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GEA ARIETE, Instructions For Use And Maintenance Manual

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GEA ARIETE Instructions For Use And Maintenance Manual Download Page 126

 

 

Niro Soavi S.p.A

 

 

4.7.5 ASSEMBLING AND DISASSEMBLING OF PULLEYS 

Drive pulleys are usually mounted both on the input shaft of the reduction gear 
and on the motor shaft using a “Taper-Lock” conical bushings. 
With reference to figure 4.7.6, the procedure for disassembly is the following: 
 

 

 

FIGURE 4.7.6 

 

- 

loosen retaining screws A 

- 

use one of the screws in bore B to force the bush open 

- 

extract the bush and pulley from the shaft. 

 
Assembly procedure: 

- 

clean bush and shaft thoroughly 

- 

insert “Taper-Lock” bush into pulley 

- 

partially insert threaded screws into  bores (A) 

- 

mount the pulley  on the shaft 

- 

align the pulleys 

- 

tighten screws A fully 

 
If the motor pulley is not fitted with a “Taper-Lock” bush, to install or remove the 
pulley use a suitable pulley extractor and threaded rod to mount the pulley on the 
shaft, using the threaded bore on the end of it. 
 

 
 

 

4c071e0c.doc 4.7.12 

Summary of Contents for ARIETE

Page 1: ...ZIONE INSTRUCTIONS FOR USE AND MAINTENANCE BETRIEBSANLEITUNG INSTRUCTIONS D EMPLOI ET ENTRETIEN INSTRUCCIONES PARA EL USO Y EL MANTENIMIENTO HANDLEIDING Via M da Erba Edoari 29 A 43100 Parma Italy Tel 39 0521 965411 Fax 39 0521 242819 Internet htttp www niro soavi it E mail niro soavi niro soavi it ...

Page 2: ...l for the correct safe use and operation of the machine you have purchased No one should operate or perform maintenance on this machine without first having read and understood the following Instructions for Use Maintenance For any further support or information you may contact us at the below listed address Yours faithfully Niro Soavi S p A Via Mario da Erba Edoari 29 A Parma Italia tel 39 0521 9...

Page 3: ... sections as indicated in the list of CONTENTS Each section is divided into chapters and paragraphs and pages are numbered separately in each section A specific list of contents is given at the beginning of each section The pictures and tables referred to in the text are numbered inside each section Before installing the machine you must be thoroughly familiar with the information given in Section...

Page 4: ...HEET 1 3 FLOW SHEET LEGEND SPEC 102 1 4 MACHINE INSTALLATION DRAWING 1 5 UTILITIES SPECIFICATIONS SPEC 103 1 6 RUNNING SEQUENCE ONLY IF MACHINE IS SUPPLIED WITHOUT ELECTRICAL POWER BOARD BY NIRO SOAVI 1 7 ELECTRICAL SPECIFICATIONS 1 8 DECLARATION OF CONFORMITY CE 1c00se0c doc 1 0 1 ...

Page 5: ... OPERATING CONDITIONS 2 1 Product CELL RUPTURE PRODUCT SOLUTION IN WATER 2 2 MAX Viscosity 2 3 cP 2 3 MAX Relative Humidity 40 2 4 Ambient Temperature 40 C 2 5 MAX Altitude 1000 m 2 6 MAX operating temperature 90 C 2 7 MAX temperature CIP SIP 140 C 3 TECHNICAL FEATURES 3 1 COMPRESSION BLOCK 3 1 1Type MULTIBLOCK VHP 3 1 2Number of plungers 3 3 1 3Material of plungers CERAMIC 3 1 4Plunger diameter 2...

Page 6: ...EDUCER 3 3 6 Gearbox speed reduction ratio 5 3 4 LUBRICATION 3 4 1 Type FORCED 3 4 2 Lubricating system TP3A GR 1 6 1 3 4 3 Oil Cooling system YES 3 5 MAIN ELECTRICAL CIRCUIT 3 5 1 Number of phases 3 3 5 2 Voltage 400 V 3 5 3 Frequency 50 Hz 3 6 AUX ELECTRICAL CIRCUIT 3 6 1 Number of phases 3 6 2 Voltage 24DC V 3 6 3 Frequency Hz 4 OPTIONS 4 1 Suction side pulsation damper 4 2 Delivery side pulsat...

Page 7: ......

Page 8: ...GEN SUPPLY OS OIL SUPPLY SS STEAM SUPPLY WS WATER SUPPLY R RETURN 5 MACHINERY AND EQUIPMENT AUTOMATIC ACTUATOR FOR REMOTE CONTROL GENERAL MANUAL ACTUATOR NOT FOR REMOTE CONTROL AUTOMATIC ACTUATOR WITH INTEGRATED MANUAL CONTROL FACILITY DIAPHRAGM ACTUATOR SOLENOID ACTUATOR PISTON ACTUATOR ELECTRIC AC MOTOR ADJUSTABLE SPEED CONTROL COMPRESSOR OR VACUUM PUMP GENERAL FAN PUMP FOR LIQUIDS GENERAL CENTR...

Page 9: ...ECTION Q QUALITY 5 INTEGRATE OR TOTALIZE INTEGRATING OR SUMMATING R NUCLEAR RADIATION RECORDING S SPEED OR FREQUENCY SWITCHING 2 T TEMPERATURE TRANSMITTING U MULTIVARIABLE MULTIFUNCTION UNIT V VISCOSITY VALVE DAMPER ACTU ELEMENT W WEIGHT OR FORCE X UNSPECIFIED 5 UNCLASSIFIED FUNCTIONS Y VIBRATION COMPUTING RELAY RELAY Z EMERG SAFETY ACTING 2 EXAMPLE PDIRC DIFFERENTIAL PRESSURE INDICATION RECORDING...

Page 10: ......

Page 11: ... V 3x 400 Hz 50 kW 22 A 45 Note WATER YES NO YES PISTONS LUBRICATING COOLING FLUID STERILE CONDENSATE SPEC 103C UTILITY SPECIFICATION SIG MIB MACHINE MODEL NS 3018HA OIL EXCHANGER GEAR BOX YES COMPRESSED AIR STEAM ELECTRICITY Electrical supply V Hz Power absorbed kW Current absorbed A 1 THE CLIENT MUST INSTALL A PRESSURE REDUCER AT THE STEAM INLET CONNECTION TO ADAPT THE PRESSURE TO THE MACHINE S ...

Page 12: ...00 Max Press MPa 100 Rated Flow dm3 h 150 500 Year 2003 The undersigned DECLARES under his own responsibility that the above mentioned Machine object of this declaration IS IN CONFORMITY with the precepts of the following EEC directives and standard norms 98 37 EEC 73 23 EEC and following updated 93 68 EEC 89 336 EEC EN 292 2 A1 EN 60204 1 The above identified Machine has successfully passed all t...

Page 13: ...S 2 8 INSTALLATION 2 8 1 POSITIONING 2 8 2 ACCESS TO THE INSIDE OF THE MACHINE 2 8 3 MACHINE LEVELING 2 8 4 CONNECTION TO UTILITIES AND PRODUCT LINE 2 8 5 INSTALLATION 2 8 6 POSITIONING THE ELECTRIC EQUIPMENT 2 8 7 ELECTRICAL CONNECTIONS 2 8 8 DIRECTION OF ROTATION OF ELECTRIC MOTORS 2 9 SPECIAL NOTES 2 9 1 CONTROL BOARD TO BE PROVIDED BY THE CUSTOMER 2 9 2 ELECTRIC MOTOR SUPPLIED BY THE CUSTOMER ...

Page 14: ...oublefree operation any unauthorized modification will void the machine s guarantee immediately Because the tampering of any safety device may undermine the safety of the equipment NIRO SOAVI shall not be held liable for damages in case of accidents resulting from such unauthorized modification Keep these INSTRUCTIONS FOR USE AND MAINTENANCE within the operator s reach and make sure that their pla...

Page 15: ...members who are familiar with the INSTRUCTIONS FOR USE AND MAINTENANCE and with the specific technical information required to carry out their tasks using suitable tools and equipment only authorized personnel are allowed to access operate or service the machine All members of personnel must wear clothes that are suitable to prevent accidents due to clothing getting caught in moving machine parts ...

Page 16: ...as liquids or vapors is used it must installed by the user the same applies to systems for ventilation and exhaust of smoke and vapor from the danger zone All personnel must be aware of the potential hazards present in the danger zone and connected with the use of dangerous products for the safety of persons and of the environment Any tools and equipment used inside danger zones must be suitable f...

Page 17: ...ine In Section 1 TECHNICAL SPECIFICATIONS we have attached the Declaration of Conformity CE of the machine TYPE S N RATED FLOW dm 3 h MAX PRESS YEAR via M da Erba Edoari 29 A 43100 PARMA ITALY Niro Soavi S p A FIGURE 2 2 1 In addition to this NIRO SOAVI is certified according to UNI EN ISO 9001 for design manufacturing and servicing of homogenisers and high pressure pumps therefore your machine ha...

Page 18: ...Niro Soavi S p A FIGURE 2 2 2 2C001E0C DOC 2 2 2 ...

Page 19: ...ey protection panel for the Hercules versions without casing which includes the manufacturer s name model and type serial number The serial number is also punched on the compression head This number should always be quoted in any correspondence addressed to NIRO SOAVI s Customer Service in order to identify the machine properly 2C001E0C DOC 2 3 1 ...

Page 20: ...product treated operating and washing temperatures feed pressure specifications of required utilities use of inappropriate tools for the ordinary or extraordinary maintenance failure to perform or incorrect maintenance alterations or modifications carried out whether directly or indirectly without the specific authorization in writing by NIRO SOAVI failure to comply with the INSTRUCTIONS FOR USE M...

Page 21: ... the costs of travel board and accomodation of NIRO SOAVI s technicians 2 4 4 EXCLUSIONS AND LIMITATIONS The guarantee shall not cover the materials and parts subject to normal wear and tear such as but not limited to all the gaskets used in the machine V belts plunger seals and relevant packing and support washers safety valve seat filters etc as well as those parts whose life can not be estimate...

Page 22: ...omer usually packed in a properly sized wooden crate and wrapped in plastic film for additional protection unless otherwise specified in the Order Confirmation The wooden crate allows the machine to be handled with a fork lift or crane and appropriate marks are provided on the crate at the points for running steel cables or belts for lifting figure 2 5 1 FIGURE 2 5 1 2C001E0C DOC 2 5 1 ...

Page 23: ...s on the operator s side Forks should be adequately spaced and sized so as to accomodate the entire base of the frame figure 2 5 2 to prevent damage to the machine frame or panels Side panels can be removed during transport to prevent damage the front part of the bodywork under the compression head has not been constructed to support the weight of the machine Do not use this part as a lifting poin...

Page 24: ...port and handling regulations as well as with regular safety standards WARNING Use only tested hoisting devices approved to support the machine s weight as indicated in the dimension drawing in Section 1 TECHNICAL SPECIFICATIONS Do not under any circumstances leave suspended loads and never stand below suspended loads WARNING The floor on which the machine is to be placed must withstand to at leas...

Page 25: ...g should be checked contents of the packing against the Packing List integrity of the packing so that any evident damage can be immediately reported to the carrier any damage suffered by the machine as a result of improper transport by the carrier In order to minimize the amount of inconvenience for the Customer NIRO SOAVI Shipping Department is always available to assist with clarifications evalu...

Page 26: ... than 95 with no condensate Vibrations should be avoided as much as possible 2 7 2 STORAGE FOR PERIODS LONGER THAN 3 MONTHS If the machine is expected to remain stored for over three months before installation provide a closed storage place protected from bad weather dust or corrosive releases as described before Observe the above precautions for electric components In addition YOU MUST loosen the...

Page 27: ...ane or fork lift The front part and head require routine servicing allow sufficient space to permit complete removal of the head if required In addition make sure the machine is not placed near sources of heat which may undermine the necessary cooling or near obstacles which may obstruct a free air flow Plan suitable drainage points to be available in the area where the machine is installed in ord...

Page 28: ...ors the machine should be operated ONLY with the panneling in place or protections completely closed Panels may be removed to allow maintenance and or installation work to be carried out Side panels are fitted with handles and special key locks to access the inside of the machine WARNING To prevent accidents ensure that ALL retainers are tightened before starting the machine to remove or replace p...

Page 29: ... proceed as follows lift the machine and place the pads under the legs lower the machine until the legs sit firmly on the blocks adjust height from floor by tightening or loosening the adjustable legs then check the levelling with respect to the machined surface of the head make sure that the machine s weight is divided among all legs lock the legs using the appropriate lock ring figure 2 8 1 item...

Page 30: ...es of the lubrication water circuit should remain always open in a position which allows controlling an adequate flow of water for lubrication or production of enough condensate for the aseptic version Keep in mind that excessive lubrication water can lead to flooding of the sump where water is collected with the risk of water going into the drive section and polluting the lubrication oil for this...

Page 31: ...unterpressures not bigger than those indicated in the Technical Specifications Section 10 but as this is a positive displacement pump it can create dangerous overpressure which can burst the pipes downstream the machine when the outlet is closed for the liquid flow WARNING For safety reasons we recommend you ALWAYS install a safety valve downstream the machine to protect the line and users You sho...

Page 32: ...acement pump lobe single screw etc or diaphragm pump is used a suitable by pass pipe regulated by a modulating valve on the infeed pump and or an adequate speed regulating system for the infeed pump to ensure correct machine feeding if the products treated vary greatly in terms of viscosity or if a positive displacement pump must be used for viscous products and washing water you must use a pump s...

Page 33: ...m counterpressure on the line the pulsation damper is always recommended for flow rates exceeding 5000 6000 l h on the suction end it must be installed as close as possible to the machine inlet while on the delivery end it must be installed on a horizontal pipe at a distance of minimum 1 meter from adjacent bends For technical details about size and installation please contact NIRO SOAVI the pulsa...

Page 34: ...d to cavitation Feeding pressure should therefore be increased by 1 bar for each 5 C of temperature increase above 90 C added to the minimum feeding pressure specified in Section 1 TECHNICAL SPECIFICATIONS This value must be doubled in case of products with a viscosity value greater than 500 cP For special products and special process temperatures contact NIRO SOAVI the machine is fitted with auto...

Page 35: ... suspended dust or corrosive release Before ordering the machine the Customer should make sure that the intended place of installation is suitable to protect the equipment from any aggression Besides it should be ascertained that no heat sources are present in the vicinity to avoid local overheating and ensure that all electric equipment can be cooled down efficiently When forced ventilation is pr...

Page 36: ...s the power details of the machine and wiring diagrams reference should be made to the electric specifications and diagrams shown in Section 1 TECHNICAL SPECIFICATIONS and in Section 6 WIRING DIAGRAM CAUTION The indications given concerning the wiring refer to standard laying and environmental conditions the values shown are purely indicative therefore they should ALWAYS be cross checked by the us...

Page 37: ...S unless otherwise specified by the direction of the arrows on the machine flywheel and or motor oil pump motor only for machines with motor driven lubrication pump follow the direction of the arrow printed on the pump body In case of mistake the low pressure in the circuit triggers the pressure switch which prevents the machine operation electric fan of main motor only for machines designed for v...

Page 38: ...be held liable for damages caused to either persons or the machine due to mistakes made in the design and or execution of the control board CAUTION The control board should be built in accordance with the local operational and safety regulations in force 2 9 2 ELECTRIC MOTOR SUPPLIED BY THE CUSTOMER The electric motor shall be made in accordance with the general specifications laid down by NIRO SO...

Page 39: ...t a temperature of approximately 20 C so it is possible to verify the deviation of the machine s actual flow rate compared to the rated value 5 with product However at the time of start up after the machine has been installed in the production line a final test of the conditions of operation is required Upon request of the Customer NIRO SOAVI can dispatch an engineer for the first machine start up...

Page 40: ...d any standard mild detergent To prevent water from entering the machine place a suitable covering over the ventilation hole do not wet the electric panel or the control panel The HERCULES industrial version is supplied without external paneling but only with protection panels to cover moving parts in this case make sure you do not wet unnecessarily the electrical components of the machine WARNING...

Page 41: ...ts cables and protection sheaths and all the plastic parts for separate disposal The machine is manufactured with the following materials in various quantities stainless steel steel alloys and steel for construction purposes cast iron The following are also present in very limited amounts aluminium copper bronze ceramic PTFE nitrile viton PVC PEEK Elastomers and plastic materials All these materia...

Page 42: ...les due to the homogenizing effect The application of the 2nd stage should be decided on the basis of specific considerations concerning the type of product As a general rule the second stage pressure is usually applied as 1 10 to 1 5 of the maximum homogenizing pressure according to the processed product requirements The formula which relates the homogenizing pressures in a two stage system see f...

