuring point
53
Chapter III:
54
Signal:
Type:
Name:
A selection menu of user-defined frequency tables will be displayed, provided these have been drawn up, and the frequency
counter has been selected.
log. resolution:
Symbol
Type:
Frequency counter
54
Chapter III:
55
Signal
Name:
A selection menu of user-defined frequency tables will be displayed, provided these have been drawn up. These may be
selected or new Names may be entered.
Maximum frequency:
Logical resolution:
55
Chapter III:
13.2.2
56
Sample rate
A double click on the function symbol Sample rate will call the
following menu:
Signal name:
Rate
Maximum recommended
sample rate:
Note:
Signal expression:
56
Chapter III:
57
Rate
Click on the arrow and you can select the required time base
for the sample rate.
:
Note:
The automatic transfer mechanism sends the data automatically continuously to the PC via the RS 232 interface. The data
will be stored in ASCII format. The transfer rate of the data is
the same as the sample rate.
Note:
The data will be also stored on the memory card. The data on
the memory card will be stored in Binary format.
Clicking the data will be send to the PC after configuration and
stored on harddisk, when there is a connection between PC
and DALOG.
The data will be stored under a file name, e.g. buf_0002.dat.
The system will set a default file name. The user can define is
own specific file name. The file name must always have the
extension *.DAT. The target directory in this case, is the
DALOG directory. It could be also any other directory, e.g.
C:\transfer\buf_0002.dat
57
Chapter III:
13.2.3
58
Signal expression:
Filter size
Number of values:
Note:
58
Chapter III:
13.2.4
59
Signal expression:
Type:
Limit:
Note:
With a correct configuration set-up, the limit value must be entered in a physical unit, see figure below, after you have previously selected a physical unit at the input channel, too.
When you have not selected any physical unit, the input may be
within the permissible resolution of 10-Bit (1024 values) or 12Bit (4096 values) only.
For entering the limit value, the icon Limit above must have
been integrated in a configuration.
59
Chapter III:
13.2.5
60
Signal expression:
Type:
Limit:
Note:
With a correct configuration set-up, the limit value must be entered in a physical unit, see figure below, after you have previously selected a physical unit at the input channel, too.
When you have not selected any physical unit, the input may be
within the permissible resolution of 10-Bit (1024 values) or 12Bit (4096 values) only.
For entering the limit value, the icon Limit below must have
been integrated in a configuration.
60
Chapter III:
13.2.6
61
Data buffer
After a double click on the icon data buffer the menu below will
be displayed at the screen when the data buffers are configured
for the first time:
Size:
The entry will be stored. The menu window buffer will be displayed at the screen.
61
Chapter III:
File:
62
Size:
Size:
Maximum available
buffer size
Note:
Attention:
62
Chapter III:
63
Stop symbol
13.2.7
Logical AND
Configuring not possible
However, a name may be allocated for each configuration symbol. To do so, double click on the icon, the window below will
then be displayed.
Note:
63
Chapter III:
13.2.8
64
Logical OR
Configuring not possible
13.2.9
Logical NOT
Configuring not possible
13.2.10
JK flipflop
Configuring not possible
13.2.11
Pulse generator
When you double click on the function symbol Impulse generator the following menu will be displayed at the screen.
The pulse generator outputs trigger pulses following input
pulses. These input pulses may be initiated e.g. by a timer
(clock), violations of limit values, logical links etc.
Thus measurement data logging can be controlled efficiently,
and references to maintenance intervals that are due etc. may
be given.
64
Chapter III:
65
Signal expression:
Counter:
Pulse length:
Here you can enter the minimum pulse length that the pulse
must have to be counted as input pulse.
Click on the arrow to select the required time base by means of
the mouse. As default, the pulse length is set to Minimal duration.
Validity:
13.2.12
Phone messages
Here DALOG may independently give messages to the user in
connection with events (mobile phone messages). The messages are given to Pager, SMS (GSM-network) and modem.
65
Chapter III:
13.2.13
66
Digital outputs
Total number:
In use
Selection:
Note:
66
Chapter III:
67
Signal expression:
Connection:
Name:
Here the user can enter a designation of his own (name) for the
digital output, e.g. LowFilter.
The input will be stored. The following symbol will be displayed.
The input entered in the window Configure digital output will be
indicated directly, e.g. TORQUE > 130%
13.2.14
Timer
67
Chapter III:
68
Signal expression:
First pulse:
Here you may determine the time for the first starting pulse.
