Instruction Manual For Power Monitor (PM) Series · instruction manual for power monitor (pm)...

PM Series_MANUAL_1/07/04

Instruction Manual For Power Monitor

(PM) Series

14845 WEST 64th AVENUE • ARVADA, COLORADO 80007 USA PHONE: (1+) 303-425-0800 • FAX: (1+) 303-425-0896 • WEBSITE: WWW.SUNDYNE.COM


Table of Contents

Description Page

Legal Declarations 3

Model Number Definitions 3

Introduction 4

Basic Power Monitor

Product Specifications 4

Wiring Diagrams

3-Phase Models Using Internal CT Only 5

3-Phase Models Using External CT 6

1-Phase Model Using Internal CT Only 7

Terminal Block Connections and Definitions 8

Mounting Information 9

Panel Function Definitions 10

Determining Low and High Trips Limits 11

Application Notes

Using an External CT 13

Automatic Reset 13

Utilizing the Analog Output 13

Inverted Relay Operation 13

Troubleshooting 14

Optional Display Panel

Product Specifications 15

Wiring Diagram 16

Terminal Block Connections and Definitions 16

Mounting Information 17

Panel Definitions 18

Panel Programming Steps and Function Definitions 19

Application Notes:

Using an External CT 20

Automatic Reset 20

Utilizing the 4-20 mA Output 20

Hardware and Software Lock 20

Troubleshooting 21

Set-Up Examples 22


WARRANTY

Sundyne Corporation warrants to Buyer for a period of twenty-four (24) months that equipment at the time of shipment will be free from defects of design, material and workmanship. If any defects or malperformance occur during the warranty period, Sundyne’s sole obligation shall be limited to alteration, repair or replacement at Sundyne’s expense, F.O.B. Factory, of parts or equipment, which upon return to Sundyne and upon Sundyne’s examination prove to be defective. Equipment and accessories not manufactured by Sundyne are warranty only to extend of and by the original manufacturers’ warranty. Sundyne shall not be liable for damage or wear to equipment caused by abnormal conditions, vibration, failure to properly prime or operate equipment without flow or caused by corrosives, abrasives or foreign objects. THE FOREGING WARRANTY IS EXCLUSIVE AND INLIEU OF ALL OTHER WARRANTIES WHETHER EXPRESSED OR IMPLIED INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. In no even shall Sundyne be liable for consequential or incidental damages.

EUROPEAN UNION MACHINERY DIRECTIVE

This document incorporates information relevant to the Machinery Directive 98/37/EC. It should be read prior to the use of our equipment. Individual maintenance manuals that also conform to the EU Directive should be read when dealing with all models. Although PM Series power monitor complies with the EMC and Low Voltage Directives, satisfactory performance cannot be guaranteed in high noise environments that are outside the EMC limits.

THIRD PARTY APPROVALS

The PM Series products are designed to meet the industrial control equipment guidelines outlined by Underwriter’s Laboratories (UL) Bulletin 508 and Canadian Standards Association (CSA) Standard 22.2. Please consult the factory for the specific model approval status.

COPYRIGHT

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical, photo copying, recording or otherwise without the prior permission of Sundyne Corporation.

2003 Sundyne Corporation


FIGURE 1

MO

TOR

INPU

TS

CURRENT

PERCENTAGE OF MOTOR LOAD0 50 100

INPUTPOWER

FIGURE 2

Introduction:

The relationships between AC motor current and AC motor input power with respect to motor load are shown in figure 1. The motor current remains almost constant between 0 to 50% of motor load while the motor power increases uniformly with increasing load. Using this linear relationship between input power, the user has a method of linking motor power to the pump performance curve to predict flow rate as long as the motor speed remains constant. Motor output power is calculated by multiplying the measured input power by the motor efficiency marked on the motor nameplate. This motor efficiency can fluctuate by several percentage points over the entire motor load range depending on the motor manufacturer standards.

A power monitor is a simple flow indicator that associates a digital (input or calculated output power) value to a specific pump flow rate. The decision-making capability inside the power monitor permits the user to setup a power window of pump operation. This window has a programmable low limit (value just above minimum flow) and a programmable high limit (value equal to the point just prior to end of curve/cavitation). If the pump motor operates outside of this window longer than a defined time period, then the monitor will open a relay contact (electrical mechanical switch) that will cause a controller to remove power from the pump motor, thus stopping the pump operation before damage can occur.

-Basic Power Monitor-

Product Specifications:

Model No. Description - Voltage Sampling Range PM 1200 3-PH Power Monitor, 230 to 575 VAC PM 1300 3-PH Power Monitor, 600 to 660* VAC (Optional) PM 1100 1-PH Power Monitor, 100 to 250 VAC (Optional)

*Note: Underwriters Laboratory has a maximum voltage limit of 600 VAC, model PM1300 cannot be UL listed.

Motor Current Sampling Range (All Models) Internal CT 0 – 65 Amp External CT N Amp with CT ratio of N: 5 Amp

High Trip Limit High Trip = kW range set (adjustable from panel pot) Low Trip Limit Range 20 to 80% of kW Power Range (adjustable from panel pot) Start-Up / Low Trip Delay 1 - 30 seconds (adjustable from panel pot) High Trip Delay 1 - 10 seconds (adjustable from panel pot) Frequency Range 45 - 65 Hz Control Supply 115/230 VAC ± 10%, 50/60 Hz, 1-Ph Relay Output: Rating Type

5 Amp @ 250 VAC (non-inductive) SPDT, Normally Close

Analog Output 0 –10 VDC (directly proportional to kW range selected). Activation Voltage - K Inputs 12 – 30 VDC Environment Restriction The unit must be kept away from moisture. Operating Temperature +5 to +122°F (-15 to +50 °C) Enclosure: Material Mounting Rating Dimensions

Upper:White Lexan (UL94-V0), Lower:Black Noryl (UL94-V0) 35 mm DIN Rail NEMA 1 Type (IP 20) 2.76 in. x 3.38 in. x 2.28 in. (70 mm x 86 mm x 58 mm)

Third Party Approvals CE (UL and C-UL pending)


Wiring Diagram: 3-Phase Unit with Internal CT Only

Note: The normally closed (NC) relay contact is closed when the unit is powered and no

trip condition exists.