Page 43: ...e chambers to avoid contamination from outside sources Condensate is produced by steam condensation at a temperature of approximately 140 to 150C through water run in a heat exchanger The cooling water should be clean and preferably softened to avoid scaling deposits in the exchanger Water hardness must be under 8 dH 15 fH with recommended chloride value 25 mg liter and in no case greater than 200...

Page 44: ...te stops in case of fixed flow rate speed machines or with the lowest speed possible in case of operation with frequency converter During the sterilizing phase the alarm for HIGH CONDENSATE TEMPERATURE may go on you may either exclude it or just switch it off 2 13 2 2 REGULATING THE FLOW OF COOLING WATER During operation the cooling water on off valve whether manual or solenoid should remain open ...

Page 45: ...fat part milk cream coming directly from the centrifuge is homogenized then mixed downstream of the homogenizing valve to get fresh milk with standardized fat content The system includes in addition to the homogenizing valve a special mixing chamber featuring the recombination of the two portions using the high speed turbulence of the flow plus a by pass system with pneumatic valve and check valve...

Page 46: ...be closed during normal operation opened during desludging phase and cleaning of the equipment A FIGURE 2 13 3 Follow the instructions below for the correct operation of the system Open the pneumatic butterfly valve few seconds before the desludging phase of the centrifuge the single acting check valve installed prevents the product to be homogenized from flowing through the by pass even when the ...

Page 47: ... open vessel or tank without pressure if the backpressure generated by the downstream plant is not enough to make the system work properly it will be necessary to install a suitable adjustable backpressure valve WARNING To ensure the complete and proper cleaning of the by pass circuit it is necessary to keep the pneumatic butterfly valve pos A figure 2 13 3 during the cleaning phase Moreover the b...

Page 48: ...ENIZING PRESSURE ADJUSTMENT 1 STAGE 3 4 2 HOMOGENIZING PRESSURE ADJUSTMENT 2 STAGES 3 4 3 REMOTE PNEUMATIC CONTROL OPTIONAL 3 5 MACHINE STOP 3 5 1 EMERGENCY STOP 3 6 CLEANING 3 7 SAFETY DEVICES 3 7 1 OVERPRESSURE VALVE 3 7 1 1 OPERATION 3 7 1 2 CLEANING 3 7 2 PROTECTIONS ON MAIN MOTOR 3 7 3 EMERGENCY PUSH BUTTON 3 7 4 COMPRESSION HEAD GUARD 3 8 TROUBLESHOOTING 3 9 SPECIAL FEATURES OF NON STANDARD ...

Page 49: ...s can be applied to a wide range of products with variable viscosity and it allows to obtain more stable suspensions through micronization and dissipation of solid particles depending on the level of pressure applied To find out about the specific configuretion of the machine model technical data accessories and optionals see Section 1 TECHNICAL SPECIFICATIONS WARNING For safety during transport t...

Page 50: ...s not in constant use For correct and safe use of the machine we recommend that you carry out the periodical check required depending on the type of machine use to ensure the machine is in perfect condition and prevent possible problems if any it is also a good practice to check from time to time that the machine is being operated in accordance with the prescription of the manual Specific indicati...

Page 51: ...e Section 4 MAINTENANCE Verify that plungers are tight and that seal packings are in place if they have been removed during storage or after standstill of over 3 months Check the direction of rotation of motors as described in Section 2 GENERALS chapter 2 8 7 Make sure that all protection panels are in place and securely fixed CAUTION Failure to observe the last recommendation here above may in ca...

Page 52: ...Niro Soavi S p A FIGURE 3 2 1 2 1 D A B C FIGURE 3 2 2 3C001E0C DOC 3 2 3 ...

Page 53: ...3 3 1 The control panel configurated according to the Customer s requirements is on the left hand side of the machine front an EMERGENCY STOP PUSH BUTTON is always fitted on each machine ATTENTION Adequate free space must be provided in front of the machine under any circumstances in order to allow immediate access to the emergency push button and any start stop or setting devices FIGURE 3 3 1 3C0...

Page 54: ...eral alarm light with symbol These controls are available only if the electric board has been supplied by NIRO SOAVI Pneumatic controls for adjustment of the homogenizing pressure 1st and 2nd stage consisting in an air operated control to switch pressure ON and OFF and a pneumatic regulator to increase or reduce pressure shown on a measuring scale Pressure gauges for controlling pressure of air se...

Page 55: ...ckings and plungers with ceramic plungers this incorrect procedure may cause plungers failure because of thermal shock For further details on thermal shock problems with ceramic plungers see Section 4 MAINTENANCE WARNING An excess of cooling water can lead to flooding of the sump or excessive water splashing on guiding pistons with the risk of water going into the drive section It is therefore imp...

Page 56: ...machine and optionals provided opening of any utility solenoid valve optional start of the oil motor driven pump if this type has been provided start of electric fans if provided start of main motor In case the control board is supplied by the Customer the correct operating sequence is provided see Section 1 TECHNICAL SPECIFICATIONS and should be observed strictly To identify the machine configura...

Page 57: ... fully backed off counterclockwise set the pneumatic switch to ON position rotate the reducer knob clockwise until the desired homogenizing pressure is obtained by reading the reached value on the pressure gauge CAUTION To allow a slow gradual pressure increase the pneumatic adjustment system has been designed to ensure a certain inertia Operate the pressure regulator slowly while checking the act...

Page 58: ...re is allowed ONLY for machines with operating pressure up to 250 bar to prevent overstressing the machine and avoid too rapid an increase of pressure as this could cause the safety valve to open 2 1 D A B C FIGURE 3 4 1 3C001E0C DOC 3 4 2 ...

Page 59: ...eached value on the pressure gauge set the 1st stage pneumatic switch C to ON position rotate the 1st stage reducer knob D until the desired homogenizing pressure is obtained by reading the reached value on the pressure gauge WARNING To allow a slow gradual pressure increase the pneumatic adjustment system has been designed to ensure a certain inertia Operate the pressure regulator slowly while ch...

Page 60: ... bar to prevent overstressing the machine and avoid too rapid an increase of pressure CAUTION To release homogenizing pressure in a two stage system you need to reverse the procedure used to give pressure Therefore first release pressure from the 1st stage and then from the 2nd stage 3C001E0C DOC 3 4 4 ...

Page 61: ...ant to send the signal gradually over approximately 30 seconds 1 minute to avoid a sudden increase of homogenizing pressure which could cause the overpressure valve located on the compression head to open The remote control system via proportional solenoid valve uses also an ON OFF solenoid valve for switching pressure on and off this can be installed as an optional even with the manual control sy...

Page 62: ...1 TECHNICAL SPECIFICATIONS for Customers who wish to make their own board if it has not been supplied by NIRO SOAVI cut off power using the main switch 3 5 1 EMERGENCY STOP In case of dangerous situations or serious machine failure the operation can be immediately halted by pressing the emergency push button located on the front panel figure 3 5 1 After you have done that release pressure followin...

Page 63: ...hly if the cleaning solutions involve the use of concentrated products or powders first prepare the solutions separately in order to avoid any undissolved clods or solid particles Cleaning should be performed in a closed cycle C I P while the machine is running at homogenizing pressure equal to zero for homogenizers This allows avoiding energy waste and damage to the homogenizing valve WARNING For...

Page 64: ...tr max temp C Caustic Soda NaOH 3 90 Nitric Acid HNO3 1 70 Phosphoric Acid H3PO4 3 85 Hot Water 95 Hot Pressurized Water Steam 130 CAUTION Dispose of the cleaning solution and washing fluids as prescribed by the laws in force locally 3C001E0C DOC 3 6 2 ...

Page 65: ...ency push button and a guard to protect the head as described here below 3 7 1 OVERPRESSURE VALVE The pressure relief valve has been designed by NIRO SOAVI to protect the machine from the possibility of overpressure which might be producted inside the compression head as a consequence of the pumping action of the machine CAUTION The safety valve is used to protect the machine piping downstream the...

Page 66: ...e pressure regulating device until the valve is closing or reducing the pump speed in case of high pressure pumps Once the valve has closed again normal operating pressure can be re established provided the machine has not been damaged and the cause of overpressure has been addressed ATTENTION The discharge pipe must ALWAYS be directed downwards to avoid harming the operator the Customer shall be ...

Page 67: ...e of starting device and conditions of operation These protections consist of magnetic and thermal cutout switches quick fuses or automatic switches for short circuits automatic switches or the frequency converter itself for protection against overheating For the specific case see Section 1 TECHNICAL SPECIFICATIONS 3 7 3 EMERGENCY PUSH BUTTON On the front panel of the machine there is installed an...

Page 68: ... additional guard to protect the operator from any projection of machine parts from high temperatures possibly reached by the head and from any injury caused by protruding sharp parts WARNING The machine should not be used if the guard is not correctly secured in place 3C001E0C DOC 3 7 4 ...

Page 69: ... not start check the electrical wiring fuses automatic switches the drive belts are broken or loose replace or tighten the belts 2 There is no product flow no feed flow or pressure to the machine inlet feed properly the machine see Section 1 TECHNICAL SPECIFICATIONS feeding piping clogged or closed clean properly the pipeline and filters bypass valve if any opened close the bypass valve 3 Reduced ...

Page 70: ...ession head broken springs replace Section 4 MAINTENANCE not enough or too high feeding pressure feed properly the machine worn out pumping valves replace Section 4 MAINTENANCE pumping valves not working properly verify the valve cleaning and wear air into the product eliminate air 5 Noisy drive end wear of bearings check lubricate grease and eventually replace the bearings loose plungers tighten ...

Page 71: ...i 8 No cooling water on plungers valve on water plant closed open water filter clogged disassemble and clean no pressure in the water circuit check the required water supply conditions at Section 1 TECHNICAL SPECIFICATIONS 9 Pulsating delivery pressure not enough feeding pressure feed properly the machine damaged or worn out pumping valves replace Section 4 MAINTENANCE pump valves not suitable for...

Page 72: ...umatic circuit and the air supply Section 4 MAINTENANCE Defective pneumatic actuator Replace 11 Homogenizing pressure not reached Not enough feeding pressure Feed properly the machine Blocked homogenizing valve Disassemble and clean Section 4 MAINTENANCE Worn out homogenizing valve Replace Section 4 MAINTENANCE Faulty pressure gauge Replace Section 4 MAINTENANCE Damaged homogenizing valve shaft Re...

Page 73: ...ration of the homogenizing valve dampening device Check the pneumatic plant and dampening device Section 4 MAINTENANCE Pumping valves not suitable for the product Contact NIRO SOAVI Unsteady backpressure Adjust the backpressure 13 Noisy homogenizing valve Worn out homogenizing valve Replace Section 4 MAINTENANCE No oil or air pressure into the dampening device Check and restore correct operating c...

Page 74: ...er in the oil because of broken oil cooler Pressure check the oil cooler and replace Excess of water on the plungers Adjust the water flow to reduce splashing and sump flooding 16 Oil overheats and darkens Machine overload Eliminate overload Faulty oil cooler or lack of cooling water Check the oil cooler and the water flow Worn out bearings Contact NIRO SOAVI 17 No oil flow and pressure Wrong oil ...

Page 75: ...h Check the pressure switch and in case replace contact NIRO SOAVI Leaking oil cooler Check and replace contact NIRO SOAVI 19 Main motor overload Too high homogenizing pressure Reduce to nominal value Wear on drive end Check wear and contact NIRO SOAVI Too high belts tension Check belts tension Faulty main motor Check main motor in case replace 20 Oil leakage in the water sump Leakage from crosshe...

Page 76: ...Niro Soavi S p A 3 9 SPECIAL FEATURES OF NON STANDARD MACHINES BLANK PAGE Ricerca Guasti 21 2 ...

Page 77: ...MATION 4 2 ORDINARY MAINTENANCE 4 3 TIGHENING BOLTS AND STUDS 4 4 COMPRESSION HEAD 4 5 HOMOGENIZING GROUP 4 6 OVERPRESSURE VALVE AND PRESSURE GAUGE 4 7 TRANSMISSION 4 8 POWER END CRANKCASE 4 9 LUBRICATION 4 10 PNEUMATIC PLANT 4 11 ASEPTIC PLANT 4c00se0c doc 4 0 1 ...

Page 78: ... of this Manual are essential to execute a correct maintenance and ensure a good lasting performance of the machine as well as compliance with safety regulations currently in force CAUTION For the personnel safety any check and maintenance operation should be carried out with the MACHINE STOPPED and with the isolator switch LOCKED with the appropriate padlock in the OPEN POSITION CAUTION The use a...

Page 79: ...ions listed here below are described with detailed procedures in the following paragraphs Execute carefully all the checks prescribed in these tables and note scrupulously the DATE MACHINE HOURS OPERATOR in the Tables for the checks to be performed every 1500 HOURS 6 MONTHS and every 3000 HOURS 12 NONTHS In this way the machine will be maintained in the best conditions of running and safety and a ...

Page 80: ...ers check drive check belt tensioning check tightening of drive elements and reducer support When hrs Action required Mach hrs Operator Date 1500 and every 1500 hrs change lubrication oil clean replace filters lubrication system pneumatic system water system check drive belt wear tensioning and if required replace check wear of plungers and if required replace check pressurization of pneumatic sys...

Page 81: ...ters lubrication system pneumatic system water system check drive belt wear tensioning and if required replace check wear of plungers and if required replace check pressurization of pneumatic system and oil level 9000 check replace springs and pumping valves check replace homogenizing valve 10500 change lubrication oil clean replace filters lubrication system pneumatic system water system check dr...

Page 82: ...PRESSURE MACHINES OVER 600 bar When Action required Machine hrs Every 50 hrs visual check for leaks in packings and head gaskets check tightening of nuts in all high pressure head elements Every 100 hrs check packings and head gaskets and if required replace check pumping valve seats and if required replace check ball valves and if required replace check springs and if required replace check homog...

Page 83: ...Niro Soavi S p A ORDINARY MAINTENANCE LOG When hrs Action required Mach hrs Operator Date 4c010e0c doc 4 2 5 ...

Page 84: ... they do not become loose NIRO SOAVI supplies a Maintenance box with the wrenches needed for the nuts fitted on their machines we suggest you use a dynamometric wrench not included to check tightening torques as specified in the table below STUD SIZE TIGHTENING TORQUE N m TIGHTENING TORQUE lb ft M 8 8 10 6 8 M 10 15 20 11 15 M 12 25 30 19 22 M 16 60 70 44 52 M 20 120 140 89 104 M 24 210 230 155 17...

Page 85: ...em refer to the torque values shown in Table 4 3 1 to avoid imposing abnormal stress and undermining their strentgh CAUTION For safety reasons it is strictly forbidden to replace studs in the high pressure head with non original spare parts which might not be able to stand the stress applied resulting in severe risk of injury 4c010e0c doc 4 3 2 ...

Page 86: ...ou are reassembling parts which are in contact with the gaskets Gaskets should be greased with a food grade lubricant and assembled with non sharp tools which might damage them in any case keep in mind that forced or incorrect assembling can affect the life and seal of gaskets To identify and position gaskets correctly refer to the drawings provided herein for the disassembling of compression head...

Page 87: ...u should bear in mind the following information Thermal shock is due to rapid temperature change in the fluid which is in contact with the plunger exceeding approximately 70 C Make absolutely sure that the plungers are not operated without liquid even for a short period of time the temperature generated on the surface of the plunger due to friction can result in the plunger breaking once the cooli...

Page 88: ...place them before assembling back the plungers and head see paragraph 4 4 2 Before you begin with disassembly make sure all the necessary spare parts are available Ceramic pistons figure 4 4 1 are fixed by a clamp B to remove them first unscrew the clamp s retaining screws A and move the plunger away from the extension C To open the clamp it may help to insert one of the screws in the middle bore ...

Page 89: ... torque 7 8 N m Take care not to bend the ceramic plungers as you risk breaking them CAUTION We recommend you move the plungers to the outer dead center completely forward by rotating the flywheel while the guide plungers must be taken back to the inner dead center completely back in order to have more space for tightening the packing flanges CAUTION Plungers must be mounted one by one starting wi...

Page 90: ...tion and that the various clamps do not interfere with one another during alternating plunger movements We therefore suggest that you rotate the drive pulley by hand to verify that plunger movement is correct CAUTION tighten the nuts DIAGONALLY as shown in figure 4 4 2 apply the torque values given in table 4 3 1 FIGURE 4 4 2 ...

Page 91: ...ive replacement on the basis of their expected mean life In high pressure machines check and preventive replacement of packings should be carried out every 100 200 hours Replacement is necessary when you notice leaks from the sump the production cycle can be allowed to go on if the leak is not too big Plunger gaskets in high pressure machines must be considered as one single seal system in which a...