Input is in the format:
Day.Month.Year Hour:Minute:Second,
e.g. 16.12.1996 15:25:31
Here you determine the interval, i.e. the interval at which the
trigger pulse is to be initiated, e. g.
13.2.15
Delay timer
With the function Delay timer you may initiate the following:
A trigger pulse for delayed start or for delayed terminating
a measuring data logging after an exactly defined period
Pretriggering, e.g. following a limit value violation
Double click on the icon Delay timer and the following menu
will be displayed at the screen:
68
Chapter III:
69
Signal expression:
Delay:
Here you determine the length of the delay until the trigger
pulse occurs.
Click on the arrow to select the required time base.
Restart:
Important:
Explanation:
Trigger:
Pretrigger:
Posttrigger:
Note:
69
Chapter III:
Pretrigger:
70
13.2.16
Stop watch
You can log the following with the function stop watch:
Individual or sum periods, such as operating times of
machines, the duration of a limit value violation etc.
Double click on the icon stop watch and the following menu will
be displayed at the screen:
Resolution:
Result:
The currently measured time value after the start of the stop
watch will be stored.
Validity:
temporary
permanent
The time counter will remain stored even after the supply
voltage has been switched off.
70
Chapter III:
Starting value:
71
Start symbol
, as e.g. the
Linking a triggering element to the Start symbol
trigger pulse of a timer, limit above and/or below, will set the
stop watch going.
Stop symbol
, will stop
Note:
When the stop watch is started again, the measured times will
be summed up one after the other!
Reset symbol
Note:
, will reset
With another start the stop watch is started again and will begin
at "zero".
71
Chapter III:
13.2.17
72
Data vector
Here you can generate a data vector. With the data vector,
statistical characteristics such as average, variance, effective
value can be formed and/or may also be used for carrying out a
FFT.
Linking a triggering element, as e.g. trigger pulse of a timer,
limit above and/or below is via the Start symbol .
Double click on the opposite symbol and the window below will
be displayed.
Sampling
Size:
Here you can define the vector length in a time unit or number
of values. The maximum length of the vector is 8192 values.
Note:
72
Chapter III:
13.2.18
73
Result
Here you define the name and the type of result of the variable
calculated.
Name:
Result type:
73
Chapter III:
74
binary logic
analog value
Signal
Name:
Result range:
logical resolution:
74
Chapter III:
Formula:
75
Chapter III:
13.2.18.1 Arithmetic
76
Examples:
Attention:
76
Chapter III:
Note:
77
You can only correctly add or subtract parts of the formula you
entered to and/or from a constant when the constant represents
the same physical value!
All the following arithmetical terms represent e.g. an electrical
voltage:
U 40 mV
P / 1.1 A
1.1* (P + 10 W) / I 2.5 kV
Incorrect would be for example:
U0
10 mA + U
logical And
logical Or
logical Not
logical equality
logical inequality
Examples:
greater
greater or equal
less
less or equal
U >= 5 V
P1 < (U * I 10 mW)
77
Chapter III:
78
Note:
13.2.18.4 Statistics
78
Chapter III:
79
Designation
min(vec)
max(vec)
Number of elements in
the vector, the result is
without physical units
n(vec)
s(vec)
yi
ssq(vec)
y2i
Mathematical derivation
(1/nr)y2i
eff(vec)
((1/nr)y2i)
var(vec)
(1/nr)(yi-y)2
Standard deviation of
the original data
sdev(vec)
((1/nr)(yi-y)2)
intercept(vec)
Corr(vec)
The Bravais Pearsoncorrelation coefficient is
a measure for the
quality of the correlation
of the data and the time,
i.e. corr(vec) = 0 means
uncorrelated and
corr(vec) = +1 or 1
means completely
correlated.
(ti-t)*(yi-y)/((ti-t)2)
y-((ti-t)*(yi-y)/((ti-t)2))*t
(ti-t)*(yi-y)/((ti-t)2*(yi-y)2)
79
Chapter III:
Designation
80
Mathematical derivation
Special characteristics
for the frequency
range
In a frequency
spectrum, a maximum
frequency amplitude
value is searched within
a user-defined upper
and lower limit and the
associated frequency
value is put out
peak(fft,minf,maxf)
e.g. peak(FFT01, 200Hz,
300Hz)
The maximum amplitude value
is searched between 200Hz
and 300Hz and is put out.