CAUTION

The PM Series power monitor is directly connected to the AC supply that powers the motor. Dangerous voltage potentials are present. Qualified personnel must perform all installation and servicing with the AC supply disconnected and locked out.

FIGURE 3

!

STARTING COIL

5 L3 17+12V

12

11

10

9

N

230 VAC

115 VAC

7

8

6

VN

VP

VD +

GND

K2

K3

K1

24

23

22

21

19

20

18

INTERNAL CURRENT SENSOR

4

2

3 L2

1 L1

NO

C

NC

16

15

14

13

START

STOP

PHASE L1

PHASE L2

PHASE L3

M

M

AUX.

OL

MOTOR STARTER

MOTOR3-PHASE

AC

VOLTAGECONTROL

VOLTAGE

0 - 10 VDC

OPTIONALDISPLAY

M

M


FIGURE 4

FIGURE 5

STARTING COIL

5 L3 17+12V

12

1110

9

7

8

6

GND

K2K3

K1

24

23

22

21

19

20

18


4

2

3 L2

1 L1

NOCNC

16

15

14

13

START

STOP

PHASE L1

PHASE L2

PHASE L3

M

M

AUX.

OL

MOTOR STARTER

MOTOR3-PHASE

AC

VOLTAGE

EXTERNAL CURRENT TRANSFORMER

N

115 VACCONTROLVOLTAGE

230 VAC

VNVPVD + DISPLAY

OPTIONAL

0 - 10 VDC

X1X2

M

M

HI

FIGURE 4

Wiring Diagram: 3-Phase Unit with External CT



Using an External Current Transformer

1. The external CT must be rated for wattmeter usage to obtain correct power reading.

2. The “XI” wire lead from the transformer is passed through the internal CT and is connected to the other wire lead, X2.

3. To maintain proper current direction, the wire from the power supply must enter the core of the external CT from the side marked “HI”.

4. Refer to the page 13 in application notes for further details.

CAUTION


SECONDARY WIRES

EXTERNAL CT WITH ONE TURN

WIRE WITH MOTORCURRENT FLOWING

CONNECT THRUINTERNAL CT

!


Wiring Diagram: 1-Phase Unit with Internal CT



CAUTION


FIGURE 6

!

STARTING COIL

5 17+12V

12

11

10

9

N

230 VAC

115 VAC

7

8

6

VN

VP

VD +

GND

K2

K3

K1

24

23

22

21

19

20

18


4

2

3 L2

1 L1

NO

C

NC

16

15

14

13

START

STOP

PHASE L1

PHASE L2

M

M

M

AUX.

OL

MOTOR STARTER

MOTOR1-PHASE

AC

VOLTAGECONTROL

VOLTAGE

0 - 10 VDC

OPTIONALDISPLAY


(115 /230 VAC, 50/60 Hz, PH 1)MOTOR SAMPLE VOLTAGE INPUT

EXTERNAL DISPLAY SIGNALTRIP INHIBIT INPUTSREMOTE RESET AND

ANALOG OUTPUTSIGNAL (0 - 10 VDC)

INTERNAL RELAY

14

11 2

1313

CONTROL VOLTAGE

CONTACTS (NO, NC)

22

1063 4 5 87 9

181615 17 2019 21

121112

242324

Int. C T

Hig h T rip

M ax 65A

L1

x10 High Delay(s)

Sta rt- T

5

0Limit / Range (kW)

L2 L3

01

432

5

9 1.32

678

4

52

36

44

2820

60

76

68

Lo w T ripLimit (%)

9 1

78

63

4

20 9

6578

Hig h

Low

T s

Loa d

Reset

15

Low Delay(s)0 30

Ts Delay(s)

15

0

0

5

30

10

PM Series

17+12V

VN

VP

VD +

GND

K2

K3

K1

24

23

22

21

19

20

18

16

0 - 10 VDC

PLC12 - 30 VDC

COMMONDC SUPPLY

Terminal Block Connections and Definitions:

Field Wiring Guidelines

1. It is strongly recommended that all

wiring be done according to local electrical codes.

2. The terminal block will accept a maximum of 12-gauge wire (2 mm).

3. Maximum recommended installation torque for the terminal block screws is 7 lb-in (0.79 N-m).

4. The internal CT opening has maximum opening of 0.39 in. (10 mm) that limits the wire size to #6 (4.1 mm).

5. Use copper wire only.

No. Description No. Description 1 Phase Voltage L1 Input 13 Relay Contact, Normally Closed 2 Do not use 14 Relay Contact, Pole 3 Phase Voltage L2 Input 15 Relay Contact, Normally Open 4 Do not use 16 Do not use 5 Phase Voltage L3 Input 17 +12 VDC Unregulated (For ”K” Inputs Only) 6 Do not use 18 K1, External and Automatic Reset 7 230 VAC 19 K2, Disable Low Trip Function 8 Do not use 20 K3, Disable High Trip Function 9 115 VAC 21 Isolated DC Ground

10 Do not use 22 VD+, Display input 11 N 23 VP, Analog Output 12 Do not use 24 VN, Analog Output

Remote Reset and Inhibit Inputs:

The control inputs are isolated (2500 Vrms) by means of opto-couplers. Connecting terminal 17 (isolated 12 VDC, unregulated supply) to one of the inputs will activate it. The inputs can also be wired for PLC operation:

Analog Output:

A non-isolated monitoring signal (0 – 10 VDC) is available at terminals 23 (VP) and 24 (VN) that can be connected to a voltmeter for digital visualization of the measured input power.