Page 92: ...the side plungers With reference to figure 4 4 3 move the plunger all the way forward outer dead center remove the plunger clamp figure 4 4 1 item B by loosening the screws figure 4 4 1 item A if necessary insert one of the two screws in the middle bore of the clamp to loosen it move the guide plunger all the way back inner dead center disconnect water or sterile condensate pipe loosen the retaini...

Page 93: ...Niro Soavi S p A 4C042E0C DOC 4 4 8 FIGURE 4 4 3 FIGURE 4 4 3 ...

Page 94: ... packing taking care to stagger the joints regularly for exambple by 120 If the packing is a standard type with multiple V rings or a single plastic piece insert it all in one go Insert the plunger to give the rings the required shape Insert the double conic washer M as shown in the picture making sure that the direction of assembly is the one shown in the cross section Insert the packing washer L...

Page 95: ... 4 4 6 Seat and ball are made of special hard alloys very resistant to wear these however need to be replaced if they show signs of wear on the surface or if pressure becomes unstable or the machine s flow is reduced The spring tends to lose gradually the original elasticity and for this reason it should be replaced approximately every 1000 hours of operation unless broken earlier generally becaus...

Page 96: ...components can be calculated by assuming a specific weight of approximately 8 kg dm3 These operations require 2 people FIGURE 4 4 5 Once the manifolds have been removed the valve assemblies for suction and delivery are the same with the configuration shown in figure 4 4 5 or 4 4 6 Bear in mind that the seat E made of special wear resistant material is forced into the seat housing A so in case of r...

Page 97: ...e assemblies position the seat housing A and the guide M where present using the existing studs as guides For suction valve assemblies the seat housing A and the guide M where present must be placed on the bottom support flanges or on the suction manifold itself if made as one single element depending on machine model Insert the inner components ball D spring C and valve cap B making sure that the...

Page 98: ...le light marking by pricks on seat surface does not affect the valve sealing and functionality The lifetime of the seats is normally longer than the one of the valves and depends on the characteristics of the product and on the working conditions of the machine In case of particularly abrasive products seats can be refurbished or replaced when necessary To do this you need to remove the seats from...

Page 99: ...y speaking it is possible to describe the micronization of the particles dispersed in the liquid phase as a resulting of combined turbulence shear local cavitation and high speed impact effects These three parts manufactured from very hard material are normally subject to more or less wear depending on the type of product handled therefore various effects resulting from wear or damage can be notic...

Page 100: ...ed on its internal surface and good performance is undermined We recommend replacing the ring when the groove is approximately 1 mm deep CAUTION the impact head and the passage head are manufactured from a material whose hardness is suitable to withstand the abrasive action of the product handled for a long time Whenever wear signs appear that may jeopardize the homogenizing efficiency working sur...

Page 101: ... block is quite heavy For all handling operations use both hands to avoid any accident to the personnel and use suitable personal safety protections Loose the nuts M of the studs of the homogenizing group Remove the pneumatic actuator group L and the supporting flange N which are coupled through the screws K pull out the guide H together with the shaft S on the impact head G if needed you can leve...

Page 102: ...ng U The above mentioned items are assembled into an housing D Remove also all the Oring gaskets Z W E F and the antiextrusion rings A C if installed Remove the guide T of the impact head G and check its inner surface if wear marks are present or there is excessive play between the guide T and the impact head G it is necessary to replace it 4c053e0c doc 4 5 4 ...

Page 103: ...bled CAUTION to facilitate the gasket assembling grease them with food grade Vaseline or similar FIGURA 4 5 3 Put the homogenizing valve chamber B on its side and insert the impact head guide T Put inside the impact head G and make sure this is not coming out of its guide T Assemble the impact ring U Put the homogenizing valve chamber on the studs and push it towards the compression head Assemble ...

Page 104: ...re not damaged Place the gaskets P and R into their grooves Put from the top the impact head shaft S into the guide H being careful not to damage the gasket P Check the smooth sliding of the impact head shaft S into the guide H Proceed with assembling of the homogenizing group Insert the assembly guide and impact head into the homogenizing chamber B from the top Assemble the flange N together with...

Page 105: ...y inserting the shaft G from the bottom It is important to always refer to the specific detail drawings in Section 5 SPARE PARTS CATALOGUE FIGURE 4 5 4 4 5 4PNEUMATIC ACTUATOR The pneumatic control assembly comprising a pneumatic actuator L does not require any particular maintenance fig 4 5 2 In case of oil leak or difficulty to keep the homogenizing pressure not related to any other cause see Se...

Page 106: ...or 4 times to apply and release pressure Please follow the specific instructions listed at SECTION 4 Charter 4 10 Pneumatic Plant 4 5 5 ASEPTIC VERSION The homogenizing assembly used in the aseptic version is the same as the one used in the sanitary version in terms of functional features the only difference is that the impact head shaft is flushed with sterile condensate used as barrier fluid The...

Page 107: ... the O ring B and the anti extrusion rings A and C Make sure you do not lose the ball E as the valve cannot work without it we recommend you always keep a spare seat and ball in case you need to replace them Valve maintenance does NOT require replacing the spring to avoid sudden release of the spring s preloading DO NOT remove the elastic ring L Carefully clean the seat B from any product residues...

Page 108: ...eak the seal unless with written authorization by NIRO SOAVI In case of modification of the valve setpoint without authorization the warranty on the machine is immediately void and moreover this may cause ranger for the safety of the personnel using the machine as the overpressure relief valve is a fundamental safety device for the machine accordino to the CE safety regulations CAUTION It is absol...

Page 109: ...Niro Soavi S p A FIGURE 4 6 1 4c063e0c doc 4 6 3 ...

Page 110: ...ssure gauges or pressure measuring devices are available as alternatives analog pressure gauge with signal transmitter with 4 20 mA output for remote transmission of pressure signal pressure transducer this is a sensor which gives an electric signal to be amplified in order to obtain a 4 20 mA output of the pressure signal digital pressure gauge with built in display this transducer has a display ...

Page 111: ...can be separated once the semi rings D have been removed Figure 4 6 3 shows the analog configuretion for disassembling the pressure transducer FIGURE 4 6 2 Steps to be followed for assembly figure 4 6 2 or 4 6 3 insert the gasket E on the pressure gauge rod used only to protect from dirt insert the gasket G inside its housing in the flange or head food grade Vaseline or other suitable lubricants s...

Page 112: ...from 600 bar upwards insert the flange F on the pressare gauge body A and fit the two semi rings D to hold the flange in position insert the pressure gauge prepared in this way into its housing and place the flange F on the studs H screw the nuts on G by hand before tightening them fully FIGURE 4 6 3 4c063e0c doc 4 6 6 ...

Page 113: ...heir housing For assembly follow these steps figure 4 6 4 fit anti extrusion ring C gasket B and anti extrusion ring A onto the end of the pressure gauge M or transducer T food grade Vaseline or other suitable lubricants should be used for easier assembly fit the pressure gauge M or transducer T into its housing with digital pressure gauges make sure you do not force the element using the head of ...

Page 114: ...n pressed for a few seconds to reset the instrument to ZERO if the reading given is NEGATIVE If the display reads BATT it means that the battery is down and needs to be replaced Disassemble the pressure gauge and on a dry surface remove the rear screws to lift off the cover on the battery housing The battery used is a long life 9V lithium battery size PP3 in special circumstances a standard 9V alk...

Page 115: ... machine not in operation to check for possibile lubrication oil leaks and more importantly for loosening of nuts bolts belt tensioning components and reduction gear support parts Excessive movement of drive components due to loosening of locking elements caused by vibrations can result in slack couplings and consequent breakage of elements during machine operation CAUTION It is important to regul...

Page 116: ...eeds to be drained off completely if room temperature drops below 4 C As the reduction unit is pivoting its movement is free and will increase when the machine runs loaded This movement can be considered normal when all the belt tensioning elements and reduction gear support elements have been properly tightened using also lock nuts WARNING It is forbidden to alter the tensioning system of the red...

Page 117: ...G 220 BMB 220 BP Energol GR XP 220 ESSO Spartan EP 220 MOBIL Mobilgear 630 SHELL Omala oil 220 TEXACO Meropa 220 IP Mellana 220 AGIP Blasia 220 TABLE 4 7 1 For heavy duty applications continuous operation high temperatures and to extend time between replacements specified below we recommend the use of SYNTHETIC OIL with viscosity ISO VG 220 EP as specified in Table 4 7 2 Marca Tipo MOBIL Mobil SHC...

Page 118: ...power mains switch must be LOCKED IN THE ON POSITION with a padlock for the safety of personnel INSPECTION OF THE PULLEYS Worn pulleys significantly reduce the life of belts which can touch the bottom of the groove causing slipping which provokes wear and superficial burning If the sides of the groove are hollow the contact between the sides of the belt and the pulley is not uniform and the lower ...

Page 119: ...ng SELECTION OF BELTS Use at the same time belts of the same make of the same type and of the same lot since there may be differences both in size and in performance Moreover it is essential not to use new belts with others that have already been used because of a different extension adjustment to the grooves of the pulleys and differences in performance which would considerably affect the duratio...

Page 120: ...ce to figure 4 7 3 loosen the lock nut A retaining the tie rod B and then change the length of the rod to allow disassembly and assembly of belts Once the belts have been tensioned lock the tie rod with the lock nut For correct belts tensioning refer to paragraph 4 7 3 During installation belts must never be forced with a tool into the pulley s grooves to avoid the risk of damaging both thus reduc...

Page 121: ...ring the first 24 48 hours of running in check the stretch frequently remember that excessive stretch reduces the life of the belts and of the bearings that support the drive Arrange for the stretch to be tightened as soon as any slipping occurs Belt slipping can cause overheating and create hazard particularly if the machine is designed for operation in danger zones explosion proof version The fo...

Page 122: ... 1 TABLE 4 7 4 BELTS TENSIONING SECOND METHOD Measure the length of the free section t figure 4 7 5 and apply to its half point a force P perpendicular to the belt that causes a deformation of 1 6 mm every 100 mm of free length F 1 6 x T 100 mm The intensity of the force in Newton should be in the interval of values shown in table 4 7 6 it is measured by means of a special dynamometer which is not...

Page 123: ... 10 m s V 10 20 m s V 20 30 m s 67 95 12 18 10 16 8 14 SPZ 95 19 26 17 24 15 22 100 140 22 32 18 26 15 22 SPA 141 33 48 27 40 23 34 160 265 38 56 32 50 28 42 SPB 266 57 72 51 64 43 58 224 355 72 102 60 90 50 80 SPC 356 103 132 91 120 81 110 TABLE 4 7 6 4c071e0c doc 4 7 9 ...

Page 124: ... presence of a regular squeaking similar to that of a bearing that is insufficiently lubricated does not cause any damage to the transmission and may be caused by the presence of dirt Do not try to eliminate this noise by oiling the belts DIRT AND FOREIGN MATERIALS Dirt and dust may accelerate wear of the belts and pulleys and obstruct a good traction It is necessary to regularly clean the drive s...

Page 125: ...rations EXPOSURE TO HEAT Check that the belts are not exposed to sources of heat an exposure to temperatures greater than 60 C will shorten their life WEAR Check the condition of the sides of the belt an anomalous wear may cause slipping or excessive wear of the grooves of the pulleys 4c071e0c doc 4 7 11 ...

Page 126: ...e of the screws in bore B to force the bush open extract the bush and pulley from the shaft Assembly procedure clean bush and shaft thoroughly insert Taper Lock bush into pulley partially insert threaded screws into bores A mount the pulley on the shaft align the pulleys tighten screws A fully If the motor pulley is not fitted with a Taper Lock bush to install or remove the pulley use a suitable p...

Page 127: ... of excellent reliability and durability Correct lubrication is fundamental for the life of the drive body and of its components so it is absolutely necessary to comply with the instructions given in terms of recommended change frequency Chapter 4 2 filter cleaning level and type of lubricant used Chpater 4 9 Under normal conditions the power end does not require servicing Should you notice abnorm...

Page 128: ...guide plunger gaskets in case of lubrication oil leaks inside the sump If the surface of the crosshead extension is badly scratched it is necessary to replace the complet guide pistons Such kind of maintenance requires skilled personnel therefore it is recommended to contact NIRO SOAVI Customer Service for advice and support CAUTION All inspection and maintenance operations must be carried out wit...

Page 129: ...e flange M from the guide plunger Q remove the scraping ring L and the seal gasket J ASSEMBLY fit the scraping ring L and gasket J inside the flange M in the seat check and clean the plunger stem if the surface is badly scored or the chrome plate damages the whole plunger must be replaced The guide plunger stem cannot be supplied separately as spare part insert the complete O Ring flange H onto th...

Page 130: ...lows is installed to protect the guide plunger stem In this case the bellows must be removed to replace the gaskets and then inserted onto the guide plunger stem Q and snapped on locked against the flange M in the seat provided 4c081e0c doc 4 8 4 ...

Page 131: ...rom 5 C and 40 C please contanct NIRO SOAVI Customer Service to obtain the type of lubricant suitable for any specific conditions found locally CAUTION Used oils are extremely harmful to environment and should be disposed of correctly in accordance with the local regulations CAUTION All inspection and maintenance operations must be carried out with the MACHINE NOT IN OPERATION the power mains swit...

Page 132: ...M 150 Amoco American industrial oil 150 Mobil DTE 19M Total Azolla ZS 150 Mobil DTE Extra Heavy Fina Hyidran 150 Chevron EP Hydr oil 150 Api Cis 150 Castrol Hyspin AWS 150 Kuwait Petr Int Q8 haidn 150 Esso Exxon Nuto H 150 ELF Olna DS 150 Shell Omala 150 ARAL Motanol HP150 TABLE 4 9 1 MODEL OIL VOLUME liters WITH OIL PUMP OIL VOLUME liters SPLASH SYSTEM NS 1003 1 2 NS 2006 3 0 1 5 NS 3006 4 5 3 0 ...

Page 133: ...afety pressure switch set to 3 bar to stop the machine if lubrication pressure is insufficient The lubrication system diagram is shown in Section 5 SPARE PARTS CATALOGUE while figure 4 9 1 gives an exploded view of the lubrication unit The lubrication control unit is made up of the sub components shown in figure 4 9 2 electric motor Z joint between pump and motor G body C with by pass valve F gear...

Page 134: ...Niro Soavi S p A FIGURE 4 9 1 4c091e0c doc 4 9 4 ...

Page 135: ...achine stopped for at least 1 hour See for reference figure 4 9 3 FIGURE 4 9 3 The start of the machine is causing the oil to flow into and fill the lubricating circuit then it is normal to observe a lowering of the oil level on the sightglass during the operation of the machine If oil drops below the required level top it up through the orange filler located inside the machine on the body cover T...

Page 136: ... be due to problems with the cooling system of the water oil exchanger where used connected with scaling or very high water temperature The water temperature must conform with the values given in Section 1 TECHNICAL SPECIFICATIONS The pressure in the lubrication circuit can be adjusted via the by pass valve F in the lubrication unit body C figure 4 9 2 FIGURE 4 9 2 DO NOT REMOVE THE VALVE FROM THE...

Page 137: ...for Regular Servicing at Chapter 4 2 Use only oil as specified in Table 4 9 1 To change the oil see figure 4 9 1 prepare a reservoir to collect the oil and of a size that is suitable to contain the amount of oil found in the machine according to table 4 9 2 open the filling tap on the crankase cover open the drain valve and the plug J and let the oil drain out once the oil has drained out complete...

Page 138: ...ntering trough the crosshead seals it is recommended to check the surface of crosshead extensions for scratches and to replace the crosshead seals in case of oil leakage or oil into the water according to what is mentioned in paragraph 4 8 1 OIL FILTERS CHANGE Oil filters change is extremely important to guarantee proper and reliable operation of the lubricating system It is therefore necessary to...

Page 139: ...owards the outside WARNING Carry out the operations with utmost caution wearing suitable protection for the body and the eyes against any petrol splashes wear a filtering mask and do not inhale the vapour if there is any contact with the eyes wash abundantly with water and consult a doctor OIL COOLER MAINTENANCE The machine is equipped with a water oil cooler which is not requiring usually any mai...

Page 140: ...is recommended to protect it from extreme temperatures which may damage the gaskets and corrosive fluids as its body is made with Aluminium alloys and not in stainless steel In case the pneumatic actuator is not working properly we recommed its replacement it s anyway available upon request to Niro Soavi Spare Parts Dept the complete gaskets spare kit The pneumatic plant can be configured in vario...

Page 141: ...icating the pressure effectively supplied to the pneumatic actuator A damper tank K for oil and pressurized air The effect of dampening of the vibrations induced on the homogenizing valve by the normal reciprocating movement of the plungers is granted by a suitable air oil damper vessel K which is connected to the lower part of the pneumatic actuator of the homogenizing group This damper tank is p...