FFT01 = Name of the FFT
power(fft,minf,maxf)
Determines the sum of
the amplitude squares of e.g. power(FFT01, 200Hz,
a FFT in a user-defined 300Hz)
frequency band
sqr(val)
13.2.19
Derivation
Double click on the icon Derivation and the following menu will
be displayed:
You can initiate a trigger pulse with rising and/or falling edge
with the function Derivation.
80
Chapter III:
81
Signal expression:
Measuring range:
Indicates the measuring range selected for this signal and the
associated physical unit, e.g. 0 - 230 kNm/s.
When a sensor type has not been selected, the resolution: 0
8191 will be displayed here. This is a 13 bit value.
The user may create files for generating the derivation by
himself. By forming the difference between two values
(amplitude change) within a given period the derivation (rising
or falling edge) is determined. The rate of change of the
amplitudes is specified by the sample rate.
Log. resolution:
Name.:
81
Chapter III:
13.2.20
82
Number of classes:
82
Chapter III:
83
Reset range
The user can define the reset range of the hysteresis, e.g.
20mV.
File:
Number of seperate
fatigue load matrices
If the classification data are triggered then the user can define,
how many max. number of seperate fatigue load matrices can
be stored on memory card, before the first one will be
overwritten, e.g. 10.
Maximum number of
blocks available
Erase single fatigue load If you build only one fatigue load matrix then you can click on
matrix only after upload the square. The single fatigue load matrix will only erase after
upload to PC.
to PC
Number of limits
Number of defined
classes
83
Chapter III:
84
Lower limit:
Upper limit:
84
Chapter III:
Number of classes to
insert:
85
13.2.21
Windowing:
85
Chapter III:
Number of samples:
86
Used fraction of system Indicates the rate of usage of the DALOG system memory.
memory:
Note:
13.2.22
Sum
Double click on the icon Sum and the following menu will be
displayed:
The Sum serves for counting the trigger pulses, as limit above
and/or limit below, time pulses etc.
Size:
Result:
Validity:
temporary:
86
Chapter III:
87
permanent:
The counter value will remain stored even after the supply
voltage has been switched off.
Start value:
Determines the start value for the counter. Only active when
you have clicked on the menu item: permanent: before.
The icon Sum has two different ways to trigger function
mechanisms:
Start symbol
Reset symbol
In order to read the data into a data buffer on into an event etc.,
a sample rate icon must be linked to the sum symbol.
13.2.23
Minimum
Double click on the icon Minimum and the following menu will
be displayed:
You can determine the minimum of a signal within a defined
period by the function minimum.
Absolute value
preservation
Here you can determine for how long the minimum value is to
be preserved before a new minimum will be formed.
Click on the arrow to select the required time base.
87
Chapter III:
13.2.24
88
One-sided recursive
filtering
Note:
Maximum
Double click on the icon Maximum and the following menu will
be displayed:
You can determine the maximum of a signal within a defined
period by the function maximum..
Type:
Absolute value
preservation
Here you can determine for how long the maximum value is to
be preserved before a new maximum will be formed.
Click on the arrow to select the required time base.
One-sided recursive
filtering
Note:
88
Chapter III:
13.2.25
89
Event
Double click on the icon Event and the following menu will be
displayed:
You can represent the following in tabular form by the event
function:
time (date and hour)
the name of the event
the absolute value of the triggering event as a function of
other variables measured at the same instant.
In an instant you will get a survey of the state of your plant at
the time a trigger event has occurred.
Name:
Type:
Protocol
general event
warning
failure occurred
89
Chapter III:
Possible data:
90
Here you can select which data are also to be recorded at the
time of the occurrence of the event.
To do so, click on the names that can be selected, as e.g.
speed, etc.
Then click on the field
. The data will also be recorded,
when you exit the menu window by OK.
Note:
Record the following
data:
13.2.26
13.2.27
90
Chapter III:
14
91
14.1
Setting up a configuration
In the following, you will see a representation of some icons
such as new data channel, sample rate and data puffer, that
appears to be random at the first glance.
