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CG Drives & Automation, 01-6142-01r0 Getting Started 39
5. Getting Started
This chapter is a step by step guide that will show you the
quickest way to get the pumps running.
We assume that:
• the AC drive is mounted on a wall or in a cabinet as in
the chapter 2. page 11.
• mains and motor cable are connected according to
chapter 3.3 page 23.
• control cables are connected according to chapter 4.4
page 31.
FlowDrive can operate as a Standalone unit (1 drive) or in a
Master-Follower configuration (2 drives).
Sections
Chapter 5.1 - Describes how to use the function keys on the
control panel.
Chapter 5.2 - Covers generic configuration like language
and motor parameters.
Chapter 5.3 - Describes configuration of level control
parameters related to the pump sump.
Chapter 5.4 - Describes how to start up the system and
make sure everything is correctly configured.
Chapter 5.5 - Run the Auto tune program.
Chapter 5.6 - Configuration of additional features.
5.1 Function keys
The function keys operate the menus and are also used for
programming and read-outs of all the menu settings.
5.1.1 Using the function keys
Fig. 48 Example of menu navigation when entering motor
voltage
Example:
Setting Motor data.
Menu [100], “Preferred View” is displayed when started.
1. Press to display menu [200], “Main Setup”.
2. Press and then two times to display menu [220],
“Motor Data”.
3. Press to display menu [221] and set motor voltage.
4. Change the value using the and keys. Confirm
with .
step to lower menu level or confirm changed setting
step to higher menu level or ignore changed setting
step to next menu on the same level
step to previous menu on the same level
increase value or change selection
decrease value or change selection
- Toggle between menus in the toggle loop
- Switching between local and remote control
- Change the sign of a value
ESC
NEXT
100
200
300
220
221
210
NEXT
ESC
NEXT
NEXT
NEXT
Содержание
- Emotron fld48 52 69 frame sizes b f and c2 f2 0 5 200 kw 3
- Emotron flowdrive 3
- Always take adequate precautions before opening the ac drive although the connections for the control signals and the switches are isolated from the main voltage do not touch the control board when the ac drive is switched on 5
- Before you begin with installation commissioning or powering up the unit for the first time it is very important that you carefully study this instruction manual following symbols can appear in this manual or on the product itself always read these first before continuing 5
- Congratulations for choosing a product from cg drives automation 5
- Earth leakage current 5
- Earthing 5
- Emc regulations 5
- Fld48 230 480 v fld52 440 525 v fld69 500 690 v 5
- Handling the ac drive 5
- If work must be carried out on a connected motor or on the driven machine the mains voltage must always be disconnected from the ac drive first wait at least minutes before starting work 5
- In order to comply with the emc directive it is absolutely necessary to follow the installation instructions all installation descriptions in this manual follow the emc directive 5
- Installation commissioning demounting taking measurements etc of or on the ac drive may only be carried out by personnel technically qualified for the task a number of national regional and local regulations govern handling storage and installation of the equipment always observe current rules and legislation 5
- Mains voltage selection 5
- Opening the ac drive 5
- Precautions to be taken with a connected motor 5
- Residual current device rcd compatibility 5
- Safety instructions 5
- The ac drive may be ordered for use with the mains voltage range listed below 5
- The ac drive must always be earthed via the mains safety earth connection 5
- This product cause a dc current in the protective conductor where a residual current device rcd is used for protection in case of direct or indirect contact only a type b rcd is allowed on the supply side of this product use rcd of 300 ma minimum 5
- Alarms 6
- Condensation 6
- Dc link residual voltage 6
- Heat warning 6
- Incorrect connection 6
- It mains supply 6
- Power factor capacitors for improving co 6
- Precautions during autoreset 6
- Transport 6
- Voltage tests megger 6
- Contents 7
- Contents 3 7
- Control connections 29 7
- Emc and standards 45 7
- Getting started 39 7
- Index 63 7
- Installation 17 7