Page 142: ...6 bar when the machine is stopped Oil into this circuit does not requie any ch ange but only refilling in case the level is low If during the above mentioned procedures of filling up or during the homogenizing valve maintenance some air bubbles are present into the plastic pipes it is possible toeliminate the same by application and release of the pressure to the actuator through the pneumatic swi...

Page 143: ...E 24 Total Azolla ZS 32 BP Energol HLP 32 Fina Hyidran 32 Chevron EP Hydr oil 32 Api CIS 32 Castrol Hyspin AWS 32 Kuwait Petr Int Q8 haidn 32 Esso Exxon Nuto H 32 ELF Olna DS 32 TABLE 4 10 2 4 10 1 PNEUMATIC PLANT WITH LOCAL MANUAL ADJUSTMENT The pneumatic plant for local and manual pressure adjustment allows to adjust the homogenizing pressure from the machine front panel through a pneumatic regu...

Page 144: ...ended to follow the indications in the specific wiring diagram supplied in the manual which is showing also the numbering of terminals on the terminal board for proper connection In case of malfunctioning of the system it is possible to follow the below listed indications Wrong connection make sure the wiring is made according to the supplied diagram Not enough air pressure supply required minimum...

Page 145: ...gs by adjusting the ZERO and SPAN screws located on the proportional valve body under a protection cover see figure 4 10 4 The proportional valve is installed inside the machine cabinet on left hand side and it is possible to access to it by removing the left side panel of the machine Usually it is not required to have any maintenance on these components and in case of faulty operation their repla...

Page 146: ...d protective clothing CLEANING THE HAET EXCHANGER Washing operations are carried out when the exchanger is insulated from the rest of the system using the supplied valves and circulating a descaling solution into the cooling water side of the exchanger at the concentration and temperature indicated by the suppliers e g caustic soda NaOH solution at 3 and 80 C or 2 nitric acid HNO3 at 50 C The heat...

Page 147: ...r operation of the exchanger it should be set to 1 2 bar Valves C are used to adjust the flow of cooling water so that the temperature of the condensate flow is approximately 40 60 C ASEPTIC CHAMBERS The aseptic chambers of the plungers only require replacement of the gaskets To avoid contamination make sure you accurately clean and sterilize the aseptic chambers whenever there are product leaks f...

Page 148: ... be replaced are gaskets P and S and any guide rings T U To remove the gaskets you need to disassemble the plungers and remove any sealing elastic rings not shown in the drawing refer to the exploded view in SECTION 5 SPARE PARTS CATALOGUE FIGURE 4 11 2 4c111e0c doc 4 11 3 ...

Page 149: ...SECTION 5 SPARE PARTS CATALOGUE INDEX 5 1 HOW TO USE THE SPARE PARTS CATALOGUE 5 2 HOW TO ORDER SPARE PARTS 5 3 RECOMMENDED SPARE PARTS 5 4 MAINTENANCE BOX 5 5 SPARE PARTS LISTS AND ASSEMBLY DRAWINGS 5C001E0C DOC 5 1 0 ...

Page 150: ...s are maintained only original spare parts must be used on NIRO SOAVI machines The use of non original spare parts shall instantly invalidate the guarantee This catalogue has information on how to order spare parts selecting the parts in the attached tables and their code number in the relative tables 5C001E0C DOC 5 1 1 ...

Page 151: ...e part code number if necessary a brief description of the component for easier identification if applicable the item number on the assembly drawing in the SPARE PARTS CATALOGUE the means of transport or dispatch requested if this is not specified NIRO SOAVI will arrange suitable transport at their discretion whether urgent as this may affect cost exact address and name of contact person To order ...

Page 152: ...iro Soavi S p A NIRO SOAVI ORIGINAL SPARE PARTS INQUIRY FORM To Fax No From Name Reply Fax No e mail Model Serial No URGENT QUOTATION ORDER No Part CODE Qty Description Shipping Specs 5C001E0C DOC 5 2 2 ...

Page 153: ...toms problems or miscarriage In any case NIRO SOAVI shall not be responsible for delays occurring due to the shipment of spare parts The following is a list of spare parts which in our experience is important to have in stock a complete set of gaskets two sets in case of VHP high pressure compression blocks two sets of packings including packing washers and anti extrusion rings one or two plungers...

Page 154: ...drain check 13 Passage head 1 st 46 14 Impact ring 1 st 47 Lubrication plant 15 Impact head 1 st 48 Lubrication unit 16 Gaskets 1 st 49 Pump driven by crankshaft 17 Passage head 2 st 50 Heat exchanger oil water 18 Impact ring 2 st 51 Suction oil filter 19 Impact head 2 st 52 Delivery oil filter 20 Gaskets 2 st 53 Condensate discharge 21 54 Gaskets 22 55 Oil level 23 56 Oil piping check 24 Transmis...

Page 155: ...Niro Soavi S p A 5C001E0C DOC 5 3 3 ...

Page 156: ...stalling or removing plungers and packings where required The set of spanners DOES NOT INCLUDE a Torque Wrench which is recommended for correct tightening of nuts and studs to the torque values given in Section 4 MAINTENANCE The maintenance box includes a basic set of spare gaskets Please find attached a list of the tools supplied for ordinary maintenance 5C001E0C DOC 5 4 1 ...

Page 157: ...8 LEVAGOMME PRY BAR 2 810612 GOLFARE EYEBOLT 2 350114 GIRAVITE A CROCE 8X150 SCREWDRIVER 8X150 1 810010 CHIAVE WRENCH 1 350229 BUSTA PORTA ATTREZZI BAG FOR TOOLS 1 350037 MOLLA SPRING 6 0122300 1 MOLLA SPRING 1 0130263 ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 1 0130982 RONDELLA WASHER 6 0133837 RONDELLA WASHER 3 0134661 ORING ORING 1 140393VF ORING ORING 1 130031S ORING ORING 1 140335VF ORING ORIN...

Page 158: ...TS LIST AND ASSEMBLY DRAWINGS You will find attached assembly drawings and a list of components and spare parts The first code of each spare parts list indicates the assembly drawing which the components refer to 5C001E0C DOC 5 5 1 ...

Page 159: ...O STUD 12 0134624 16 DADO NUT 12 760019 17 COLLETTORE MANIFOLD 1 0134620 2 18 DADO NUT 12 760019 19 PRIGIONIERO STUD 12 0134623 20 ASSIEME ASSEMBLY DRAWING 3 0128496 3 21 CAMERA ASETTICA ASEPTIC CHAMBER 3 0123557 4 22 PRIGIONIERO STUD 12 0134625 23 DADO NUT 12 760022 24 CODICE NON PRESENTE NOT EXISTING CODE 25 CODICE NON PRESENTE NOT EXISTING CODE 26 SPINA PIN 6 990015 27 CODICE NON PRESENTE NOT E...

Page 160: ......

Page 161: ...RUSIONE ANTIEXTRUSION RING 6 0134692 10 ORING ORING 6 140029PU 11 CONTENITORE VALVOLA VALVE HOUSING 3 0134627 2 1 ASSIEME ASSEMBLY DRAWING 3 0132876 2 ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 3 0134692 3 ORING ORING 3 140029PU 4 CONTENTITORE SEDE VALVOLA VALVE SEAT HOUSING 3 0134629 2 5 SEDE VALVOLA VALVE SEAT 3 0134628 6 SFERA BALL 3 190064 7 MOLLA SPRING 3 0122300 1 8 COPERCHIO VALVOLA VALVE COV...

Page 162: ......

Page 163: ...ription Description Qty Part Code 1 ASSIEME ASSEMBLY DRAWING 3 0128496 3 2 PISTONE PLUNGER 3 0124559 060 3 MORSETTO CLAMP 3 0133638 4 PROLUNGA EXTENSION 3 0134656 5 VITE SCREW 12 69TE6X20 SPARES_4759 xls PLUNGER GROUP ...

Page 164: ......

Page 165: ...v 0 Item Description Description Qty Part Code 1 ASSIEME ASSEMBLY DRAWING 3 0134662 1 2 RONDELLA WASHER 6 0133837 3 PACCHETTO PACKING 3 41511CX201 4 RONDELLA WASHER 3 0134661 SPARES_4759 xls PACKING GROUP ...

Page 166: ......

Page 167: ...Code 1 ASSIEME ASSEMBLY DRAWING 3 0123557 4 2 ORING ORING 3 140033VF 3 FLANGIA FLANGE 3 0134650 4 CAMERA ASETTICA ASEPTIC CHAMBER 3 0134652 5 ORING ORING 3 140166VF 6 ORING ORING 3 140205VF 7 VITE SCREW 6 69TCE6X20 SPARES_4759 xls ASEPTIC CHAMBER ...

Page 168: ......

Page 169: ...SIEME ASSEMBLY DRAWING 1 0124219 2 TRASMETTITORE TRANSMITTER 1 320127 3 RONDELLA WASHER 1 0123486 4 FLANGIA FLANGE 1 0133649 5 ORING ORING 1 130031S 6 ORING ORING 1 140393VF 7 PRIGIONIERO STUD 4 0126273 8 DADO NUT 4 760011 SPARES_4759 xls MANOMETER GROUP ...

Page 170: ......

Page 171: ...N RING 1 0127432 9 6 SFERA BALL 1 190009 7 ALBERINO SHAFT 1 0130261 3 8 ORING ORING 1 140030 9 ANELLO ELASTICO SNAP RING 1 210030 10 ORING ORING 2 140030 11 CUSCINETTO BEARING 1 220197 12 MOLLA SPRING 1 0130263 13 CORPO BODY 1 0131526 3 15 DISTANZIERE SPACER 1 0131527 16 COPERCHIO VALVOLA VALVE COVER 1 0130266 17 FLANGIA FLANGE 1 0130604 18 DADO NUT 4 760006 19 PRIGIONIERO STUD 4 0122926 20 TUBO P...

Page 172: ......

Page 173: ...140035VF 13 DISTANZIERE SPACER 1 0132329 2 14 TESTINA D URTO IMPACT HEAD 1 0122780 15 ALBERINO SHAFT 1 0132330 2 16 GUIDA GUIDE 1 0132474 2 17 ORING ORING 1 140024VF 18 ORING ORING 1 140330VF 19 BOCCOLA BUSHING 1 260358 20 BOCCOLA BUSHING 1 260359 21 FLANGIA FLANGE 1 0131268 22 PRIGIONIERO STUD 4 0125377 23 DADO NUT 4 760006 24 SUPPORTO SUPPORT 1 0132337 25 VITE SCREW 4 69TE12X30 26 FLANGIA FLANGE...

Page 174: ......

Page 175: ...BRONZE BEARING 2 0133610 11 PISTONE DI GUIDA GUIDE PLUNGER 3 0133712 12 SPINOTTO WHRIST PIN 3 250020 13 RONDELLA WASHER 6 0133853 14 BIELLA CONROD 3 280135 15 BRONZINA BRONZE BEARING 3 280064 16 FLANGIA FLANGE 3 0134554 17 ANELLO RASCHIATORE ROD SCRAPER 3 160107 18 ORING ORING 3 140107 19 GUARNIZIONE GASKET 3 160111 20 VITE SCREW 20 70TE6X20 21 PARASPRUZZI SPLASH GUARD 3 0102560 22 SPINA PIN 2 012...

Page 176: ......

Page 177: ...4643 12 DADO NUT 3 660008 13 BARRA FILETTATA THREAD BAR 1 0134024 14 BLOCCHETTO BLOCK 1 0134235 15 BUSSOLA BUSHING 1 0133771 16 RONDELLA WASHER 1 0133864 17 BOCCOLA BUSHING 4 260486 18 BLOCCHETTO BLOCK 1 0134234 19 ANELLO ELASTICO SNAP RING 2 210075 20 DADO NUT 2 660006 21 VITE SCREW 2 70TE16X70 22 RONDELLA WASHER 1 680045 23 PULEGGIA PULLEY 1 610637 24 BUSSOLA BUSHING 1 610647 25 CINGHIA BELT 4 4...

Page 178: ......

Page 179: ...E 6 CODICE NON PRESENTE NOT EXISTING CODE 7 CODICE NON PRESENTE NOT EXISTING CODE 8 ORING ORING 1 140335VF 9 ANELLO RING 1 0133944 10 TAPPO PLUG 1 0133888 11 FLANGIA FLANGE 1 0133889 12 VITE SCREW 2 69TE12X30 13 FLANGIA FLANGE 1 0134694 2 14 FLANGIA FLANGE 1 0134695 2 15 FLANGIA FLANGE 1 0134696 2 16 VITE SCREW 4 69TE12X55 17 VITE SCREW 2 69TE12X90 18 ORING ORING 3 140205VF SPARES_4759 xls MANIFOL...

Page 180: ......

Page 181: ...SSEMBLY DRAWING 1 0134204 4 2 FLANGIA FLANGE 1 0134698 2 3 ORING ORING 1 140205VF 4 CODICE NON PRESENTE NOT EXISTING CODE 5 CODICE NON PRESENTE NOT EXISTING CODE 6 CODICE NON PRESENTE NOT EXISTING CODE 7 VITE SCREW 4 69TE16X40 SPARES_4759 xls OUTLET FLANGE GROUP ...

Page 182: ......

Page 183: ...EGULATOR 1 390270 10 ELETTROVALVOLA ELECTROVALVE 1 390263 11 ELETTROVALVOLA ELECTROVALVE 1 390230 12 DOSATORE FLOW BATCHER 1 390046 13 MANOMETRO MANOMETER 1 320361 14 GIUNTO COUPLING 1 260310 15 GIUNTO COUPLING 2 260313 16 CODICE NON PRESENTE NOT EXISTING CODE 17 GIUNTO COUPLING 1 260310 18 GIUNTO COUPLING 1 260314 19 STROZZATORE CHOSKER 1 350167 20 RUBINETTO BALL TAP 1 580002 21 OLIO OIL 2 530006...

Page 184: ......

Page 185: ...ETER 1 320360 7 PRESSOSTATO PRESSURE SWITCH 1 EF0043 8 TAPPO PLUG 1 170010 9 CODICE NON PRESENTE NOT EXISTING CODE 10 LIVELLO OLIO OIL LEVEL 1 170049 11 RUBINETTO BALL TAP 1 580012 12 TAPPO PLUG 2 260904 13 SUPPORTO SUPPORT 1 261191 14 FLANGIA FLANGE 1 110570 15 CODICE NON PRESENTE NOT EXISTING CODE 16 GIUNTO COUPLING 1 261185 17 VITE SCREW 4 69TCE6X20 18 CODICE NON PRESENTE NOT EXISTING CODE 19 T...

Page 186: ......

Page 187: ...ion Lubricating Unit TP3 TT 0100 Performances Gear Pump Displacement Motor RPM 50 Hz NSOA Code 260454 Type OR TP3A GR1 6 1 140117 Coupling 3 4 G 3 8 G RI05120600 Nominal Flow 50 Hz Nominal Flow 60 Hz STD Pressure 35 C Tank Lt 8 1 G TP3 NIRO SOAVI Screw TEF M6x14 V60103001 F80110004 0133364 Plug TCEI 1 2 G OR TB050801 OR 261189 Technical Data Motor Type IEC Motor Type NEMA USA Motor RPM 60 Hz 26118...

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Page 189: ... EXISTING CODE 17 CODICE NON PRESENTE NOT EXISTING CODE 18 CODICE NON PRESENTE NOT EXISTING CODE 19 CODICE NON PRESENTE NOT EXISTING CODE 20 CODICE NON PRESENTE NOT EXISTING CODE 21 CODICE NON PRESENTE NOT EXISTING CODE 22 CODICE NON PRESENTE NOT EXISTING CODE 23 CODICE NON PRESENTE NOT EXISTING CODE 24 CODICE NON PRESENTE NOT EXISTING CODE 25 CODICE NON PRESENTE NOT EXISTING CODE 26 CODICE NON PR...

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Page 191: ...0134757 3 FLUSSOSTATO FLOW SWITCH 1 EFB039 4 RIDUZIONE REDUCTION 1 0134758 5 RACCORDO CONNECTION 8 260721 1 6 RIDUZIONE REDUCTION 1 0134759 7 TRONCHETTO FERRULE 1 0134750 2 8 CURVA CURVE 1 0134767 9 NIPPLO NIPPLE 1 0134768 10 GUARNIZIONE GASKET 2 140013VF 11 GUARNIZIONE GASKET 1 140173VF SPARES_4759 xls ASEPTIC PLANT ...

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Page 193: ...30 140024PU ORING ORING 90 140029PU ORING ORING 15 140033VF ORING ORING 15 140166VF ORING ORING 15 140205VF ORING ORING 5 140027VF ORING ORING 5 140022VF ORING ORING 5 140030VF ORING ORING 5 140035VF ORING ORING 5 140024VF ORING ORING 5 140330VF ORING ORING 5 140024VF ORING ORING 5 140330VF ORING ORING 5 140013VF ORING ORING 15 140030 ORING ORING 5 130031S ORING ORING 5 140393VF ORING ORING 25 140...