Zero kW Power 0 V High Trip (kW Range Setting) 10 V Minimum Load Impedance 1 Meg. Ohms FIGURE 8

FIGURE 7


!

10

PM Series

15 16 1918

108 9 11 1212

222120 23 2424

2.28 IN. (58 MM)

3.38 IN. (86 MM)

0.39 IN. (10 MM)

CORE OF INTERNALCURRENT TRANSFORMER

MOUNT RELEASE

L1 L 2 L3

Reset

Ts

Low

HighL imit / Ran ge ( kW)x10

Int. CT

Hi gh Trip

Ma x 65A

0

5432

1

46

.789

32

1

Load

S tart-T

68

Low Tri pLim it (%)

28

36

44

7620

5260

1

465

90

78

32

65

90

78

Ts De lay(s )

Low Delay (s)

0

0

15

30

30

Hig h De lay(s )0

15

5

2.76 IN. (70 MM)

211

43 765

1413

13 17

Mounting Information:

The power monitor must be installed inside either a motor starter control cabinet or a similar electrical enclosure to shield it from moisture. The unit attaches to a standard 35 mm DIN rail (not supplied by Sundyne).

Environment Restriction The unit must be kept away from moisture. Operating Temperature +5 to +122°F (-15 to +50 °C) Enclosure: Material Mounting Rating Dimensions

Upper: White Lexan (UL94-V0), Lower: Black Noryl (UL94-V0) 35 mm DIN Rail NEMA 1 Type (IP 20) 2.76 in. x 3.38 in. x 2.28 in. (70 mm x 86 mm x 58 mm)

Warning

The PM Series products are not to be located in Hazardous Areas, which are defined as areas where there is a presence or possible presence of a flammable gas/air mixture.

FIGURE 9


START-UP TIME DELAY SETTINGRELAY CONTACT STATUSLOW TRIP STATUSHIGH TRIP STATUSSTART TIME DELAY STATUS

HIGH TRIP TIME DELAY SETTING

LOCAL RESET BUTTON

LOAD MEASURED LED

LOW TRIP TIME DELAY SETTINGLOW LIMIT SETTING

HIGH LIMIT MULTIPLIERHIGH LIMIT SETTING (3-DIGIT)

5

0

High Trip

L2

14

1 21

Max 65AIn t. CT

L1

x10

4

123

13

High Delay(s)

Low Delay( s)

Ts Delay(s)

22

10985 6 73 4

4

1

Limit ( %)

Low Trip

18

L 32 8

44

36

Limit / Rang e (kW)

16

6 4

87.9 1

23

15

5 6

9023

87

17

68

7620

5260

0

0

15

Start-T

20

5 6

087

9

19

5

0

15

21

121112

Lo w

Rese t

30

30

L oad

High

Ts

24

10

2313 24

P M Series

Panel Function Definitions:

Marking

Function Description

X1 - X10

High Limit Multiplier: Adjusts the High Trip limit setting value by a factor of 10.

High Trip

Limit

High Limit Setting: Upper power limit of the operating window is defined by this value. If the measured power is higher than this value, then a trip condition is recognized.

High Trip

Delay

High Trip Delay Time Setting: When the measured power exceeds the High Trip setting, an internal timer is activated. The measured power must return below this limit within a defined time period or a trip condition will be accepted. This time period is defined as the High Trip Delay.

Load

Load Measured LED: Will be on when the measured load is higher than 5% of kW setting, otherwise it will flash at 1/2-second intervals.

Ts

Start Time Delay Status: The LED is on when start-up timer is active.

High

High Trip Status: The LED is on when High Trip condition is recognized, and the LED flashes (0.5 second on-off) when High Trip condition is accepted.

Low

Low Trip Status: The LED is on when High Trip condition is recognized, and the LED flashes (0.5 second on-off) when High Trip condition is accepted.

Relay Contact Status: The LED is on when the internal, normally closed relay contact is closed.

Ts(s)

Start Up Time Delay Setting: The High and Low trip functions are disabled during motor start-up (power-up) for a fixed period of time.

Reset

Local Reset Button: Push to clear all trip functions to close relay contact

Low Trip

Delay

Low Trip Delay Time Setting: When the measured power falls below the Low Trip setting, an internal timer is activated. The measured power must return above this limit within a defined time period or a trip condition will be accepted. This time period is defined as the Low Trip Delay.

Low Trip

Limit

Low Limit Setting: Lower power limit of the operating window is defined by this value. If the measured power is lower than this value, then a trip condition is recognized.