- Introduction 5 7
- Mounting 11 7
- Options 47 7
- Safety instructions 1 7
- Technical data 53 7
- Delivery and unpacking 9
- Introduction 9
- Motors 9
- Prerequisites 9
- Using of the instruction manual 9
- In the following table we have listed available options and the name of the instruction manual or data sheet instruction plus document number further in this main manual we are often referring to these instructions 10
- Instruction manuals for optional equipment 10
- Table 1 available options and documents 10
- The warranty applies when the equipment is installed operated and maintained according to instructions in this instruction manual duration of warranty as per contract faults that arise due to faulty installation or operation are not covered by the warranty 10
- Warranty 10
- Fig 1 gives an example of the type code numbering used on all ac drive 11
- Fig 1 type code number 11
- Fld 48 017 20 c e a v n n n n a n 11
- Type code number 11
- With this code number the exact type of the drive can be determined this identification will be required for type specific information when mounting and installing the code number is located on the product label on the unit 11
- By using the optional extended emc filter the ac drive fulfils requirements according to category c 12
- Category c power drive system pds of rated voltage 1 00 v which is neither a plug in device nor a movable device and when used in the first environment is intended to be installed and commissioned only by a professional 12
- Category c3 pds of rated voltage 1 00 v intended for use in the second environment and not intended for use in the first environment 12
- Category c4 pds or rated voltage equal or above 1 00 v or rated current equal to or above 400 a or intended for use in complex systems in the second environment 12
- First environment extended emc as environment that includes domestic premises it also includes establishments directly connected without intermediate transformers to a low voltage power supply network that supplies buildings used for domestic purposes 12
- May be used the standard ac drive is designed to meet the requirements according to category c3 12
- Product standard en iec 61800 3 second edition of 2004 defines the 12
- Product standard for emc 12
- Second environment standard emc includes all other establishments 12
- Standards 12
- The ac drive complies with the product standard en iec 61800 3 2004 any kind of metal screened cable 12
- The ac drives described in this instruction manual comply with the standards listed in table 2 for the declarations of conformity and manufacturer s certificate contact your supplier for more information or visit www emotron com www cgglobal com 12
- Table 2 standards 13
- Abbreviations and symbols 14
- Definitions 14
- Dismantling and scrapping 14
- Disposal of old electrical and electronic equipment 14
- Glossary 14
- In this manual the following abbreviations are used 14
- In this manual the following definitions for current torque and frequency are used 14
- Table 3 abbreviations 14
- Table 4 definitions 14
- The enclosures of the drives are made from recyclable material as aluminium iron and plastic each drive contains a number of components demanding special treatment for example electrolytic capacitors the circuit boards contain small amounts of tin and lead any local or national regulations in force for the disposal and recycling of these materials must be complied with 14
- This symbol on the product or on its packaging indicates that this product shall be taken to the applicable collection point for the recycling of electrical and electronic equipment by ensuring this product is disposed of correctly you will help prevent potentially negative consequences for the environment and human health which could otherwise be caused by inappropriate waste handling of this product the recycling of materials will help to conserve natural resources for more detailed information about recycling this product please contact the local distributor of the product 14
- Cooling 15
- Lifting instructions 15
- Mounting 15
- Recommended for ac drive models 090 to 250 15
- Stand alone units 15
- Fig 4 emotron fld model 48 52 003 to 018 frame size b 16
- Fig 5 cable interface for mains motor and communication emotron fld model 48 52 003 to 018 frame size b 16
- Fig 6 emotron fldmodel 48 52 003 to 018 frame size b example with optional crio interface and d sub connectors 16