Page 194: ...NDLE 4 170007 5 VITE SCREW 8 69CR6 6 GAMBO SHANK 4 350450 7 GUAINA PROTECTING COVERING 4 350451 8 PANNELLO PANEL 11 350057 9 PROTEZIONE PROTECTION 1 0134614 9 10 SUPPORTO SUPPORT 1 0134688 9 11 PROTEZIONE PROTECTION 1 0134651 A COMPLETAMENTO FOR COMPLETION RONDELLA WASHER 1 0134765 TAPPO PLUG 2 260362 RONDELLA WASHER 1 0134726 SPARES_4759 xls CASING ...

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Page 196: ...Niro Soavi S p A SECTION 6 ELECTRICAL DIAGRAMS INDEX 6 1 ELECTRICAL DIAGRAMS 6C001E0C DOC 6 1 0 ...

Page 197: ...diagram of the Electric Power Board if the same or its engineering is supplied by Niro Soavi We recommend to check carefully the wiring diagrams to proceed with correct connection of the machinhe and its components The wiring of the machine and its components must be done by qualified personnel who must be able to understand properly the supplied electrical documentation and wiring diagrams 6C001E...

Page 198: ...umber 242 MC 1100 Draw Check Appr Scale Date Page MIB 10 01 03 Rev Sign Date of Order Serial Model 1 220217 4759 NS3018H This Drawing is property of NIRO SOAVI which will guard its rights by law terms Drawing Cover Sheet Description 242MC1100 PHONE 39 0521 965411 FAX 39 0521 242819 Niro Soavi S p A via M da Erba Edoari 29 A 43100 PARMA ITALY Specialty Products Division 1 1 ...

Page 199: ...3 MIB MODIFY 18 37 Inverter Run Fault Logic E Scheme 242MC1100 1 23 01 03 MIB MODIFY 19 37 Switchboard Cooling Fan E Scheme 242MC1100 1 23 01 03 MIB MODIFY 20 37 Generic Alarm E Scheme 242MC1100 1 23 01 03 MIB MODIFY 21 37 YA 2421102 Oil Pressure Switch E Scheme 242MC1100 1 23 01 03 MIB MODIFY 22 37 FS 2421100 Water Flow Switch E Scheme 242MC1100 1 23 01 03 MIB MODIFY 23 37 Switchboard Thermostat ...

Page 200: ... 242MC1100 23 01 03 MIB MODIFY 13 37 E Scheme 242MC1100 23 01 03 MIB MODIFY 14 37 E Scheme 242MC1100 23 01 03 MIB MODIFY 15 37 E Scheme 242MC1100 23 01 03 MIB MODIFY 16 37 E Scheme 242MC1100 23 01 03 MIB MODIFY 17 37 E Scheme 242MC1100 23 01 03 MIB MODIFY 18 37 E Scheme 242MC1100 23 01 03 MIB MODIFY 19 37 E Scheme 242MC1100 23 01 03 MIB MODIFY 20 37 E Scheme 242MC1100 23 01 03 MIB MODIFY 21 37 E S...

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Page 204: ...V 50 60Hz 18 5 kW C T 110 IP20 242P1100 K1 1 CONTACTOR SIEMENS 3RT1036 1BB40 24 V DC S2 22 kW 2 PROTECTIONS FOR TERMINALS For KM U1 SIEMENS 3RT1936 4EA2 1 AUXILIARY CONTACTS MODULE For KM U1 SIEMENS 3RH1921 1FA22 contacts 2 N O 2 N C 1 DIODE PROTECTION SIEMENS 3RT1936 1ER00 242PO1100 F1 1 THREE POLES THERMAL MAGNETIC SWITCH For M PO SIEMENS 3RV1011 1BA10 1 4 2 A Gr S00 242VMP1100 F1 1 THREE POLES ...

Page 205: ...0 230 v 1500 VA GS1 1 TRHEE PHASES SWITCHING POWER SUPPLY For 24Vd c Auxiliary Circuits SIEMENS SITOP 6EP1434 2BA00 10A FP 1 THREE POLES AUTOMATIC SWITCH SIEMENS 5SY6320 7BB 20 A Characteristic C FVQ 1 TWO POLES AUTOMATIC SWITCH SIEMENS 5SY6215 7BB 1 6 A Characteristic C FVQ1 1 TWO POLES AUTOMATIC SWITCH DIFFER 30mA SIEMENS 5SY6214 7BB 5SM2322 0 0 3 A Characteristic C 30mA FXS 1 TWO POLES AUTOMATI...

Page 206: ...C KAEM1 1 AUXILIARY CONTACTOR For the Emergency Circuit SIEMENS 3RH1140 1BB40 24 V DC Gr S00 KAVQ1 1 AUXILIARY CONTACTOR SIEMENS 3RH1140 1BB40 24 V DC Gr S00 1 AUXILIARY CONTACTS MODULE For KM VQ SIEMENS 3RH1911 1FA22 contacts 2 N O 2 N C 2 DIODE PROTECTION SIEMENS 3RT1916 1LM00 KAEM 1 SECURITY DEVICE PILZ PNOZ 1 24Vdc 24Vd c 3 5 Watt 3 contacts N O 1 N C KA1 1 RELAY OMRON MY4 IN D2 24VDC 24 V DC ...

Page 207: ...ON PYC A1 KTEM 1 TIMER With 2 Delayed Contacts to Excitation OMRON H3YN 2 24V DC 0 10 Min KT1 1 TIMER With 2 Delayed Contacts to Excitation OMRON H3YN 2 24V DC 0 10 Min KT2 1 TIMER With 2 Delayed Contacts to Excitation OMRON H3YN 2 24V DC 0 10 Min KTSPO 1 TIMER With 2 Delayed Contacts to Excitation OMRON H3YN 2 24V DC 0 10 Min 4 SOCKET For H3Y Timers OMRON PYF08 A N 70 x 22 5 mm Beige 4 PAIR of CL...

Page 208: ...ONTACTS for PUSHBUTTONS For HL SIEMENS 3SB1400 2A Connection for BA9s 9 LAMPS for PUSHBUTTONS For HL OSRAM BA 9s 24 30 Va c d c 2 Watt 2 INSERTABLE WHITE TAG Incised in ENGLISH For QF On Switchboard Front MODERNOTECNICA T 1567 B 67 x 15mm Writing 3 mm Max 3 Lines 25 Characters 2 PROTECTIVE SLIDE for Tag For QF MODERNOTECNICA T 1567 V 67 x 15 mm 2 TAG HOLDER For QF On Switchboard Front MODERNOTECNI...

Page 209: ... WEIDMÜLLER WDU 2 5 102000 2 5 mmq BEIGE 22 TERMINALS X8 WEIDMÜLLER WDU 2 5 102006 2 5 mmq ORANGE 2 TERMINALS X2 WEIDMÜLLER WDU 4 102010 4 mmq BEIGE 1 GROUND TERMINALS X2 WEIDMÜLLER WPE 4 101010 4 mmq GIALLO VERDE M VQ 1 COOLING FAN for the SWITCHBOARD RITTAL SK 3325 100 230V 50 60Hz 2 FILTER RITTAL SK 3325 00 3 GASKET RITTAL 3192 100 1 THERMOSTAT RITTAL SK 3111 000 1 STAINLESS STEEL CABINET RITTA...

Page 210: ...NUFACTURER TYPE CHARACTERISTICS PHONE 39 0521 965411 FAX 39 0521 242819 Niro Soavi S p A via M da Erba Edoari 29 A 43100 PARMA ITALY Specialty Products Division 1 METAL DOCUMENT HOLDER RITTAL PS 4118 000 1 LAMP INTAKE RITTAL PS4139 140 1 CABLE RITTAL PS4115 100 1 DOOR SWITCH RITTAL PS4315 300 1 SOCKETS WITH FILTER RITTAL DK 7240 230 ...

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Page 251: ...CABLE 2x1 5mm2 SC 242MC1100 140MC1100 11 Capacity Out SIC2421100_AI W2 SCREENED CABLE 2x1 5mm2 SC 242MC1100 140MC1100 12 Capacity Setting SIC2421100_AO W1 SCREENED CABLE 2x1 5mm2 SC 140MC1100 242MC1100 13 Pressure Setting PV2421112 W2 SCREENED CABLE 2x1 5mm2 SC 141IO1100 242MC1100 14 Pressure Output PIC2421112 W2 SCREENED CABLE 2x1 5mm2 SC 242MC1100 141IO1100 15 Rem Contact 2421100 W4 N1VV K 7x1 5...

Page 252: ...i 29 A 43100 PARMA ITALY Specialty Products Division 1 2 3 4 5 6 7 1 1 THERMAL PROTECTION DEVICES LIST TAG No Designation Calibration A F0 Main Switch 60 242 P 1100 F1 Main Motor 63 FP Power Circuits 20 242 PO 1100 F1 Oil Pump Motor 1 242 VMP 1100 F1 Cooling Fan Motor 0 24 FXS TCXS prot 13 FXS1 Lamp Intake Prot 8 30mA Diff FXS2 Fluorescent Tube 2 FXS3 Intakes 6 FVQ TCVQ Prot 1 6 FVQ1 Switchboard F...

Page 253: ... Data Lenght mm 800 Weight 300 kg Depth mm 500 IEC X Dimensions Height mm 2000 Construction Roules 3x 400 Vac Auxiliary Voltage 24V DC Supply Voltage 50 Hz Top X Symm Short Circuits Current 9 kA Terminal strip Position Bottom Draw Check Appr Scale Date Page MIB 11 12 02 Rev Sign Date of Order Serial Model 1 220217 4759 NS3018H This Drawing is property of NIRO SOAVI which will guard its rights by l...

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Page 256: ...Local reversing Disable Disable Disable Disable 17 Local reset Enable Enable Enable Enable 18 Data change lock Not locked Not locked Not locked Not locked 19 Power up action Local stop Local stop Local stop Local stop 27 Warning readout Line 1 2 Line 1 2 Line 1 2 Line 1 2 100 Config mode Speed open loop Speed open loop Speed open loop Speed open loop 101 Torque charact H constant torque N constant...

Page 257: ...al voltage 0 0 V 0 0 V 0 0 V 0 0 V 200 Out freq rng rot 132 hz clock wise 132 hz clock wise 132 hz clock wise 132 hz clock wise 201 Out freq low lim 15 2 Hz 15 5 Hz 15 5 Hz 15 5 Hz 202 Out freq hi lim 47 7 Hz 51 6 Hz 51 6 Hz 51 6 Hz 203 Ref feedb range Min max Min max Min max Min max 204 Min reference 15 200 15 500 15 500 15 500 205 Max reference 47 700 51 600 51 600 51 600 206 Ramp type Linear Li...

Page 258: ... Digital input 27 Coast inverse Coast inverse Coast inverse Coast inverse 305 Digital input 29 No operation No operation No operation No operation 306 Digital input 32 No operation No operation No operation No operation 307 Digital input 33 No operation No operation No operation No operation 308 Ai V 53 funct No operation No operation No operation No operation 309 Ai 53 scale low 0 0 V 0 0 V 0 0 V...

Page 259: ... 402 Br power lim kw 21 6 kW 21 6 kW 21 6 kW 21 6 kW 403 Power monitoring Warning Warning Warning Warning 404 Brake check Off Off Off Off 405 Reset mode Manual reset Manual reset Manual reset Manual reset 406 Autorestart time 5 s 5 s 5 s 5 s 407 Mains failure No function No function No function No function 408 Quick discharge Disable Disable Disable Disable 409 Trip delay torq 61 s 61 s 61 s 61 s ...

Page 260: ...roc integr t 9999 00 s 9999 00 s 9999 00 s 9999 00 s 442 Proc diff time 0 00 s 0 00 s 0 00 s 0 00 s 443 Proc diff gain 5 0 5 0 5 0 5 0 444 Proc filter time 0 01 s 0 01 s 0 01 s 0 01 s 445 Flying start Disable Disable Disable Disable 446 Switch pattern Sfavm Sfavm Sfavm Sfavm 447 Tor sf comp 0 0 0 0 448 Tor sf gearratio 1 00 1 00 1 00 1 00 449 Tor sf fric loss 0 00 0 00 0 00 0 00 450 Mains fail vol...

Page 261: ...e Fc profile Fc profile 513 Bus timeout time 1 s 1 s 1 s 1 s 514 Bus timeout func Off Off Off Off 618 Reset kwh count Do not reset Do not reset Do not reset Do not reset 619 Reset run hour Do not reset Do not reset Do not reset Do not reset 620 Operation mode Normal operation Normal operation Normal operation Normal operation Page 6 ...

Page 262: ...USTOMER REV 1 220217 JOB NIRO SOAVI RUNNING SEQUENCE SET THE FREQUENCY INVERTER TO ACHIEVE THE NOTE CAPACITY AT CAPACITY AT PUSH THE STOP BUTTON DISCONNECT THE SOLENOID VALVE FOR AIR SUPPLY RESET 1st HOMO STAGE MODULATING VALVES SETTING THE SIGNAL TO 4 mA DISCONNECT THE FREQUENCY CONVERTER RUN CONTACT DISCONNECT THE FREQUENCY CONVERTER POWER SUPPLY DISCONNECT THE LUBRICATING OIL PUMP MOTOR DISCONN...

Page 263: ...ELAY INTERVENTION OF THE THERMISTORS ON THE MAIN MOTOR WINDINGS INTERVENTION OF THE LUBRICATING OIL PRESSURE SWITCH REPEAT THE RESULT OF THE SEQUENCE DESCRIBED AT POINT 4 REPEAT THE RESULT OF THE SEQUENCE DESCRIBED AT POINT 4 INTERVENTION ON THE EMERGENCY STOP PUSHBUTTON Sheet 2 of 2 44__4759 E4C xls ...

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Page 267: ...0 20 30 40 SITOP Power 10 6EP1434 2BA00 SITOP Power 20 6EP1436 2BA00 SITOP Power 30 6EP1437 2BA00 SITOP Power 40 6EP1437 2BA10 Betriebsanleitung Best Nr C98130 A7500 A1 06 6419 Operating instructions Instructions Istruzioni di servizio Instrucciones ...

Page 268: ...es les informations de détail relatives à tous les types du produit et ne peut pas non plus tenir compte de tous les cas d installation d exploitation et de maintenance imaginables Pour de plus amples informations veuillez vous adresser à votre agence Siemens ou consultez le catalogue KT 10 Alimentations SITOP power Sous réserve de modifications techniques En cas de divergences le texte allemand f...

Page 269: ...ice see page 2 for item No from 22 8 to 26 4 V Ripple content of output voltage 150 mVss ripple 240 mVss spikes DC output current 0 10 A 0 20 A 0 30 A 0 40A Two devices of identical design may be connected in parallel in order to improve the performance voltage see notes in Catalog KT10 Environmental conditions Temperature Storage and transport 25 to 85 C Operating 0 to 55 C Operation in parallel ...

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Page 271: ... 230 400 V 50 60 Hz applicable in networks up to 250 440 V AC 60 V DC per pole z Standards EN 60 898 DIN VDE 0641 Part 11 IEC 60 898 z Auxiliary switches AS and fault signal contacts FC retrofittable z Characteristic B Line protection mainly used for outlet circuits no proof required regarding personal safety Order numbers are available on request 2001 2002 Siemens Automation and Drives Guest cata...

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Page 273: ...e following ambient housing temperature 35 C 100 60 C 87 Rated operational voltage Ue V 690 2 Rated frequency Hz 50 60 Rated insulation voltage Ui V 690 Rated impulse strength Uimp kV 6 Utilization category IEC 60 947 2 circuit breaker A IEC 60 947 4 1 motor starter AC 3 CLASS In acc with IEC 60 947 4 1 10 10 20 Direct current short circuit breaking capacity time constant τ 5 ms time constant t 5 ...

Page 274: ...nst touching by fingers Temperature compensation In acc with IEC 60 947 4 1 C 20 to 60 Phase loss sensitivity In acc with IEC 60 947 4 1 Yes Explosion protection In acc with DIN VDE 0165 and EN 50 019 Yes for 3RV10 KEMA test certificate no Ex 97 4 32 36 4 Isolating function In acc with IEC 60 947 2 Yes Main and emergency stop switch features5 In acc with IEC 60 204 1 VDE 0113 Yes Safe isolation be...

Page 275: ...inely stranded without wire end ferrule AWG cables single core or stranded mm mm mm AWG 2 x 0 25 to 2 5 2 x 0 25 to 1 5 2 x 0 25 to 2 5 2 x 24 to 14 Max outer diameter of the conductor insulation 3 6 mm Permissible service position Any In acc with IEC 60 447 start com mand I Right or above Transverse auxiliary switch at front with 1 changeover contact Switching capacity with different voltages Rat...