91
Chapter III:
92
92
Chapter III:
93
14.2
14.2.1
Chapter III:
14.2.2
94
14.2.3
14.2.4
14.2.5
94
Chapter III
15
Data analysis
15.1
95
Monochrome mode
Y-axis
X-axis
Header line
95
Chapter III
Will shift the signal curves to the left or to the right point by
point.
or
SHIFT
96
or
SHIFT
Will shift the signal curve from trigger point to trigger point.
or
SHIFT
SHIFT
At the zero mark of the X-axis, trigger begin or end and/or pretrigger begin or end of the signal curve will be indicated. The
pre- and/or posttrigger point will be marked by a short vertical
line in the signal curve.
or
Name:
96
Chapter III
Buffer:
97
Color selection
You can select a color for the individual signal curves by clicking here. In addition, individual signals may be masked by the
menu item invisible.
The signals and the associated Y axis can be shifted continuously at the screen.
97
Chapter III
Note:
98
Here you can set the printer via the set-up and the signal curve
can be printed (see chapter III 3.3).
Bar Graph
Bar Graph
Line Graph
98
Chapter III
99
Header line
Y-axis
X-axis
or
SHIFT
At the zero mark of the x-axis, trigger begin or end and/or pretrigger begin or end of the signal curve will be indicated. The
pre- and/or posttrigger point will be marked by a short vertical
line in the signal curve.
or
SHIFT
Bar Graph
Line Graph
99
Chapter III
100
When you click here, the following configuration menu Frequency analysis will be displayed at the screen.
Topmost line
Data
Name:
Windowing:
Samples shown in
window
Here you can set how may spectral lines are to be indicated in
the online window.
The number of spectral lines is a function of the resolution
selected and may be max. 4096.
100
Chapter III
Offset:
101
Actuate the OK button, the selection will be stored and you will
exit the menu.
Scale:
Here you can select the scaling of the Y axis of the frequency
representation - absolute, logarithmic.
101
Chapter III
Acceleration data:
102
15.2
A double click on the offline icon will open the offline window for
the representation of the signal curve in tabular form.
Monochrome mode
Chapter III
103
Event
Note:
The columns indicated after these two menu items are a function of the kind of configuration concerned, e.g.:
Period of time during which the event occurs without interruption
Should there be a question mark in this column, there has been
an interruption in data recording while this event has occurred,
e.g. by a data upload or an interruption in the power supply.
In the following columns the signal expression concerned and
the absolute value of the event as well as the individual data
available at that time are given.
Which data are indicated here depends on the configuration.
Should there be more columns and data than can be indicated
at the screen, these may be made visible by the vertical and
horizontal scrollbars.
Period
Click here or actuate the Print button, and the following menu
will be displayed at the screen.
If you want to have only the data columns visible at the screen
butindicated in the ASCII format, click on the
ton, if all data columns are to be exported to ASCII, click on
. After you have clicked on one of the buttons,
the events will be displayed at the screen in the editor below.
Now you can edit or print the data.
103
Chapter III
Set-up
104
Note:
104
Chapter III
15.3
105
A double click on the online icon will open the online window for
the representation of the signal curve in tabular form.
Monochrome mode
Events
Tool button
general event
warning
failure
Here you can enter a name for the event window. This name
will be indicated in the configuration menu beside the event
icon, too. The other functions are not active in this mode.
105
Chapter III
Event window
Tool button
topmost line
106
Color selection:
106
Chapter III
15.4
15.4.1
107
or
SHIFT
or
SHIFT
is used for the communication between
The chain symbol
several open analysis and/or event windows. When you click on
the chain icon in the opened windows, the same time (date,
time) will automatically be indicated in all chained windows
when the signal curves are shifted. This means that when you
click e.g. on a selected event, the corresponding signal curve
will be indicated in another opened and chained window simultaneously.
Export data
107
Chapter III
108
Name:
Raw data:
108
Chapter III
109
Here you can select the scaling of the Y-axis of the classification percent, absolute or logarithmic.
Scaling:
Layout:
Actuate the OK button, the selection will be stored and you will
exit the menu.
109
Chapter III
15.4.2
110
110
Chapter III
111
Name:
Y-axis
Show:
Marking
Colors
In this menu item you can choose the color distribution in dependence of the classification frequency. Shifting the arrows the
color distribution at screen will be more light or more dark.
Actuate the OK button, the selection will be stored and you will
exit the menu.
111
Chapter III
15.4.3
112
Raw data:
Name:
112
Chapter III
X-axis
113
Y-axis
Layout
Here you can select different presentation layouts for the 5/2
dimensional classification analysis without marking, with dots,
with crosses, with wireframe.