FIGURE 10


LOW LIMIT

Max 6 5AReset

L 1 L2 L3

68

7 620

3 6

280 30Low Delay( s)

Load

Ts

High

Low

Lim it / Ra ng e ( kW)

282 .High Trip

Int. CT

x1 0 1 091 0

34 5

76

34 5

0 10828

Start -T

High Dela y(s)

60

Limit (%)5 2

44

Low T rip

9019

15

15

0 30Ts Dela y(s)

7654

376 5x 1

PM Series

Determining the Low and High Trip Limits:

The basic power monitor performs three tasks once it is connected to a pump drive motor:

• Measure the electrical input power in kW • Compare the measured power value to a minimum and maximum power settings • Set and latch an internal relay contact (open or close) based on the comparison result

The minimum (Low) limit is the input power measurement setting that is associated with:

• Low Flow • Severe Cavitation

• Magnetic Decoupling (Magnetic Drive Pumps) • Reduction in Fluid Viscosity

The maximum (High) limit is the input power measurement setting that is associated with:

• Seizure of Rotating Parts • High Flow Operation (Operating at the end of pump curve) • Increase in Fluid Viscosity

The High and Low limits (trips) can be estimated from the pump performance curve:

1. Write down the motor output power (POUT @ min. and POUT @ max.) values for the minimum and maximum flow points that are defined by application sheet.

2. Calculate the percentage ratio of minimum power to the maximum power: (POUT @ Min / POUT @ Max) x 100 3. Set the Low Limit (%) dial to this percentage value or to the nearest percentage value

above it. (for example, if 41.5 % is calculated, then choose 44%) 4. Multiply the POUT @ Max by the specific gravity (S.G.) of the fluid to be pumped. 5. Add any magnetic coupling (PMC) losses (if any) to this value. 6. Determine what motor size (or rating) is needed to

operate the pump for the maximum flow. 7. Select a motor from a manufacturer’s catalog, and record

the motor efficiency value at full load. 8. Divide the adjusted maximum power value by the motor

efficiency value. (Note: If this power value is not in kW, then convert it)

9. Set the High Limit (3-digit) to this value.

Note: The motor power required by the pump can change if the fluid property (specific gravity, viscosity, temperature) changes in the application.

To operate the monitor when the limits are not known, it is recommended to set the pots to values shown and/or calculated from this table:

Adjust Monitor Panel Pots for Initial Start-Up as Follows

Marking Definition Initial Set Value Ts(s) Start Time Delay 5 Seconds (Approximately)

High - Tr(s) High Trip Delay 5 Seconds (Approximately) Low - Tr(s) Low Trip Delay 5 Seconds (Approximately) Low Limit Low Trip Value 20%

High Limit

High Trip Value2

Motor rated power (hp) x 0.746 / 0.81 Motor rated power (kW) / 0.81

Note: 1. The monitor measures input power in kW, so this equation estimates the

input power value in kW of the pump motor at 100% of rated load. The equation assumes that the motor is 80% efficient.

2. If external CT is to be used, then refer to application section on page 13 for kW range setting limits on the monitor.

HIGH LIMIT

FIGURE 11


!

!

DELAY TIMERS SETTINGS

Max 6 5AReset

L 1 L2 L3

68

7 620

3 6

280 30Low Delay( s)

Load

Ts

High

Low

Lim it / Ra ng e ( kW)

282 .High Trip

Int. CT

x1 0 1 091 0

34 5

76

34 5

0 10828

Start -T

High Dela y(s)

60

Limit (%)5 2

44

Low T rip

9019

15

15

0 30Ts Dela y(s)

7654

376 5x 1

PM Series

A simple way to set the Low and High Trip values is to operate the pump at the two extreme flow rates (maximum and minimum) defined in application parameters.

1. Make sure that the suction pipe and the pump are filled with liquid, and the suction valve is completely open.

2. Start the pump, and adjust the discharge valve until the application maximum flow is reached.

PUMP OPERATION

Do not run out on the pump curve if throttling is necessary because cavitation may occur.

3. Decrease kW setting value slowly until the HIGH LED turns on. The motor starter can and will switch off at this point after the time delay is completed. (Press the Reset button on monitor panel to clear any trips.)

4. Start the pump again and verify that the pump does shut-off at this point. The HIGH LED will be on, and Contact LED is off. Note: The time to shut-off the pump from a start-up

condition is equal to the sum of start time (Ts) and the High Limit Delay Setting (High-Tr).

5. If the pump does not shut off, then repeat steps 3 and 4 until the pump does shut off at this flow point.

6. Press the Reset button on the monitor panel to clear any trips.

7. Start the pump again and adjust the discharge value for the normal operating flow point.

Note: Only two LEDs (LOAD and Contact) should be on after Ts LED is off.

8. Adjust the discharge valve to the minimum flow point required in the application. If this value is very close to no flow condition, then consult with the pump manufacturer for cautionary advice.

PUMP OPERATION

Try to limit pump operation time at minimum flow for no more than a few seconds until the Low Trip Limit is set. Do not exceed 5-10 seconds at any one time.

9. Increase the LOW Trip limit setting until the LOW LED is on. The motor starter can and will switch off at this point after the time delay is completed. (Press the Reset button on monitor panel to clear any trips)

10. Start the pump again and adjust the discharge valve until the normal operating flow is reached. Only two LEDs (Load and Contact) should be on after Ts LED is off.

11. Verify the limits by adjusting the discharge valve for the two flow conditions. Fine-tune the trip limits where it is needed. (Time delays may also need tuning to reduce nuisance tripping.)

Note: Let the pump run for a few hours to allow the AC motor to warm-up. The trip values may need to be fine-tuned to compensate for power variation between cold (not used for 24 hours) motor and hot (operating for 2 hours or more) motor.

FIGURE 12


13NC14

16

17

15

+12V

CNO

17+12V

VN

VP

VD +

GND

K2

K3

K1

24

23

22

21

19

20

18

16

0 - 10 VDC

WIRE JUMPER

Application Notes:

Using an External CT with the Power Monitor The kW range on the monitor must be adjusted to accept only the 0 – 5 amps current range from the CT secondary. The recommended kW value is shown in this chart for the nominal line voltage or a value can be calculated from the basic power equation given:

The maximum kW range with external CT (N:5) is defined:

Max. kW = N (primary value) x kW Setting (monitor) x 0.2

Note: The nominal motor voltage can influence this maximum kW setting for the Monitor. If the calculated kW value is higher than the kW setting shown for the voltage indicated, then use the kW setting shown for the voltage as the maximum kW setting.