Page 276: ...05 Circuit breaker Hp rating Rated current To 240 VAC To AC 480 Y 277 V To AC 600 Y 347 V For FLA max In Icu 1 Icu 1 Icu 1 Type V 1 phase 3 phase A kA kA kA 0 11 to 2 50 50 10 3RV10 11 2 5 50 50 10 3RV16 11 0BD10 115 3 2 50 50 10 200 1 3 4 50 50 10 Frame size S00 230 2 3 5 50 50 10 460 7 6 3 50 50 10 FLA max 12 A 600 V 575 600 10 8 50 50 10 NEMA Size 00 10 50 50 10 12 50 50 10 0 11 to 3 2 50 50 30...

Page 277: ... 480 Y 277 V To AC 600 Y 347 V For FLA max In Icu 1 Icu 1 Icu 1 Type V 1 phase 3 phase A kA kA kA 0 11 to 1 6 50 50 30 3RV10 21 2 50 50 30 3RV19 28 1H 115 2 2 5 50 50 30 200 3 7 3 2 50 50 30 Frame size S0 230 3 7 4 50 50 30 460 15 5 50 50 30 FLA max 22 A 480 V 575 600 10 6 3 50 50 30 12 5 A 600 V 8 50 50 30 NEMA Size 1 10 50 50 30 12 5 50 50 30 16 50 50 20 50 50 22 50 50 0 9 to 16 50 50 25 3RV10 3...

Page 278: ...1 100 100 100 100 100 100 100 100 100 100 1 25 100 100 100 100 100 100 100 100 2 2 20 1 6 100 100 100 100 100 100 100 100 2 2 20 2 100 100 100 100 100 100 10 10 35 2 2 35 2 5 100 100 100 100 100 100 10 10 35 2 2 35 3 2 100 100 100 100 50 10 40 1 3 3 40 2 2 40 4 100 100 100 100 50 10 40 1 3 3 40 2 2 40 5 100 100 100 100 50 10 50 1 3 3 50 2 2 50 6 3 100 100 100 100 50 10 50 1 3 3 50 2 2 50 8 100 100...

Page 279: ... 125 1 50 20 125 1 12 6 100 6 3 63 50 100 100 50 25 125 1 50 20 125 1 12 6 100 6 3 80 63 100 100 50 25 160 1 50 20 160 1 12 6 100 6 3 80 75 100 100 50 25 160 1 50 20 160 1 8 4 125 5 3 100 90 100 100 50 25 160 1 50 20 160 1 8 4 125 5 3 125 100 100 100 50 25 160 1 50 20 160 1 8 4 125 5 3 125 3RV1 42 Frame size S3 With increased switching capacity 16 100 100 100 50 100 50 30 15 80 12 7 63 20 100 100 ...

Page 280: ...upstream circuit breaker required because it is short circuit proof up to 100 kA 1 10 overvoltage 2 5 overvoltage Characteristics You can obtain the characteristics for all the setting ranges from our Techni cal Assistance team by e mail nst technical assistance siemens de Standard circuit breaker with limiter function Standard circuit breaker To 500 VAC 1 525 V 2 To 690 VAC 1 Type Rated current I...

Page 281: ...45 S3 3RT10 46 Rated insulation voltage VAC 600 600 600 600 600 600 Continuous current at 40 C Open and enclosed A 45 55 50 90 105 105 Maximum horsepower ratings s and u approved values Rated power At 200V hp 10 10 15 20 25 30 of three phase induction motors 230 V hp 10 15 15 25 30 30 At 50 60 Hz 460V hp 25 30 40 50 60 75 575V hp 30 40 50 60 75 100 Short circuit protection kA 5 5 5 10 10 10 contac...

Page 282: ...onal voltage Ue 24 V 60 V 110 V 125 V A A A A 101 2 1 0 9 220 V 440 V 600 V2 A A A 0 3 0 14 0 1 Contact reliability at 17 V 1 mA in acc with DIN EN 60 947 5 4 Contact fault frequency 10 8 i e 1 fault in 100 mill operating cycles Contactor Frame size Type S00 3RT1 1 Rated insulation voltage Ui pollution degree 3 V 690 Rated impulse strength Uimp kV 6 Protective separation between the coil and main ...

Page 283: ... 85 to 1 1 x Us Power input of the magnet coils cold coil and at 1 0 x Us Standard version For USA and Canada AC operation Hz 50 60 50 60 Making capacity cos ϕ Holding power cos ϕ VA VA 27 24 3 26 4 31 7 0 8 0 75 0 81 0 77 4 4 3 4 4 7 5 1 0 27 0 27 0 26 0 27 DC operation Making capacity holding power W 3 3 Contactor Frame size Type S00 S00 S00 3RT10 15 3RT10 16 3RT10 Main circuit Current carrying ...

Page 284: ...C 1 switching of resistive loads L R 1 ms Rated operational current Ie at 60 C Number of conducting paths in series connection 1 2 3 1 2 3 1 2 3 Up to 24 V 60 V 110 V A A A 15 15 15 15 15 15 1 5 8 4 15 20 20 20 20 20 20 2 1 12 20 20 20 20 20 20 20 2 1 12 20 220 V 440 V 600 V A A A 0 6 1 2 15 0 42 1 6 0 9 0 42 0 5 0 7 0 8 1 6 20 0 6 0 8 1 3 0 6 0 7 1 0 8 1 6 20 0 6 0 8 1 3 0 6 0 7 1 Utilization cat...

Page 285: ... 15 5 and 10 10 Short circuit protection for contactors without overload relay Short circuit protection for contactors with overload relay see Chapter 4 Short circuit protection for unwelded contactors see Chapter 5 overload and short circuit protection only with the 3RV10 circuit breaker Short circuit protection for fuseless load feeders see Chapter 5 Contactor Frame size Type S0 3RT10 23 3RT10 2...

Page 286: ...al currents Ie Up to 400 V 500 V 690 V A A A 9 6 5 5 2 12 12 9 17 17 13 25 18 13 Rated power of motors with slipring or squirrel cage rotor at 50 Hz and 60 Hz At 110 V 120 V 127 V 200 V 220 V kW kW kW kW kW 1 1 1 1 1 1 2 2 3 1 5 1 5 1 5 3 3 2 2 2 2 2 2 4 4 3 3 3 5 5 5 5 230 V 240 V 380 V kW kW kW 3 3 4 3 3 5 5 4 4 7 5 5 5 5 5 11 400 V 415 V 440 V kW kW kW 4 4 4 5 5 5 5 5 5 7 5 7 5 9 11 11 11 460 V...

Page 287: ...U z z 1 5 1 h With AC 1 With AC 2 With AC 3 With AC 4 1 h 1 h 1 h 1 h AC DC 1000 1000 1000 300 AC DC 1000 1000 1000 300 AC DC 1000 750 750 250 Contactors with overload relay average value 1 h 15 15 15 Contactor Frame size Type S2 3RT10 3 Mechanical life Basic units Basic unit with attached auxiliary switch block Electronically optimized auxiliary switch block Opera ting cyc les 10 mill 10 mill 5 m...

Page 288: ...at Ik 1 kA Or miniature circuit breaker with C characteristic short circuit current Ik 400 A A 10 10 10 Contactor Frame size Type S2 3RT10 34 S2 3RT10 35 S2 3RT10 36 Drive Operating range of the magnet coils AC DC 0 8 to 1 1 x Us Power input of the magnet coils cold coil and at 1 0 x Us Standard version AC operation Hz 50 50 60 50 50 60 Making capacity cos ϕ Holding power cos ϕ VA VA 104 127 113 0...

Page 289: ... 11 11 18 5 15 15 22 400 V 415 V 440 V kW kW kW 15 15 18 5 18 5 18 5 18 5 22 22 22 460 V 500 V 575 V kW kW kW 18 5 18 5 18 5 22 22 22 30 30 22 660 V 690 V kW kW 18 5 18 5 22 22 22 22 Thermal stress 10 s current1 A 320 400 400 Power loss per conducting path With Ie AC 3 W 1 8 2 6 5 Utilization category AC 4 contact service life of approximately 200 000 operating cycles at Ia 6 x Ie Rated operationa...

Page 290: ...ors L R 15 ms Rated operational current Ie at 60 C Number of conducting paths in series connection 1 2 3 1 2 3 1 2 3 Up to 24 V 60 V 110 V A A A 35 45 45 6 45 45 2 5 25 45 35 55 55 6 45 55 2 5 25 55 35 50 50 6 45 50 2 5 25 50 220 V 440 V 600 V A A A 1 5 25 0 1 0 27 0 6 0 06 0 16 0 35 1 5 25 0 1 0 27 0 6 0 06 0 16 0 35 1 5 25 0 1 0 27 0 6 0 06 0 16 0 35 Switching frequency Switching frequency z in ...

Page 291: ... and 6 2 10 Short circuit protection for contactors without overload relay Short circuit protection for contactors with overload relay see Part 4 Short circuit protection for fuseless load feeders see Chapter 5 Contactor Frame size Type S3 3RT10 44 S3 3RT10 45 S3 3RT10 46 Main circuit Fuse applications performance class gL gG NH type 3NA DIAZED type 5SB NEOZED type 5SE In acc with IEC 60 947 4 DIN...

Page 292: ... 50 35 50 35 Utilization categories AC 2 and AC 3 Rated operational currents Ie Up to 400 V 500 V 690 V 1000 V A A A A 65 65 47 25 80 80 58 30 95 95 58 30 Rated power of motors with slipring or squirrel cage rotor at 50 Hz and 60 Hz at 230 V 400 V 500 V 690 V 1000 V kW kW kW kW kW 18 5 30 37 55 30 22 37 45 55 37 22 45 55 55 37 Thermal stress 10 s current1 A 600 760 760 Power loss per conducting pa...

Page 293: ...d operation fre quency 1 h 5000 1000 5000 1000 5000 1000 Dependency of switching frequency z on operating current I and operating voltage U z z 1 5 1 h With AC 1 With AC 2 With AC 3 With AC 4 1 h 1 h 1 h 1 h AC DC 1000 400 1000 300 AC DC 900 400 1000 300 AC DC 900 350 850 250 Contactors with overload relay average value 1 h 15 15 15 Contactor Frame size Type S3 3RT14 46 Mechanical life Opera ting ...

Page 294: ...operation fre quency 1 h 5000 1000 Rated operation In acc with AC 1 In acc with AC 3 1 h 1 h 650 650 1000 1000 Dependency of switching frequency z on operating current I and operating voltage U z z 1 5 1 h Contactor Frame size Type S3 3RT14 46 Current carrying capacity with alternating current Utilization category AC 1 switching of resistive loads Rated operational currents Ie At 40 C up to 690 V ...

Page 295: ...RT13 46 General specifications Mechanical life Opera ting cycles 30 mill 10 mill Electrical service life with Ie AC 1 Opera ting cycles Approx 0 5 mill Rated insulation voltage Ui pollution degree 3 V 690 Permissible ambient temperature For operation During storage C C 25 to 60 55 to 80 Degree of protection in acc with IEC 60 947 1 and DIN 40 050 Terminal housing IP20 IP 20 IP 00 Short circuit pro...

Page 296: ...0 8 1 6 18 18 0 6 0 8 1 3 1 3 22 22 22 22 22 22 22 22 2 1 12 22 22 0 8 1 6 22 22 0 6 0 8 1 3 1 3 35 35 35 35 20 35 35 35 4 5 35 35 35 1 5 35 35 0 4 1 2 9 2 9 Utilization categories DC 3 and DC 5 shunt and series motors L R 15 ms Rated operational currents Ie at 40 C Number of conducting paths in series connection 1 2 3 4 1 2 3 4 1 2 3 4 Up to 24 V 60 V 110 V 220 V 440 V A A A A A 18 18 18 18 0 5 5...

Page 297: ... 3 V 690 Permissible ambient temperature For operation During storage C C 25 to 60 55 to 80 Degree of protection in acc with IEC 60 947 1 and DIN 40 050 IP20 IP 20 terminal housing IP 00 Short circuit protection for contactors without overload relay Main circuit Fuse links performance class gL gG NH type 3NA DIAZED type 5SB NEOZED type 5SE In acc with IEC 60 947 4 DIN EN 60 947 4 VDE 0660 Part 102...

Page 298: ...5 2 5 10 16 Utilization categories AC 2 and AC 3 Rated operational currents Ie at 60 C Up to 400 V A 9 12 25 1 40 Rated power of motors with slipring or squirrel cage rotor at 50 Hz and 60 Hz and At 230 V 400 V kW kW 3 4 3 5 5 5 5 11 9 5 18 5 Current carrying capacity with direct current Utilization category DC 1 switching of resistive loads L R 1 ms Rated operational current Ie at 60 C Number of ...

Page 299: ... Two 1 pole auxiliary switch blocks can be built on to the 3RT10 2 contactor relays Contactor Frame size Type S00 3RT10 1 1HB4 S00 3RT10 1 1JB4 S00 3RT10 1 1KB4 S0 3RT10 2 1KB40 Mechanical life Opera ting cycles 30 mill 30 mill 30 mill 10 mill Operating range of the magnet coils 0 7 to 1 25 x Us q 17 V to 30 V Power input of the magnet coil with a cold coil With Us 17 V W 1 2 1 2 1 2 2 1 24V W 2 3...

Page 300: ...mance class gL gG A 4 Switching frequency Loaded with Ie 230 VAC Loaded with 3RT1016 contactor 230 VAC 1 h 1 h 2500 2500 2500 5000 Recovery time ms 50 150 Minimum on time ms 35 200 off delay Residual current mA 5 Voltage drop in switched state V 3 5 Short term current car rying capacity A 10 to 10 ms Setting accuracy in relation to the value at the end of the scale 15 15 Repeatability 1 1 Mechanic...

Page 301: ...e class gL gG DIAZED type 5SB NEOZED type 5SE Short circuit current Ik 1 kA A A 10 62 if the auxiliary contact of the overload relay is in the circuit of the contactor coil Circuit breaker with C characteristic A A 10 62 if the auxiliary contact of the overload relay is in the circuit of the contactor coil Size of the individual contac tors Line contactor Delta contactor Star contactor K1 K3 K2 Ty...

Page 302: ...lta starting Starter Frame sizes S S S Type 3RA 00 00 00 14 15 00 00 00 14 16 0 0 0 14 23 0 0 0 14 25 2 2 0 14 34 2 2 2 14 35 2 2 2 14 36 3 3 2 14 44 3 3 2 14 45 Current carrying capacity for the AC 3 utili zation category Switchover time to 20 s Rated operational current At 400 V 500 V 690 V A A A 12 8 7 6 9 17 11 3 9 25 20 8 20 8 28 28 22 5 39 39 39 51 51 51 57 57 57 85 85 85 92 92 92 Rated powe...

Page 303: ... terminals Without LED indicator yp Standard with LED indicator With LED indicator and test button Standard DPDT MY2N MY2IN MY2 4PDT MY4N MY4IN MY4 4PDT bifurcated MY4ZN MY4ZIN MY4Z With built in diode DC l DPDT MY2N D2 MY2IN D2 DC only 4PDT MY4N D2 MY4IN D2 4PDT bifurcated MY4ZN D2 MY4ZIN D2 With built in CR 220 240 VAC DPDT MY2N CR MY2IN CR 220 240 VAC 110 120 VAC only 4PDT MY4N CR MY4IN CR 110 ...

Page 304: ... 1 000 mm PFP 100N PFP 100N2 End Plate PFP M Spacer PFP S Specifications Coil Ratings Rated voltage Rated current Coil resistance Coil inductance reference value Must operate voltage Must release voltage Max voltage Power consump tion 50 Hz 60 Hz Arm OFF Arm ON of rated voltage approx AC 6 V 214 1 mA 183 mA 12 2 0 04 H 0 08 H 80 30 i 110 1 0 to 1 2 VA 12 V 106 5 mA 91 mA 46 0 17 H 0 33 H max min 1...

Page 305: ...e Destruction 10 to 55 Hz 1 0 mm double amplitude Malfunction 10 to 55 Hz 1 0 mm double amplitude Shock resistance Destruction 1 000 m s2 Malfunction 200 m s2 Life expectancy See the following table Ambient temperature Operating 55 C to 70 C with no icing Ambient humidity Operating 35 to 85 Weight Approx 35 g Note The values given above are initial values Life Expectancy Characteristics Pole Mecha...