Color
Here you can select different colors for the presentation of the
markings black, grey, light grey, white.
Colors
In this menu item you can choose the color distribution in dependence of the classification frequency. Shifting the arrows the
color distribution at screen will be more light or more dark.
Actuate the OK button, the selection will be stored and you will
exit the menu.
113
Chapter III
16
114
Data-Upload
Double click and the following menu will be displayed:
Buffer
Upload
Here you can transfer individual data for the data buffer selected or all the measurement data for all data buffers to the
PC. During the transfer of the measurement data from the
DALOG System to the PC, the measurement in the DALOG
System is stopped.
Erase:
In the menu item Erase you can delete only data that are stored
on the PC.
No data will be deleted. This menu item is set as default and
need not be activated.
Measurement data stored at a former date will be erased automatically during the data upload.
Only data from a specified date will be deleted. Time and date
must be entered in the format: 10:15 12.03.95
Here you can transfer selected measurement data stored on the
memory card of the DALOG System to the PC.
Load:
Single data blocks of the selected data buffer can be transferred from the memory card to the PC. To do this, click on the
individual data blocks that are to be transferred. The data
blocks on which you have clicked will be highlighted in color.
The selection will be stored. The following display mask will be
indicated at the screen.
114
Chapter III
Upload
115
When the data blocks are indicated and are transferred from the
DALOG System to PC, all measurements will be stopped until
cancelled or until the uploading is completed.
The data on the memory card will not be deleted by an upload
process, i.e. data transfer from the DALOG System to the PC.
115
Chapter III
17
Online representation
17.1
116
A double click on the online icon will open the online window for
the graphical representation of the signal curve
Monochrome mode
Header line
Indicates the user-defined name, e.g. Acceleration or the number of the signal curves indicated simultaneously in the online
window when a name for this window has not been entered.
The numerical value given in square brackets corresponds to
the time between two longitudinal lines, e.g. 100ms.
Y axis
Indicates the amplitude values in the physical unit with an abbreviation to allow a definite attribution of the measuring input
concerned
Note:
Tool button
116
Chapter III
117
Topmost line
Name:
Channel selection:
117
Chapter III
Trigger
118
After clicking on the rectangular field, the user can enter a trigger threshold. The measuring signal will thus no longer be displayed continuously, but at rest, similar to an oscilloscope operation.
In the configuration window the indication triggering by e.g.
channel 1 will be given.
Color:
Note:
118
Chapter III
17.2
119
When you click on the sinus button, the bar representation will
be switched back to continuous signal curve.
Tool button
Topmost line
119
Chapter III
120
Name:
Channel select:
Color:
120
Chapter III
17.3
121
Header line
Y axis
Note:
Export data
Print
121
Chapter III
Start symbol
Stop symbol
Tool button
Topmost line
122
Name:
Windowing:
122
Chapter III
123
Samples shown in
window:
Here you can set how may spectral lines are to be indicated in
the online window.
The number of spectral lines is a function of the resolution
selected and may be max. 4096.
Offset:
123
Chapter III
124
Actuate the OK button, the selection will be stored and you will
exit the menu.
Scale:
Here you can select the scaling of the Y axis of the frequency
representation - absolute, logarithmic.
Acceleration data:
124
Chapter III
18
18.1
Exporting data
Export event data
125
Click here or actuate the Print button, the following menu will
be displayed at the screen.
If you want to have only the data columns visible at the screen
indicated in the ASCII format, click on the
button, if all data columns are to be exported to ASCII, click on
. After you have clicked on one of the buttons,
the events will be displayed at the screen in the editor below.
Now you can edit or print the data.
18.2
Print Editor
Menu item File
When you click here, the contents of the event window shown
at the screen will be printed. When the printer has not been
connected or is not ready, a corresponding error message will
be displayed at the screen.
125
Chapter III
19
126
In the Set-up menu you can enter the printer-related settings for
an optimum printing result of the signal and frequency curves as
well as the classifications. For further information please see
your printer manual.
The window will be printed automatically, when a ready-tooperate printer has been connected. Otherwise a corresponding
error message will be given.
126
Chapter IV
IV
127
Configure
Click on the menu item Configure and the following menu will
be displayed at the screen.
Delete
When you click on the menu item Delete, the buffer will be deleted.
Memory Card
When you click on the menu item Memory Card, the buffer size
set by the user will be indicated at the screen.