- Mounting schemes 16
- Table 6 dimensions connected to fig 4 16
- Fig 10 bottom view emotron fld model 48 025 to 48 058 frame size c2 with cable interface for mains motor dc dc brake resistor and control 17
- Fig 7 emotron fld model 48 52 026 to 046 frame size c 17
- Fig 8 cable interface for mains motor and communication emotron fld model 48 52 026 to 046 frame size c 17
- Fig 9 emotron fld model 48 025 to 48 058 frame size c2 backside view 17
- Table 7 dimensions connected to fig 7 and fig 9 17
- Fig 11 emotron fld model 48 52 061 and 074 frame size d 18
- Fig 12 cable interface for mains motor and communication emotron fld model 48 52 061 and 074 frame size d 18
- Fig 13 emotron fldmodel 48 072 to 48 088 frame size d2 backside view 18
- Fig 14 bottom view emotron fld model 48 072 to 48 088 size d2 with cable interface for mains motor dc dc brake resistor and control 18
- Table 8 dimensions connected to fig 11 and fig 13 18
- Fig 15 emotron fld model 48 090 to 175 frame size e 19
- Fig 16 cable interface for mains motor dc dc brake resistor and communication emotron fld model 48 090 to 175 frame size e 19
- Fig 17 emotron fld model 48 210 to 250 frame size f emotron fld model 69 090 to 200 frame size f69 19
- Fig 18 cable interface for mains motor dc dc brake resistor and communication emotron fld model 48 210 to 250 emotron fld model 69 090 to 200 19
- Table 9 dimensions connected to fig 15 and fig 17 19
- 117 lb 68 kg 150 lb 20
- Fig 19 emotron fld model 48 106 to 48 171 frame size e2 20
- Fig 20 bottom view emotron fld model 48 106 to 48 293 frame size e2 and f2 with cable interface for mains motor dc dc brake resistor and control principle drawing 20
- Fig 21 emotron fld model 48 205 to 48 293 frame size f2 20
- G 53 kg 20
- Table 10 dimensions connected to fig 19 and fig 21 20
- Before installation 21
- Frame size c2 f2 ip20 21 21
- Frame sizes b f ip54 21
- Installation 21
- Remove open front cover 21
- Cable connections 22
- Mains cables 22
- Recommendations for selecting mains cables 22
- Remove open the lower front cover on frame size e2 and f2 ip20 21 22
- Cg drives automation 01 6142 01r0 installation 19 23
- Fig 24 mains and motor connections model 003 018 frame size b 23
- Fig 25 mains and motor connections model 026 046 frame size c 23
- Fig 26 mains and motor connections model 48 025 to 48 058 frame size c2 23
- Fig 27 mains and motor connection model 061 074 frame size d 23
- Motor cables 25
- Recommendations for selecting motor cables 25
- Switches between the motor and the ac drive 25
- Connect motor cables 26
- Long motor cables 26
- Placing of motor cables 26
- Switching in motor cables 26
- Connection of motor and mains cables for larger frame sizes 27
- Emotron fld48 090 and up emotron fld69 090 and up 27
- Cable specifications 28
- Fig 3 indicates the recommended stripping lengths for motor and mains cables 28
- Fig 36 stripping lengths for cables 28
- Motor brake mains 28
- Stripping lengths 28
- Table 12 cable specifications 28
- Table 13 stripping lengths for mains motor brake and earth cables 28
- Valid when brake chopper electronics are built in 28
- With cable shoe for m6 screw 28
- Cable connection data for mains motor and pe cables according to iec ratings 29
- Fuse data 29
- Please refer to the chapter technical data section 8 page 61 29
- Table 14 cable connector range and tightening torque for emotron fld48 and fld52 according to iec ratings 29
- Table 14 cable connector range and tightening torque for emotron fld48 and fld52 according to iec ratings 30
- Table 15 cable connector range and tightening torque for emotron fld69 according to iec ratings 30
- Valid when brake chopper electronics are built in 30
- With cable shoe for m6 screw 30
- Cable connection data for mains motor and pe cables according to nema ratings 31
- List of cable cross section connector range with minimum required awg cable cross section which fits to the terminals according to ul requirements 31
- Table 16 cable connector range and tightening torque for emotron fld48 and fld52 according to nema ratings 31
- Valid when brake chopper electronics are built in 31
- With cable shoe for m6 screw 31
- Motor thermistors offer better thermal protection for the motor depending on the type of motor thermistor fitted the optional ptc input may be used the motor thermistor gives a thermal protection independent of the speed of the motor thus of the speed of the motor fan see the functions motor 32