Page 306: ...tact ratings Operations 2 6 to 240 VAC 6 to 125 VDC 10 A 250 VAC Resistive 2 A 250 VAC PF0 4 10 A 30 VDC Resistive 2 A 30 VDC L R 7 ms 50 x 103 4 5 A 250 VAC Resistive 0 8 A 250 VAC PF0 4 5 A 30 VDC Resistive 1 5 A 30 VDC L R 7 ms 50 x 103 SEV Listings File No 99 5 50902 01 No of poles Coil ratings Contact ratings Operations 2 6 to 240 VAC 6 to 125 VDC 10 A 250 VAC 10 A 30 VDC 10 x 103 4 6 to 5 C ...

Page 307: ... Inductive Loads Life expectancy x10 operations 3 Switching current A 250 VAC 30 VDC 30 VDC 250 VAC Life expectancy x10 operations 3 Switching current A 30 VDC 250 VAC 250 VAC 30 VDC 10000 5000 3000 1000 500 300 100 50 30 10 10000 5000 3000 1000 500 300 100 50 30 10 MY4Z Resistive Loads MY4Z Inductive Loads Life expectancy x10 operations 3 Switching Current A 250 VAC 30 VDC 250 VAC 30 VDC 250 VAC ...

Page 308: ...ole Models 1 2 dia x 2 2 long holes 36 max 28 max 21 5 max 4 Pole Models 1 2 dia x 2 2 long holes 36 max 21 5 max 28 max Models with Test Button 36 max Test button Nameplate Terminal Arrangement Internal Connections Bottom View MY2 MY2N MY2IN DC Models MY2N MY2IN AC Models MY2N D2 MY2IN D2 DC Models Only ...

Page 309: ...s Only MY2N1 D2 MY2IN1 D2 DC Models Only MY4 Z MY4 Z N MY4 Z IN DC Models MY4 Z N MY4 Z IN AC Models MY4 Z N D MY4 Z IN D2 DC Models Only MY4 Z N CR MY4 Z IN CR AC Models Only MY4 Z N1 MY4 Z IN1 DC Models Only MY4 Z N1 D2 MY4 Z IN1 D2 DC Models Only Note The DC models have polarity ...

Page 310: ...s Item Pole Model Carry current Dielectric withstand voltage Insulation resistance see note 2 Track mounted S k t 2 PYF08A E 7 A 2 000 VAC 1 min 1 000 M min Socket PYF08A N see note 3 7 A see note 4 4 PYF14A E 5 A PYF14A N see note 3 5 A see note 4 Back connecting S k t 2 PY08 Y1 7 A 1 500 VAC 1 min 100 M min g Socket PY08QN Y1 PY08 02 4 PY14 Y1 3 A PY14QN Y1 PY14 02 Note 1 The values given above ...

Page 311: ...0 max 73 4 1 8 5 12 9 14 14 13 42 44 12 14 41 11 A2 A2 A1 18 7 3 0 dia 3 5 dia or M3 Note Track mounting is also possible Refer to page 12 for supporting tracks PYF14A E 31 max 29 5 max 72 max Fourteen M3 x 8 sems screws Two 4 2 X 5 mounting holes TOP VIEW Two M3 M4 or 4 5 dia holes Note Track mounting is also possible Refer to page 12 for supporting tracks PYF14A N 30 max 4 42 3 32 2 22 1 12 8 44...

Page 312: ...e PY08QN Y1 includes sections indicated by dotted lines PY08 02 16 5 max 22 max 25 5 max 29 5 max Eight 1 3 dia holes PY14 PY14 Y1 See note Fourteen 3 x 1 2 elliptical holes 25 5 max 29 5 max 24 max 42 max Note The PY14 Y1 includes sections indicated by dotted lines 20 max PY14QN PY14QN Y1 See note 29 5 max 22 max 24 max 41 5 max 42 max Note The PY14QN Y1 includes sections indicated by dotted line...

Page 313: ...PYC A1 2 pcs per set PYC P PYC E1 2 pcs per set PYC P2 4 5 1 2 36 3 4 5 36 3 5 75 4 25 4 5 0 1 5 3 3 38 5 10 28 29 max Mounting Plates for Back connecting Sockets PYP 1 PYP 36 PYP 18 Two 3 4 dia holes 72 elliptical holes 72 elliptical holes t 1 6 ...

Page 314: ... 7 3 0 15 27 0 15 PFP 100N2 29 2 1 5 27 24 16 1 4 5 15 25 25 10 25 1000 25 10 15 35 0 3 End Plate PFP M M4 x 8 pan head screw M4 spring washer 50 11 5 10 10 6 2 1 8 1 35 5 35 3 1 8 1 3 4 8 Spacer PFP S 5 16 12 44 3 16 5 34 8 ALL DIMENSIONS SHOWN ARE IN MILLIMETERS To convert millimeters into inches multiply by 0 03937 To convert grams into ounces multiply by 0 03527 Cat No J111 E1 1B ...

Page 315: ... 12 24 48 100 to 110 125 VDC 4PDT H3YN 4 H3YN 41 24 VDC 4PDT Twin contact H3YN 4 Z H3YN 41 Z Note Specify both the model number and supply voltage when ordering Example H3YN 2 24 VAC Supply voltage Model Number Legend H3YN jj j 1 2 3 1 Output 2 DPDT 4 4PDT 2 Time Range None Short time range 0 1 s to 10 min 1 Long time range 0 1 min to 10 hrs 3 Contact Type None Single contact Z Twin contact Access...

Page 316: ...W at 24 VAC 60 Hz 100 to 120 VAC Relay ON 1 5 VA 1 3 W at 120 VAC 60 Hz Relay OFF 0 6 VA 0 6 W at 120 VAC 60 Hz 200 to 230 VAC Relay ON 1 8 VA 1 5 W at 230 VAC 60 Hz Relay OFF 1 2 VA 0 9 W at 230 VAC 60 Hz 12 VDC Relay ON 0 9 W at 12 VDC Relay OFF 0 07 W at 12 VDC 24 VDC Relay ON 0 9 W at 24 VDC Relay OFF 0 07 W at 24 VDC 48 VDC Relay ON 1 0 W at 48 VDC Relay OFF 0 2 W at 48 VDC 100 to 110 VDC Rel...

Page 317: ...der no load at 1 800 operations h Electrical DPDT 500 000 operations min 5 A at 250 VAC resistive load at 1 800 operations h 4PDT 200 000 operations min H3YN 4 Z 41 Z 100 000 operations min 3 A at 250 VAC resistive load at 1 800 operations h Impulse withstand voltage Between power terminals 3 kV for 100 to 120 VAC 200 to 230 VAC 100 to 110 VDC 125 VDC 1 kV for 12 VDC 24 VDC 48 VDC 24 VAC Between e...

Page 318: ... switched at 125 VDC cosφ 1 Maximum current of 0 2 A can be switched if L R is 7 ms In both cases a life of 100 000 operations can be expected The minimum applicable load is 1 mA at 1 VDC P reference value Switching operations x 10 3 Load current A Reference A maximum current of 0 5 A can be switched at 125 VDC cosφ 1 Maximum current of 0 2 A can be switched if L R is 7 ms In both cases a life of ...

Page 319: ...PW Output indicator UP Power 13 14 Time limit contact NO 9 5 12 8 Time limit contact NC 9 1 10 2 11 3 12 4 Run Power indica tor PW Output indicator UP Power 13 14 Time limit contact NO 9 5 10 6 11 7 12 8 Flicker OFF start Power Output Time limit contact NC 9 1 12 4 Run Power indicator PW Output indicator UP Power 13 14 Time limit contact NO 9 5 12 8 Time limit contact NC 9 1 10 2 11 3 12 4 Run Pow...

Page 320: ... 0 1 to 1 s Yes H3YN 4 Z 10 s 1 to 10 s No 1 min 0 1 to 1 min No 10 min 1 to 10 min No H3YN 21 H3YN 41 H3YN 41 Z 1 min 0 1 to 1 min Yes H3YN 41 Z 10 min 1 to 10 min No 1 h 0 1 to 1 h No 10 h 1 to 10 h No Note The top two DIP switch pins are used to select the time ranges Operating Modes Operating mode Setting Factory set ON delay Yes Interval No Flicker OFF start No Flicker ON start No Note The bo...

Page 321: ...Mounting Height PYF08A PYF08A N PYF08A E PYF14A PYF14A N PYF14A E see note PY08 PY14 see note PY08QN PY14QN see note Note Models in parentheses are Sockets connecting to the H3YN 4 4 Z Fourteen 3 1 2 elliptic holes 28 max 21 5 max 28 max 21 5 max H3YN Series H3YN Series H3YN Series PY08 PY14 PY08QN PY14QN PYF08A PYF14A 6 4 63 Eight 3 x 1 2 elliptic holes ...

Page 322: ... PYF 14A Mounting Holes Fourteen M3 8 sems Two 4 2 5 mounting holes Two 4 5 dia M4 or M3 6 72 max 29 5 max 30 max 16 5 35 4 3 4 4 6 59 0 3 22 0 2 PYF 08A N Terminal Arrangement Mounting Holes for Surface Mounting 4 1 8 5 12 9 14 14 13 42 44 12 14 41 11 A2 A2 A1 19 8 3 2 dia 3 6 dia 4 42 8 44 1 12 5 14 41 12 A2 14 11 9 A1 13 A2 14 22 max 66 5 max PYF 08A N 30 max 4 3 2 1 8 7 6 5 12 11 10 9 14 14 13...

Page 323: ...Y08QN 2 PY14QN 2 PY08 02 PY14 02 Eight 3 1 2 dia holes only for PY08 Fourteen 3 1 2 dia holes See note Note With PYjQN 2 3 dimension should read 20 max and dimension 36 5 max 29 5 max 25 5 max 24 max 0 3 2 7 7 7 20 max 2 6 2 7 29 5 max 41 5 max see note 25 max 24 max 22 max H3YN Series PYj PYj 02 PYjQN 2 29 5 max 25 5 max 22 max 0 3 2 7 4 3 16 5 max 2 PY08j 02 PY14j 02 59 3 21 4 0 2 0 Terminal Arr...

Page 324: ... Sockets to be used PYP 1 Two 3 4 dia holes PYP 18 Square hole t 1 6 49 28 72 elliptic holes t 1 6 42 0 1 49 492 17 x 27 4 465 8 0 6 13 1 21 6 4 5 3 4 27 4 0 15 Hold down Clips The Hold down Clip makes it possible to mount the H3YN securely and prevent the H3YN from falling out due to vibration or shock Y92H 3 for PYFjA Socket Y92H 4 for PYj Socket Y92H 3 Y92H 4 9R 5 max 53 4 5 4 5 33 7 1 2 2 5 20...

Page 325: ... input Power 9 14 External short circuit 5 13 External input 9 13 Time limit contact NO 12 8 Time limit contact NC 12 4 Run Power indicator PW Output indicator UP 50 ms min Power 9 14 External short circuit 5 13 External input 9 13 Time limit contact NO 10 6 11 7 12 8 Time limit contact NC 10 2 11 3 12 4 Run Power indicator PW Output indicator UP Timer circuit External input 50 ms min Caution Be c...

Page 326: ... with the panel or metal parts Do not use the H3YN in places where there is excessive dust corro sive gas or direct sunlight Do not mount more than one H3YN closely together otherwise the internal parts may become damaged Make sure that there is a space of 5 mm or more between any H3YN models next to each oth er to allow heat radiation The internal parts may become damaged if a supply voltage othe...

Page 327: ...low EN 60947 5 1 10 91 Times Delay on Energisation Max 250 ms Delay on De energisation Max 50 ms Recovery Time Approx 0 3 s Simultaneity channel 1 2 Approx 140 ms Max Supply Interruption before De energisation Approx 35 ms Mechanical Data Torque Setting on Connection Terminals 1 2 Nm screws Maximum Cross Section of 2 x 2 5 mm2 External Conductors Single core or multi core with crimp connectors Dim...

Page 328: ... Safety contacts Auxiliary contact A2 L A1 L UB T11 T12 T33 T12 T34 T22 X1 X2 S1 S3 T11 T12 X2 T34 T22 T33 X1 S1 S3 l Example 3 Single channel safety gate control with manual reset X2 T34 T33 X1 T11 T22 T12 T12 S1 S3 X2 T34 T33 X1 T12 T22 T11 S3 X2 T34 T33 X1 T12 T22 T11 S1 S2 l Increase in safety contacts The number of output contacts can be increased by using expander modules or relays contactor...

Page 329: ...ency 10 55 Hz EN 60068 2 6 04 95 Amplitude 0 35 mm Climatic Suitability DIN IEC 60068 2 3 12 86 Airgap Creepage DIN VDE 0110 part 1 04 97 Ambient Temperature 10 55 C Storage Temperature 40 85 C Mechanical Data Torque Setting on Connection Terminals 0 6 Nm screws Mounting Position Any Housing Material Thermoplast Noryl SE 100 Protection Mounting IP 54 Housing IP 40 Terminal Range IP 20 The units we...

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Page 333: ...livery times on request Model No Fan and filter units SK 3325 100 3325 115 3325 024 3325 048 Rated operating voltage Volt Hz 230 50 60 115 50 60 24 DC 48 DC Air throughput unimpeded air flow 230 265 m3 h 230 m3 h Air throughput with outlet filter including standard filter mat 1 x SK 3325 200 170 205 m3 h 2 x SK 3325 200 200 230 m3 h 1 x SK 3326 200 190 215 m3 h Axial fan Self starting shaded pole ...

Page 334: ...41 Temperature dependent speed control for fan and filter units for noise reduction Filter mats are easily changed Air throughput 230 m3 h Axial fan DC motor Self starting shaded pole motor Voltage 24 V DC 48 V DC 115 V 230 V Model No SK 3325 024 3325 048 3325 115 3325 100 Fan and filter units Air throughput 230 m3 h DE SIGNE R FAN AN D FILT ER UNITS aus SK 2000 Seite 139 ...

Page 335: ...stallation of relay terminals 64 Installation of 24 Volt external DC supply 64 Installation of loadsharing 64 Installation of brake resistor temperatureswitch 65 Bus connection 65 Installation of control cables 66 Connection examples 68 Operation of the VLT frequency converter 71 Control panel 71 Display 71 LEDs 71 Control keys 72 Quick Setup via Quick menu 75 Parameter selection 75 Menu mode 75 M...

Page 336: ...102 Programming of Torque limit and stop 103 Programming 104 Operation and Display 104 Load and motor 110 References and limits 120 Inputs and outputs 128 Special functions 143 Serial communication 157 Technical functions 163 Miscellaneous 171 Trouble shooting 171 Status messages 172 List of warnings and alarms 175 Warnings 177 MG 51 A1 02 VLT is a registered Danfoss trade mark 2 ...

Page 337: ...ng instructions Software version 3 5x These operating instructions can be used for all VLT 5000 Series frequency converters with software version 3 5x The software version number can be seen from parameter 624 MG 51 A1 02 VLT is a registered Danfoss trade mark 3 Safety ...

Page 338: ...lised at 1 16 x rated motor current and rated motor frequency For the North American market The ETR functions provide class 20 motor overload protection in ac cordance with NEC 6 Do not remove the plugs for the motor and mains supply while the VLT frequency converter is con nected to mains Check that the mains supply has been disconnected and that the necessary time has passed before removing moto...

Page 339: ...V DC load sharing linkage of DC intermediate circuit as well as the motor connection for kinetic back up Using VLT 5001 5006 wait at least 4 minutes Using VLT 5008 5500 wait at least 15 minutes Please be aware that the VLT 5060 has been replaced by VLT 5062 However the sections Acces sories and General Technical Data still include VLT 5060 in this Design Guide MG 51 A1 02 VLT is a registered Danfo...

Page 340: ... for design purposes and gives a good insight into the technology product range technical data etc Quick Setup Helps the great majority of users to quickly get their VLT 5000 Series unit installed and running The Operating Instructions and the Quick Setup are delivered with the unit When reading these Operating Instructions you will come across different symbols that require special attention The ...

Page 341: ...g MI 50 NX YY VLT 5000 Brake resistors MI 50 DX YY Brake resistors for horisontal applications VLT 5001 5011 MI 50 SX YY LC filter modules MI 56 DX YY Converter for encoder inputs 5V TTL to 24 V DC MI 50 IX YY Back Plate to VLT 5000 Series MN 50 XX YY Various literature for VLT 5000 Design Guide MG 51 BX YY Data sheet MD 50 AX YY Incorporating a VLT 5000 Profibus in a Simatic S5 system MC 50 CX YY...

Page 342: ...40V Rated motor voltage 380 500 V units 380 400 415 440 460 480 500V Rated motor frequency 50 60 Hz Switching on output Unlimited Ramp times 0 05 3600 sec Torque characteristics Starting torque VLT 5001 5027 200 240 V and VLT 5001 5062 380 500 V 160 for 1 min Starting torque VLT 5032 5052 200 240 V and VLT 5060 5500 380 500 V 150 for 1 min Starting torque 180 for 0 5 sec Acceleration torque 100 Ov...