Upload
When you click on the menu item Upload, the upload window
will be displayed at the screen. Proceed as described in chapter
III 15 to upload the data. This menu item will only be active,
when there is a direct connection to the DALOG System and/or
to the memory card.
When you click on the menu item Show data offline, an analysis window will automatically be linked to the buffer selected
and the analysis window with the data will be opened.
When you click on the menu item Convert data to ASCII, the
following window will be displayed at the screen.
127
Chapter IV
128
Convert from:
In this field, date and time of the first block to be converted, e.g.
22.05.1996 9:06:46, will be indicated. Date and time may be
changed by the user, so that converting will be started at a later
date. When you do not enter anything in this field, starting will
be with the first block as default.
Convert until:
In this field, date and time of the last block to be converted, e.g.
22.05.1996 10:45:32, will be indicated. Date and time may be
changed by the user, so that converting will be completed at an
earlier date. When you do not enter anything in this field, converting will be to the last block as default.
128
Chapter IV
File
129
When you click on the menu item File, the following window will
be displayed at the screen.
You can enter a name of your own for ASCII files in the menu
window ASCII-file. The window will be closed when you click on
the OK button, and you will return to the previous menu.
Convert
When you click on the field Convert, the selected data will be
converted to ASCII format. After converting, the number of files
converted will be displayed at the screen.
The ASCII files can be viewed with any word processing program.
129
Chapter IV
130
Project:
Data format:
In this field you may select whether the data are to be stored in
the INTEL format or the Motorola format.
The field INTEL format is ticked as default.
Convert from:
In this field, date and time of the first block to be converted, e.g.
22.05.1996 9:06:46, will be indicated. Date and time may be
changed by the user, so that converting will be started at a later
date. When you do not enter anything in this field, starting will
be with the first block as default.
Convert until:
In this field, date and time of the last block to be converted, e.g.
22.05.1996 10:45:32, will be indicated. Date and time may be
changed by the user, so that converting will be completed at an
earlier date. When you do not enter anything in this field, converting will be to the last block as default.
Project
When you click on the menu item Project, the following window
will be displayed at the screen.
130
Chapter IV
131
In the menu window DIA PC Project file, you can enter a name
for the DIA PC files of your own. When you click on the OK
button, the window will be closed and you will return to the previous menu.
In the field File short name, the selected DIA PC Project file
name will be indicated now.
Convert
Click on the field Convert, and the selected data will be converted to DIA PC format. After converting, the number of files
converted will be indicated at the screen.
131
Chapter V:
V
1
132
1.1
Type of
data
Fixed value, of
any
Name
Meaning
LOGO
HDRLEN
VERSION
DATATYP
CHAR
'r'
CHAR
'S'
SHORT
36
SHORT
SHORT
LONG
PID
15
CHAR[15]
SOURCENA
ME
CHAR[8]
CFGNAME
16
132
Chapter V:
1.2
133
1.2.1
1.2.2
Type of
data
Name
Meaning
LONG
BLKLEN
Length of the entire data block including the following header data as well as the length of
BLKLEN (=4) proper
LONG
PLEN
LONG
TLEN
LONG
TTRIG.SEC
LONG
CHAR
UID
CHAR
BITS
LONG
RATE
SHORT
DATA
133
Chapter V:
1.3
134
1.3.1
Type of data
Name
UNSIGNED
CHAR
LEN
SHORT
ID
Characteristic ID of the event; value clearly identifies the event in connection with the associated
measurement configuration.
The ID value (in a range of 1...n) is contained in
bits 5...15; bits 0...4 are reserved and must be
masked, if required.
LONG
TIME
UNSIGNED
CHAR
(5)
LONG,
UNSIGNED
CHAR
UNSIGNED
CHAR
Meaning
134
Chapter V:
1.4
135
1.4.1
Type of
data
CHAR
Name
TYP
Meaning
Type of the following classification data
0 RAINFLOW classification
1 VERWEILZEIT classification
1.4.2
LONG
LEN
LONG
TFIRST.SEC
Starting time of classification; the value contains the number of seconds from 01.01.1980,
0:00 to the starting time
LONG
LONG
TLAST.SEC
LONG
TLAST.NSEC
CHAR
UID
SHORT
LIMNR
256
SHORT
[128]
LIMITS
TFIRST.NSEC Starting time of classification; the value contains nano seconds (10 to the minus 9th power)
and defines the fractional digits of the starting
time.