Automatic Reset Connecting a wire jumper between terminals 17 and 18 will enable the Automatic Reset feature. This reset feature will automatically clear a trip condition after a trip has been recognized.

Note: When this feature is used, it is strongly recommended that a separate start command be required to start the motor thus preventing unexpected system start-up.

Utilizing the Analog Output A non-isolated monitoring signal (0 – 10 VDC) is available at terminals 23 (VP) and 24 (VN) that can be connected to a voltmeter (or a process meter with scaling) for digital visualization of the measured power. The linear relationship of signal to the measured power is defined by this equation:

Measured kW = analog output value (from monitor) x kW setting value (from monitor) x 0.1

Note: Terminal 24 (VN) is connected to the measured ground reference formed by (3) Mega ohm resistors arranged in Y-configuration across three-phase line. The voltage potential is relative low, but connecting this terminal to external equipment may result in measurement errors.

Inverted Relay Operation

Depending on the specific control logic requirements, the internal relay contact action may need to be reversed where a close contact will indicate a trip condition instead of an open contact. To obtain this inverted relay operation, the user is advised to use the normally open relay contact (terminal 15) instead of normally closed contact (terminal 13). Note: When control power is applied to the monitor and

no trip condition exists, terminal 15 will be open.

Nominal Voltage kW Setting 208 VAC 1.80 230 VAC 1.99 380 VAC 3.29 415 VAC 3.59 460 VAC 3.98 575 VAC 4.98 600 VAC 5.20

Basic Power Equation kW Setting = Nom. Volt x .00866

FIGURE 13

FIGURE 14


Troubleshooting:

Condition

Suggestion

The wire direction for the current sampling is reversed through the internal CT in the Monitor. The wire from the power supply side must enter the internal CT core from the top (terminal block side marked 13-24) of the Monitor.

The current sampling is not done on the same phase wire that is connected to terminal 1 (L1) on Monitor. Have a qualified person check the wiring.

The Monitor Load LED is not on when the motor is running.

The measured power is less than 5% of kW setting, so the kW setting must be lowered. Adjust the kW setting to equal the motor rating (in kW) times 1.25 (assuming an 80% motor efficiency). Contact Sundyne for further assistance.

No LEDs are on when the monitor is powered up.

The control power supply at terminals 7 and 9 or 8 and 9 of the Monitor does not have the proper voltage. Have a qualified person check the fusing and wiring. Contact Sundyne for further assistance.

The High Trip limit may be set too high. Lower the High Trip setting until the High Trip LED goes on.

The High Trip time delay is set too high, and may need to be lowered.

The motor does not trip on the High Trip setting.

The K3 input (High Trip Inhibit) at terminal 20 is activated.

The Contact LED is off, but the motor is still running.

The trip contact may be welded together. Have a qualified person check the continuity of the contact. Contact Sundyne for further assistance.

The Low Trip limit may be set too low. Increase the Low Trip setting until the Low Trip LED goes on.

The Low Trip time delay is set too high, and may need to be lowered.

The motor does not trip on the Low Trip setting.

The K2 input (Low Trip Inhibit) at terminal 19 is activated.

The unit trips the motor during short underload or overload conditions.

Increase the trip time delays or adjust the trip limits to compensate for the intermittent load surges.

The remote switch contact may be rated for 10 A. or higher, and this contact may have oxidized causing high circuit resistance. Replace the switch with one that has a low current (1A. or less) rating.

Remote Reset and Trip Inhibits do not operate properly.

The DC common of an external driver (PLC or other control device) is not connected to the monitor common (terminal 21).


- Optional Display Panel-

Model Number

Description

PM-2000 Display Panel Only PM-2011 Display Panel with Model PM-1100 Monitor PM-2012 Display Panel with Model PM-1200 Monitor PM-2013 Display Panel with Model PM-1300 Monitor Note: The power monitor specifications are listed on

page 4 of this manual.

Product Specifications:

Product Type Display Panel

Digital Screen LED, 3 digit, 0.3 in. (7.62 mm) High

Power Requirements 10 VDC / 50 mA (Provided from Power Monitor)

Analog Output (Passive) Range

Input Voltage Range Maximum Load Resistance

Short Circuit Protection Reverse Voltage Protection

4 –20 mA ± 1% @ 24 VDC (proportion to power range set) 15 to 30 VDC R= (Vp-12)/0.022, Vp=Input Voltage (i.e. 545 Ohms @ 24VDC) Yes Yes

Activation Voltage - K Inputs 12 – 30 VDC

Start-Up Timer 1 – 999 seconds

High and Low Trip Delays 1 – 99 seconds

Trip Range 5% to 100% of Maximum Power Value

Display Power Units HP, kW, or % kW

Parameter Program Lock Software Hardware

Embedded command entered from keypad Closed connection between terminals 6 and 7

Communication Distance The maximum wire distance between the Power Monitor and the Display Panel is 25 ft (7.62 m). A twisted wire pair is recommended for the distance between 1 ft (0.3 m) to 6 ft (1.82 m), and shielded wire for distance over 6 ft (1.82 m)

Environment Restriction Keep the unit out of direct sunlight

Operating Temperature +5 to +122°F (-15 to +50 °C)

Enclosure: Material Mounting Dimensions Rating

Flame Resistant Noryl Panel 2.83 in. x 2.83 in. x 2.70 in. (72 mm x 72 mm x 68.6 mm) NEMA-12 Type (IP- 54) NEMA-4X (IP- 66) with optional translucent, plastic hood*

Third Party Approvals CE (UL and C-UL is not required if supply is under 32 VDC)

*Note: Contact the factory for further information on the optional translucent, plastic hood.