- Motors in parallel 32
- Standard motors are normally fitted with an internal fan the cooling capacity of this built in fan is dependent on the frequency of the motor at low frequency the cooling capacity will be insufficient for nominal loads please contact the motor supplier for the cooling characteristics of the motor at lower frequency 32
- T current 232 32
- T is possible to have motors in parallel as long as the total current does not exceed the nominal value of the ac drive the following has to be taken into account when setting the motor data 32
- T type 231 and motor 32
- Thermal protection on the motor 32
- Control board 33
- Control connections 33
- Fig 37 control board layout 33
- Fig 37 shows the layout of the control board which is where the parts most important to the user are located although the control board is galvanically isolated from the mains for safety reasons do not make changes while the mains supply is on 33
- Table 17 control signals 34
- Terminal connections 34
- The table describes the default functions for the signals the inputs and outputs are programmable for other functions as described in chapter 10 page 65 for signal specifications refer to chapter 8 page 53 34
- The terminal strip for connecting the control signals is accessible after opening the front panel 34
- Connect control cables 35
- Inputs configuration with the switches 35
- Fig 38 general control i o wiring 36
- Master follower 36
- Overflow level switch level sensor optional 36
- Overflow level switch optional level sensor 36
- Stand alone 36
- Table 19 terminals and description of functions 36
- Connection example 37
- Digin 5 37
- Fig 39 connection example 37
- Fig 39 gives an overall view of a ac drive connection example 37
- Awg16 and for solid wire up to 2 m 38
- Connecting the control signal cables 38
- Fig 40 connecting the control signals fld model 003 to 018 frame size b 38
- Fig 41 connecting the control signals fld model 026 to 046 frame size c 38
- Fig 42 connecting the control signals fld model 48 025 to 48 058 frame size c2 38
- Table 20 description of optional terminals in fig 40 to fig 44 38
- The standard control signal connections are suitable for stranded flexible wire up to 1 m 38
- Fig 43 connecting the control signals fld model 061 to 074 frame size d 39
- Fig 44 connecting the control signals fld model 48 072 to 48 105 frame size d2 39
- Fig 45 connecting the control signals fld model 48 090 to 250 and fld model 69 90 to 200 frame size e f and f69 principle drawing 39
- Fig 46 connecting the control signals fld model 48 142 to 48 293 frame size e2 and f2 principle drawing 39
- Analogue inputs 40
- Analogue outputs 40
- Digital 40
- Example 40
- Screening 40
- Single ended or double ended connection 40
- Types of control signals 40
- Connecting options 41
- Current signals 0 4 20 ma 41
- Twisted cables 41
- Example 43
- Function keys 43
- Getting started 43
- Sections 43
- Using the function keys 43
- Generic configuration all drives 44
- Language 44
- Set the motor data 44
- Switch on the mains 44
- Toggle loop 44
- Additional configuration for standalone master drives 45
- Level sensor configuration 45
- Set flowdrive configuration 45
- Set sump levels 45
- Example with rectangular reservoir 46
- Example with round reservoir 46
- Set reservoir geometry 46
- Clean pumps 47
- Engage auto tune program to optimize energy consumption 47
- Load monitor 47
- Run switches 47
- Start auto tune 47
- Sump level 47
- Test run 47
- Verify auto mode operation 47
- Configuration of additional features 48
- Example 48
- Flush start 48
- Pipe cleaning 48
- Pump cleaning 48
- Random start level 48
- Sump cleaning 48
- Category 0 uncontrolled stop 49
- Category 1 controlled stop 49
- Category 2 controlled stop 49
- Emc and standards 49
- Emc standards 49
- Stop categories and emergency stop 49
- Handheld control panel 2 51
- Options 51
- Options for the control panel 51
- Emosoftcom 52
- Gland kits 52
- I o board 52
- Ptc pt100 52
- Rtc real time clock board 52
- Serial communication and fieldbus 52
- Enable input and control of ac drive via normal i o control signals of ac drive 53
- Fig 52 connection of standby supply option n frame sizes b c c2 e e2 f and f2 53
- Fig 53 connection of standby supply option on frame size d and d2 53