FIGURE 15


1 2 3 4 5 6

BACK OF DISPLAY

7 8 9 10

K1

DV+

4

K2K36

5

GND2

3

1

4-20 mA OUTPUTVOLTAGE INPUT FOR 4-20 mA 10

98

7

VinIoutK GNDV+

DC SUPPLY12 - 30 VDCCOMMON

PLC

K1

OPTIONAL DISPLAY PANELPM 2000DV+

POWER MONITOR

15NO

VPVN

2324

19K2K3GNDVD +

2122

20

K1+12V 17

18

16

NCC

1314

4K2K36

5

GND23

1

4-20 mA OUTPUTVOLTAGE INPUT FOR 4-20 mA

10987

VinIoutK GNDV+

Wiring Diagram:

Terminal Block Connections and Definitions:

Field Wiring Guidelines

1. The terminal block will accept a maximum of 12-gauge wire (2 mm).

2. Maximum recommended installation torque for the terminal block screws is 4 lb-in (0.6 N-m).

3. Use copper wire only.

No. Description No. Description 1 DV+, Supply Signal from Monitor 6 K3, Hardware Parameter Lock 2 GND, DC Common 7 V+, DC Supply (For K Inputs Use Only) 3 , Cable Shield Connection 8 K GND, DC common for K Inputs Only 4 K1, Remote Reset 9 Iout, 4-20 mA Output 5 K2, Do Not Use 10 Vin, Voltage Input for 4-20 mA

Note: The I/Os on Monitor are internally switch-off when the Display Panel is connected:

• Control Inputs (K1, K2, K3) • Panel LEDs (Start-T, Low, High)

• High / Low Limit Pots • Delay Timer Pots

Remote Reset and Control Inputs:

The control inputs are isolated (2500 Vrms) by means of opto-couplers. Local operation is accomplished by connecting terminal 7 (V+) to inputs (K1 or K3) to activate them, but terminal 8 (K GND) must be connected to terminal 2 (GND). The inputs can also be wired for PLC operation:

Analog Output:

An isolated (2500 VAC to measured voltage), passive monitoring signal (4-20 mA) is available at terminals 9.

Zero Measured Power 4 mA Max. Measure Power 20 mA

Maximum Load Impedance 136 Ohms@ 15V 818 Ohms@ 30V

Note: See the application notes on page 20.

FIGURE 17

FIGURE 18

FIGURE 16


!

DETACHABLETERMINAL

BLOCK

2.70 IN. (68.6 MM)

0.25 IN. (6.35 MM)2.83 IN. (72 MM)

PRGM

HIGH

MTR EffPTR kW

Ext. CTPWR Max

LOW

PM-2000

2.83 IN. (72 MM)

T-Delay

2.50kW

Trip Pt.

Aux

Start-TLocked

kW %

HP

PM Series

Reset

Mode

TM

2.63 IN. (66.5 MM)

NEOPRENE RUBBER GASKETSUPPLIED WITH THE UNIT

PANEL WALL

ADJUSTABLE BRACKET(TWO ARE SUPPLIED)

CUTOUTDIMENSIONS

RECOMMENDED

2.68 IN. (68 MM)

2.68 IN. (68 MM)

OPTIONALTRANSLUCENT PLASTIC HOOD

Mounting Information:

The Display Panel is normally mounted to a control cabinet door or a similar electrical enclosure. The supplied neoprene rubber gasket or a similar sealing device is required to seal the air gap between the cutout opening and the enclosure from the outside environment. To obtain NEMA-4X rating, an optional translucent plastic hood is fitted over the front panel before it is mounted to the panel door.

Environment Restriction Keep away from direct sunlight Operating Temperature +5 to +122°F (-15 to +50 °C) Enclosure: Material Mounting Dimensions Rating

Flame Resistant Noryl Panel 2.83 in. x 2.83 in. x 2.70 in. (72 mm x 72 mm x 68.6 mm) NEMA-12 Type (IP - 54) NEMA-4X (IP- 66) with optional translucent, plastic hood*

* Note: Contact the factory for further information on the optional translucent, plastic hood.

Warning

The PM Series products are not to be located in Hazardous Areas, which are defined as areas where there is a presence or possible presence of a flammable gas/air mixture.

FIGURE 19

FIGURE 20


2.50

Start-TLocked

T-DelayTrip Pt.

PM-2000

HPkW

kW %Aux

PTR kW

LOWHIGH

MTR EffExt. CT

PWR MaxPRGM

Reset

Mode

PM Series

UP ARROW KEY

MODE ARROW KEY

RESET ARROW KEY

DOWN ARROW KEY

DISPLAY SCREEN

FUNCTION LEDS

Panel Definitions:

Function LEDs

Notes

HP The power reading is shown in horsepower.

kW The power reading is shown in kilowatt.

% kW The power reading is shown in percent of kilowatt.

Aux Not used.

Locked The parameters settings are protected by either software or hardware lock.

Start-T The start-up time delay (1 to 999 seconds) entered.

Trip Pt The displayed power value is a trip point.

T- Delay The time delay (1 to 99 seconds) entered for a trip (limit) point.

PRGM The monitor is in the program mode.

PWR Max The maximum motor rating entered.

Ext. CT The external current transformer (CT) ratio (off, 50 to 500) entered.

MTR Eff The motor efficiency value (50 to 100%) entered.

PTR kW The recommended kW value for Monitor Range is shown on display screen.

High The displayed value is a High Trip (limit) point.

Low The displayed value is a Low Trip (limit) point.

Buttons Notes Up Arrow Button: Push to increase value.

Down Arrow Button: Push to decrease value.

Mode Mode Switch Button: Push to advance to next function in program mode.

Reset Local Reset Button: Push to clear all trip functions and to close relay contact. Program Exit Button: Push to exit from program mode.

FIGURE 21


Panel Programming Steps and Function Definitions:

Step

Press Button

LEDs On

Display Value

Function Definition

1

Mode

PRGM, Locked

On or Off

An internal software lock can be engaged to prevent unwanted parameter changes. This software lock will automatically be switched on, if no button is pushed within a 60-second time period.

2

and

PRGM, Locked

On or Off

Press and together to toggle the lock on or off. (Default=On)

3

Mode

PRGM, Start-T

#Value

The High and Low trips are disabled during motor start-up for a fixed period of time (start-up delay). (Default =15 seconds)

4

or

PRGM, Start-T

#Value

The or are used to enter a value from 1 - 999 seconds.

5

Mode

PRGM, Trip Pt., High

#Value

Upper power limit of the operating window is defined by this value. If the measured power is higher than this value, then a trip condition is recognized. (Default value = max. power value)

6

or PRGM, Trip Pt., High

#Value

The or are used to enter a value.

7

Mode

PRGM Trip Pt., Low

#Value

Lower power limit of the operating window is defined by this value. If the measured power is lower than this value, then a trip condition is recognized. (Default value = 5% of max. power value)

8

or PRGM Trip Pt., Low

#Value


9

Mode

PRGM

T-Delay, High

#Value

When the measured power exceeds the High Trip setting, an internal timer is activated. The measured power must return below this limit within a defined time period or a trip condition will be accepted. This period is the High Trip Delay. (Default =5 seconds)

10

or PRGM T-Delay, High

#Value


11

Mode

PRGM

T-Delay, Low

#Value

When measured power falls below this Low Trip setting, an internal timer is activated. The measured power must return above this limit within a defined time period or a trip condition will be accepted. This period is the Low Trip Delay. (Default =15 seconds)

12

or PRGM T-Delay. Low

#Value


13

Mode

PRGM Hp or kW or %kW

P.Un

Select the power units (horsepower, kilowatt, or % of kW) that measured electrical power will be displayed in.

14

or PRGM Hp or kW or %kW

P.Un

The or are used to select the power units.

15

Mode

PRGM, PWR Max.

#Value

Enter motor output rating. The decimal point can be repositioned in the step 18, if required.

16

or

PRGM, PWR Max

#Value


17

Mode

PRGM, PWR Max

#Value

Place the decimal point in PWR Max. value.

18

or

PRGM, PWR Max

#Value

The or are used to shift the decimal point. (X.xx, XX.x, or XXX)

19

Mode

PRGM, Ext. CT

#Value

When the motor current is higher than 65 amps, an external CT is required. The unit will work with external CTs with ratio of xxx: 5.

20

or

PRGM, Ext. CT

#Value

The or are used to select the external CT setting: Off =No Ext. CT, 50 =50:5 CT, 60 =60:5 CT, 75 =75:5 CT, 100 =100:5 CT, 125 = 125:5 CT, 150 =150:5 CT, 200 =200:5 CT, 250 =250:5 CT, 300 =300:5 CT, 400 =400:5 CT, 500 =500:5 CT. (Default = Off)

21

Mode

PRGM, MTR Eff.

#Value

The efficiency value for 100% of motor full load is used to internally calculate the maximum input power range in kW.

22

or

PRGM, MTR Eff.

#Value

The or are used to enter a value from 50 to 100. (Default=100)

23

Mode

PRGM, PTR kW, kW

#Value

This is the maximum kW range value (calculated internally by the panel display) that should be entered on the power monitor.3

24

Mode

Hp or kW or %kW

#Value

Reads measured motor power.

Notes:

1. Press the Reset button on Display Panel to exit any time from the Program Mode. 2. An automatic “exit” signal is generated internally, if no buttons are pushed within 30 seconds while

in the Program Mode. 3. When an external CT is used, the nominal motor voltage influences the maximum kW setting for

the Monitor. The maximum kW range value for the monitor cannot be higher than the kW setting listed on page 20 in the application notes for that nominal motor voltage.


K1

DV+

4

K2K36

5

GND2

3

1

4-20 mA OUTPUTVOLTAGE INPUT FOR 4-20 mA

10

98

7

VinIoutK GNDV+

WIRE JUMPER

Application Notes: Using an External CT with Display Panel

The Display Panel calculates a maximum kW value for the Monitor under the PTR kW function. When an external CT is used, the nominal motor voltage can influence this maximum kW setting. If the calculated kW value is higher than the kW setting shown for the voltage indicated, then use the kW setting shown for the voltage as the maximum kW setting.

Note: If the specific motor voltage is not shown, then use the basic equation to calculate the maximum kW setting.

Automatic Reset

Connecting a wire jumper between terminals 4 and 7 on the Display will enable the Automatic Reset feature. This reset feature will automatically clear a trip condition after a trip has been recognized.

Note: When this feature is used, it is strongly recommended that a separate start command be required to start the motor thus preventing unexpected system start-up.