- High signal on the digital input e g terminal 10 in fig 107 which is set to enable for setting the digital input please refer to section 10 page 132 53
- Inhibit input terminals 1 dc and 2 dc on the safe stop option board should be made active by con necting 24 53
- Inhibit trigger signals with safety relay k1 via safe stop option board 53
- Power conductor stage checking status and feedback of driver circuits and igbt s 53
- Protected by a 2 a slow acting fuse from a double isolated transformer the terminals x1 1 x1 2 on size b c and e to f are voltage polarity independent the terminals a and b on size d are voltage polarity dependent 53
- Safe stop option 53
- Standby supply board option 53
- The standby supply board option is supplied with external 10 24 53
- The standby supply board option provides the possibility of keeping the communication system up and running without having the 3 phase mains connected one advantage is that the system can be set up without mains power the option will also give backup for communication failure if main power is lost 53
- To enable the ac drive to operate and run the motor the following signals should be active 53
- To realize a safe stop configuration in accordance with safe torque off sto en iec 62061 2005 sil 3 en iso 13849 1 2006 the following three parts need to be attended to 53
- To secure the supply voltage for the driver circuits of the power conductors via safety relay k1 see also fig 107 53
- Fig 56 safe stop connection 55
- Brake resistors 56
- Common mode filter 56
- Emc filter class c1 c2 56
- Liquid cooling 56
- Other options 56
- Output chokes 56
- Overshoot clamp 56
- Sine wave filter 56
- Top cover for ip20 21 version 56
- Available during limited time and as long as allowed by drive temperature 57
- Electrical specifications related to model 57
- Emotron fld ip20 21 version 57
- Emotron fld ip54 version 57
- Table 22 typical motor power at mains voltage 230 400 and 460v ac drive main voltage range 230 480 v 57
- Table 23 typical motor power at mains voltage 230 400 and 460 v ac drive main voltage range 230 480 v 57
- Technical data 57
- Available during limited time and as long as allowed by drive temperature 58
- Emotron fld 2 ip54 version model 69 250 and up also available as ip20 58
- Table 24 typical motor power at mains voltage 525 575 and 690 v ac drive main voltage range for 52 440 525 v and for 69 500 690 v 58
- General electrical specifications 59
- Table 25 general electrical specifications 59
- Example 60
- Operation at higher switching frequency 60
- Operation at higher temperatures 60
- Possible derating 60
- Select ac drive 60
- Dimensions and weights 61
- Dimensions and weights for models emotron 48 ip20 21 version 61
- Table 27 mechanical specifications 48 52 61
- Table 28 mechanical specifications 69 61
- Table 29 mechanical specifications 48 ip20 and ip21 version 61
- The protection classes ip20 and ip21 are defined according to the en 60529 standard 61
- The table below gives an overview of the dimensions and weights of the emotron ip20 21 version 61
- The table below gives an overview of the dimensions and weights the models 003 to 250 are available in ip54 as wall mounted modules protection class ip54 is according to the en 60529 standard 61
- These ac drives are available as wall mounted modules the ip20 version is optimised for cabinet mounting with the optional top cover protection class is in compliance with ip21 making it suitable for mounting directly on the electrical room wall 61
- Environmental conditions 62
- Table 30 operation 62
- Table 31 storage 62
- According to iec ratings 63
- Fuses and glands 63
- Max fuse maximum fuse value that still protects the ac drive and upholds warranty 63
- Table 32 fuses cable cross sections and glands 63
- Use mains fuses of the type gl gg conforming to iec 269 or breakers with similar characteristics check the equipment first before installing the glands 63
- For data on cable connection ranges see section 3 page 25 64
- Ip20 21 models are equipped with cable clamps instead of glands 64
- Note for ip54 models 003 to 074 cable glands are optional 64
- Table 32 fuses cable cross sections and glands 64
- Fuses according to nema ratings 65
- Table 33 types and fuses 65
- Control signals 66
- Table 34 66
- Cg drives automation sweden ab 68
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