Utilizing the 4-20 mA Output

An isolated (2500 VAC from the Power Measuring side) monitoring signal (4 – 20 mA) is available at terminals 9 (Iout) that can be connected to a process meter or to a PLC for a process feedback signal. This signal requires an external DC supply (15 to 30 VDC) to be connected to terminal 10 (Vin) for the output to work. The linear relationship of 4-20 mA signal to the measured power is defined by this equation:

Equation Definitions

Notes

Measured power = Current value (mA) x Slope + Intercept Slope = Power Max. (Value entered at PWR Max. Step) / 16 Intercept = Power Max. – (20 x Slope) Current value = 4-20 mA signal from the Display

In a trip condition, the output current value is less than 1 mA.

Hardware and Software Lock

To prevent unwanted changes to the parameter values entered into the Display, a software or hardware lock is used. The software lock will automatically be switched on, if no button is pushed within a 60-second time period.

Software (Panel Entered) Lock

Hardware (Terminal Block) Lock

• Press the Mode button once • Press and buttons together each time to

change the lock state.

Note: The parameter lock status will be displayed on LED screen.

Connect terminal 6 and 7 together to switch on the parameter lock. To use terminal 7, terminal 8 (K Gnd) must be connected to terminal 2 (Gnd)

Note: The hardware lock cannot be turned off from the front panel.

Nominal Voltage kW Setting 208 VAC 1.80 230 VAC 1.99 380 VAC 3.29 415 VAC 3.59 460 VAC 3.98 575 VAC 4.98 600 VAC 5.20

Basic Power Equation kW Setting = Nom. Volt x .00866

FIGURE 22


Troubleshooting:

Condition

Suggestion

The wire direction for the current sampling is reversed through the internal CT in the Monitor. The wire from the power supply side must enter the internal CT core from the top (terminal block side marked 13-24) of the Monitor.

The current sampling is not done on the same phase wire that is connected to terminal 1 (L1) on Monitor. Have a qualified person check the wiring.

The Display Panel does not read motor power when the motor is running.

The measured power is less than 5% of kW setting, so the kW setting must be lowered. Adjust the kW setting to equal the motor rating (in kW) times 1.25 (assuming an 80% motor efficiency). Contact Sundyne for further assistance.

The two wire connections from the Monitor to the Display Panel maybe reversed.

Display Panel does not light up when power is applied to Monitor.

Have a qualified person check the control power wiring to power monitor.

The High Trip limit may be set too high. Lower the High Trip setting until the High and Trip Pt. LEDs go on.

The motor does not trip on the High Trip setting.

The High Trip time delay is set too high, and may need to be lowered.

The trip contact on the monitor may be welded together. Have a qualified person check the continuity of the contact. Contact Sundyne for further assistance.

The Display Panel reads power when High or Low LEDs indicated a Trip.

The trip contact on the Monitor may not be wired properly to the motor starter control circuit. Have a qualified person check the control wiring from starter to Monitor.

The Low Trip limit may be set too low. Increase the Low Trip setting until the Low and Trip Pt. LEDs go on.

The motor does not trip on the Low Trip setting.

The Low Trip time delay is set too high, and may need to be lowered.

The and buttons do not work in Program Mode.

A parameter lock command is on. Turn software lock off and make sure terminals (6 and 7) on the Display Panel are disconnected. Contact Sundyne for further assistance.

The remote switch contact may be rated for 10 A. or higher, and this contact may have oxidized causing high circuit resistance. Replace the switch with one that has a low current (1A. or less) rating.

The remote Reset and Hardware Lock inputs do not operate properly.

The DC common of an external driver (PLC or other control device) is not connected to the Display K GND (terminal 8).


Setup Example:

Pump Model AC Motor Type Ansimag K326 Power Rating 15 hp Diameter 6.00 in. Nominal Voltage 460 VAC Speed 3500 rpm Full Load Amp 17.6 Max. Flow 265 gpm Efficiency 88.2 Min. Flow 15 gpm Phase 3

Pump Performance Curve Chart Definitions: BHP = Brake Horsepower TDH = Total ∆ Head Notes: This pump curve is derived from Ansimag K+ performance catalog sheet of K326 pump with the following conditions: Liquid S.G. = 1.00 Motor Speed = 3500 rpm Impeller Trim = 6.00 in.

Before starting the pump drive motor, data (parameter information) must be entered into the Display’s memory for it to operate correctly. For our example, the following information will be entered into the Display’s memory:

Data Entry Display Comments HP P. un Select HP for power Units

Start-T3 15 Start-Up Timer Delay Value in Seconds (1 – 999) Trip Pt. – High2 10.5 High Trip Value in HP Trip Pt. – Low2 4.9 Low Trip value in HP T-Delay – High3 5 High Trip Delay Value in Seconds (1 – 99) T-Delay – Low3 10 High Trip Delay Value in Seconds (1 – 99)

PTR Max. 15.0 Enter Motor Horsepower Rating 15.0 Use and buttons to position the Decimal Point, if required

Ext. CT Off Set external CT value to off.

MTR Eff 88 Enter motor efficiency value of 88 PTR kW 12.74 Internal calculated input kW value for Monitor

Notes:

1. If the parameters cannot be changed, then the Locked function is on. The procedure to switch off the parameter lock is listed on page 19 in the application notes.

2. The estimated BHP values (4.9 hp @ 15 gpm and 10.5 hp @ 265 gpm) from a pump curve are normally used, but the trips values are adjusted further after running the pump in the application. Specific gravity must be factored into the data derived from the standard pump curves.

3. The time values are practical times that can be adjusted according to the application needs.

4. The kW range on the Monitor is set to this value before operating the pump.

25

LOW TRIP

120

20

00

100

TDH

(ft)

40

60

80

180

140

160

20050 75 100 150

Capacity (gpm)125 175 275

HIGH TRIP

225 250 300

Performance BHP

13 hp

10 hp

7.5 hp

5 hp

2.5 hp

FIGURE 23


Notes

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