Page 343: ...m the supply voltage PELV In addi tion the digital inputs can be isolated from the other terminals on the control card by connecting an external 24 V DC supply and opening switch 4 See section on Installation of control cables MG 51 A1 02 VLT is a registered Danfoss trade mark 9 Technical data ...

Page 344: ...3 msec Resolution 10 bit sign Accuracy 100 1 kHz terminals 17 29 33 Max error 0 5 of full scale Accuracy 1 5 kHz terminal 17 Max error 0 1 of full scale Accuracy 1 65 kHz terminals 29 33 Max error 0 1 of full scale Reliable galvanic isolation All pulse encoder inputs are galvanically isolated from the supply voltage PELV In addition pulse and encoder inputs can be isolated from the other terminals...

Page 345: ... 24 Volt DC supply Terminal nos 35 36 Voltage range 24 V DC 15 max 37 V DC for 10 sec Max voltage ripple 2 V DC Power consumption 15 W 50 W 50 W for start up 20 msec Min pre fuse 6 Amp Reliable galvanic isolation Full galvanic isolation if the external 24 V DC supply is also of the PELV type Cable lengths cross sections and connectors Max motor cable length screened cable 150 m Max motor cable len...

Page 346: ...om 3 directions for 2 hours IEC 68 2 34 35 36 Max relative humidity 93 IEC 68 2 3 for storage transport Max relative humidity 95 non condensing IEC 721 3 3 class 3K3 for operation Aggresive environment IEC 721 3 3 Uncoated class 3C2 Aggresive environment IEC 721 3 3 Coated class 3C3 Ambient temperature IP 20 high overload torque 160 Max 45 C 24 hour average max 40 C Ambient temperature IP 20 norma...

Page 347: ...n motor terminals U V W The VLT frequency converter is protected against earth fault on motor terminals U V W Monitoring of the intermediate circuit voltage ensures that the VLT frequency converter cuts out if the inter mediate circuit voltage gets too high or too low If a motor phase is missing the VLT frequency converter cuts out see parameter 234 Motor phase monitor If there is a mains fault th...

Page 348: ... UL1 A 16 10 16 10 16 15 25 20 25 25 35 30 Efficiency3 0 95 0 95 0 95 0 95 0 95 0 95 Weight IP 20 EB kg 7 7 7 9 9 9 5 Power loss at max load W 58 76 95 126 172 194 Enclosure IP 20 IP 20 IP 20 IP 20 IP 20 IP 20 IP 20 1 If UL cUL ist to be complied with pre fuses type Bussmann KTN R or Ferraz Shawmut type ATMR class CC must be used If UL cUL is not to be complied with we recommend using the above me...

Page 349: ...tion power mm2 AWG 2 4 10 4 10 4 10 4 10 Max pre fuses UL1 A 16 6 16 6 16 10 16 10 Efficiency3 0 96 0 96 0 96 0 96 Weight IP 20 EB kg 7 7 7 7 5 Power loss at max load W 55 67 92 110 Enclosure IP 20 IP 20 IP 20 IP 20 1 If UL cUL is to be complied with pre fuses type Bussmann KTS R or Ferraz Shawmut type ATMR class CC must be used If UL cUL is not to be complied with we recommend using the above men...

Page 350: ...ss section power mm2 AWG 2 4 10 4 10 4 10 4 10 Max pre fuses UL1 A 16 15 25 20 25 25 35 30 Efficiency3 0 96 0 96 0 96 0 96 Weight IP 20 EB kg 7 5 9 5 9 5 9 5 Power loss at max load W 139 198 250 295 Enclosure IP 20 IP 20 IP 20 IP 20 1 If UL cUL is to be complied with pre fuses type Bussmann KTS R or Ferraz Shawmut type ATMR class CC must be used If UL cUL is not to be complied with we recommend us...

Page 351: ...0 Efficiency3 0 95 0 95 0 95 0 95 0 95 0 95 Weight IP 20 EB kg 8 8 8 10 10 10 Weight IP 54 kg 11 5 11 5 11 5 13 5 13 5 13 5 Power loss at max load W 58 76 95 126 172 194 Enclosure IP 20 IP 54 IP 20 IP 54 IP 20 IP 54 IP 20 IP 54 IP 20 IP 54 IP 20 IP 54 1 If UL cUL is to be complied with pre fuses type Bussmann KTN R or Ferraz Shawmut type ATMR class CC must be used If UL cUL is not to be complied w...

Page 352: ...0 4 0 4 0 4 0 Efficiency3 0 95 0 95 0 95 0 95 0 95 Weight IP 20 EB kg 21 25 27 34 36 Weight IP 54 kg 38 40 53 55 56 Power loss at max load high overload torque 160 W 340 426 626 833 994 normal overload torque 110 W 426 545 783 1042 1243 Enclosure IP 20 IP 54 IP 20 IP 54 IP 20 IP 54 IP 20 IP 54 IP 20 IP 54 1 If UL cUL is to be complied with pre fuses type Bussmann KTN R must be used If UL cUL is no...

Page 353: ...G 2 4 10 4 10 4 10 4 10 Max pre fuses UL1 A 16 6 16 6 16 10 16 10 Efficiency3 0 96 0 96 0 96 0 96 Weight IP 20 EB kg 8 8 8 8 5 Weight IP 54 kg 11 5 11 5 11 5 12 Power loss at max load W 55 67 92 110 Enclosure IP 20 IP 54 IP 20 IP 54 IP 20 IP 54 IP 20 IP 54 1 If UL cUL is to be complied with pre fuses type Bussmann KTS R or Ferraz Shawmut type ATMR class CC must be used If UL cUL is not to be compl...

Page 354: ...r mm2 AWG 2 4 10 4 10 4 10 4 10 Max pre fuses UL1 A 16 15 25 20 25 25 35 30 Efficiency3 0 96 0 96 0 96 0 96 Weight IP 20 EB kg 8 5 10 5 10 5 10 5 Weight IP 54 kg 12 14 14 14 Power loss at max load W 139 198 250 295 Enclosure IP 20 IP 54 IP 20 IP 54 IP 20 IP 54 IP 20 IP 54 1 If UL cUL is to be complied with pre fuses type Bussmann KTS R or Ferraz Shawmut type ATMR class CC must be used If UL cUL is...

Page 355: ...380 440 V 18 3 24 4 28 6 SVLT N kVA 441 500 V 18 8 24 2 29 4 Typical shaft output PVLT N kW 11 15 18 5 Typical shaft output PVLT N HP 15 20 25 Max cable cross section to motor IP 54 16 6 16 6 16 6 brake and loadsharing mm2 AWG 2 4 IP 20 16 6 16 6 35 2 Min cable cross section to motor brake and loadsharing mm2 AWG 10 8 10 8 10 8 Rated input current IL N A 380 V 32 37 5 44 IL N A 460 V 27 6 34 41 Ma...

Page 356: ...in a circuit capable of supplying a maximum of 100000 Arms symmetrical 500 V maximum 2 American Wire Gauge 3 Measured using 30 m screened motor cables at rated load and rated frequency 4 Min cable cross section is the smallest cable cross section allowed to be fitted on the terminals to comply with IP 20 Always comply with national and local regulations on min cable cross section 5 If UL cUL is to...

Page 357: ...T N kVA 441 500 V 35 9 46 8 56 3 69 3 Typical shaft output PVLT N kW 22 30 37 45 55 500 V Typical shaft output PVLT N HP 30 40 50 60 75 500 V Max cable cross section to motor IP 54 35 2 35 2 50 0 50 0 brake and loadsharing mm2 AWG 2 5 IP20 35 2 35 2 50 0 50 0 Min cable cross section to motor brake and loadsharing mm2 AWG 10 8 10 8 16 6 16 6 Rated input current IL N A 380 V 60 72 89 104 IL N A 460 ...

Page 358: ...0000 Arms symmetrical 500 V maximum 2 American Wire Gauge 3 Measured using 30 m screened motor cables at rated load and rated frequency 4 Min cable cross section is the smallest cable cross section allowed to be fitted on the terminals to comply with IP 20 Always comply with national and local regulations on min cable cross section 5 Aluminium cables with cross section above 35 mm2 must be connect...

Page 359: ...o motor brake and loadsharing 200 240 mm2 5 95 95 120 Max cross section of copper cable to motor brake and loadsharing 200 240 AWG 2 5 1 0 3 0 4 0 Max cross section of aluminium cable to motor brake and loadsharing 200 240 AWG 2 5 3 0 250mcm 300mcm Min cable cross section to motor brake and loadsharing4 mm2 AWG 2 5 10 8 10 8 10 8 1 If UL cUL is to be complied with pre fuses type Bussmann FWH or FW...

Page 360: ...1 1613 Enclosure IP 00 IP 20 IP 54 Nema 1 with terminals 1 If UL cUL is to be complied with pre fuses type Bussmann FWH or FWX must be used If UL cUL is not to be complied with we recommend using the above mentioned Bussmann fuse or type gR fuse Not following the recommendation may result in unnecessary damage of the drive in case of malfunc tion Fuses must be designed for protection in a circuit ...

Page 361: ...5 Typical shaft output 380 440 V PVLT N HP 60 75 100 Typical shaft output 441 500 V PVLT N kW 55 75 90 Typical shaft output 441 500 V PVLT N HP 75 100 125 Max cross section of copper cable to motor brake and loadsharing 380 440 V mm2 5 70 95 120 Max cross section of copper cable to motor brake and loadsharing 441 500 V mm2 5 70 70 95 Max cross section of aluminium cable to motor brake and loadshar...

Page 362: ...designed for protection in a circuit capable of supplying a maximum of 100000 Arms symmetrical 500 V maximum 2 American Wire Gauge 3 Measured using 30 m screened motor cables at rated load and rated frequency 4 Min cable cross section is the smallest cable cross section allowed to be fitted on the terminals Al ways comply with national and local regulations on min cable cross section 5 Connection ...

Page 363: ...s section of copper cable to power 441 500 V AWG 2 5 1 0 2 0 3 0 Max cross section of aluminium cable to power 380 440 V AWG 2 5 3 0 250mcm 300mcm Max cross section of aluminium cable to power 441 500 V AWG 2 5 3 0 4 0 250mcm Min cable cross section to motor brake and load sharing4 mm2 AWG 2 5 10 8 10 8 10 8 Max pre fuses mains UL1 A 150 150 250 220 250 250 Integral pre fuses softcharge circuit UL...

Page 364: ...0 m screened motor cables at rated load and rated frequency 4 Min cable cross section is the smallest cable cross section allowed to be fitted on the terminals Al ways comply with national and local regulations on min cable cross section 5 Connection stud 1 x M8 2 x M8 6 Not for new designs For new designs use VLT 5062 7 If UL cUL is to be complied with AC Littelfuse type KLK Danfoss ordering no 1...

Page 365: ...380 440 V PVLT N HP 125 150 200 250 Typical shaft output 441 500 V PVLT N kW 110 132 160 200 Typical shaft output 441 500 V PVLT N HP 150 200 150 300 Max cross section of copper cable to motor brake and loadsharing 380 440 V mm2 5 2x70 2x70 2x95 2x120 Max cross section of copper cable to motor brake and loadsharing 441 500 V mm2 5 2x70 2x70 2x95 2x120 Max cross section of aluminium cable to motor ...

Page 366: ...alfunc tion Fuses must be designed for protection in a circuit capable of supplying a maximum of 100000 Arms symmetrical 500 V maximum 2 American Wire Gauge 3 Measured using 30 m screened motor cables at rated load and rated frequency 4 Min cable cross section is the smallest cable cross section allowed to be fitted on the terminals Al ways comply with national and local regulations on min cable c...

Page 367: ... of copper cable to power 441 500 V AWG 2 5 2x1 0 2x1 0 2x3 0 2x4 0 Max cross section of aluminium cable to power 380 440 V AWG 2 5 2x2 0 2x4 0 2x250mcm 2x350mcm Max cross section of aluminium cable to power 441 500 V AWG 2 5 2x2 0 2x3 0 2x250mcm 2x300mcm Min cable cross section to motor brake and loadsharing4 mm2 AWG 2 5 10 8 10 8 10 8 16 6 Max pre fuses mains UL1 A 300 300 350 350 450 400 500 50...

Page 368: ...e Gauge 3 Measured using 30 m screened motor cables at rated load and rated frequency 4 Min cable cross section is the smallest cable cross section allowed to be fitted on the terminals Al ways comply with national and local regulations on min cable cross section 5 Connection stud 1 x M8 2 x M8 6 If UL cUL is to be complied with AC Littelfuse type KLK Danfoss ordering no 176F1148 must be used 7 If...

Page 369: ...cable to motor brake 2x185 2x240 2x300 and loadsharing 380 440 V mm2 5 3x120 3x150 3x185 3x185 Max cross section of aluminium cable to motor brake 2x150 2x185 2x240 and loadsharing 441 500 mm2 5 3x95 3x120 3x150 3x185 Max cross section of copper cable to motor brake 2x250mcm 2x350mcm 2x400mcm 2x500mcm and loadsharing 380 440 V AWG 2 5 3x2 0 3x3 0 3x4 0 3x250mcm Max cross section of copper cable to...

Page 370: ...2x500mcm to power 380 440 V AWG 2 5 3x2 0 3x3 0 3x4 0 3x250mcm Max cross section of copper cable 2x4 0 2x300mcm 2x350mcm 2x500mcm to power 441 500 V AWG 2 5 31 0 3x3 0 3x3 0 3x4 0 Max cross section of aluminium cable 2x350mcm 2x500mcm 2x600mcm 2x700mcm to power 380 440 V AWG 2 5 3x4 0 3x250mcm 3x300mcm 3x350mcm Max cross section of aluminium cable 2x300mcm 2x400mcm 2x500mcm 2x600mcm to power 441 5...

Page 371: ... Measured using 30 m screened motor cables at rated load and rated frequency 4 Min cable cross section is the smallest cable cross section allowed to be fitted on the terminals Al ways comply with national and local regulations on min cable cross section 5 Connection stud 2 x M12 3 x M12 6 If UL cUL is to be complied with AC Littelfuse type KLK Danfoss ordering no 175L3489 must be used 7 If UL cUL...

Page 372: ...296 780 270 200 D 5032 5052 200 240 V 5060 5100 380 500 V 954 370 335 780 270 225 E 5125 5250 380 500 V 1532 420 400 1380 350 225 E Compact Nema 1 with terminals 5032 5052 200 240 V 5060 5100 380 500 V 1004 370 335 780 270 225 E 5125 5250 380 500 V 1582 420 400 1380 350 225 E Compact Nema 1 5300 5500 380 500 V 2060 1200 600 4001 H Compact IP 54 5001 5003 200 240 V 5001 5005 380 500 V 460 282 195 8...

Page 373: ...VLT 5000 Series Mechanical dimensions cont MG 51 A1 02 VLT is a registered Danfoss trade mark 39 Technical data ...

Page 374: ...VLT 5000 Series Type H Nema 1 IP 54 Type I IP 00 MG 51 A1 02 VLT is a registered Danfoss trade mark 40 ...

Page 375: ...e 24 hour average temperature is not exceeded The max tempera ture and 24 hour average can be seen from the General Technical section When installing the VLT frequency converter on a non flat surface i e a frame please consult the in struction MN 50 XX YY If the ambient temperature is in the range of 45 C 55 C derating of the VLT frequency converter will be required in accordance with the diagram ...

Page 376: ...Cooling All Bookstyle units require a minimum space of 100 mm above and below the enclosure Side by side All Bookstyle units can be installed side by side with out any space between them since the units do not require any cooling on the sides MG 51 A1 02 VLT is a registered Danfoss trade mark 42 ...

Page 377: ...100 mm above and below the enclosure and must be in stalled on a plane vertical surface no spacers This applies to both IP 20 and IP 54 units Side by side All Compact units can be installed side by side with out any space between them since the units do not require any cooling on the sides MG 51 A1 02 VLT is a registered Danfoss trade mark 43 Installation ...

Page 378: ...low the enclosure and must be installed on a plane ver tical surface no spacers This applies to both IP 20 and IP 54 units Side by side Compact IP 20 Compact IP 54 flange by flange All IP 20 and IP 54 units in the above mentioned se ries can be installed side by side without any space between them since these units do not require cool ing on the sides MG 51 A1 02 VLT is a registered Danfoss trade ...

Page 379: ... ver tical surface no spacers This applies only to IP 00 and IP 20 since IP 54 always has a backplate Filter mats in IP 54 units have to be changed when they are dirty Side by side Compact IP 00 and IP 20 Compact IP 54 All IP 00 IP 20 and IP 54 units in the above mentioned series can be installed side by side without any space between them since these units do not require cooling on the sides MG 5...

Page 380: ... mats in IP 54 units have to be changed when they are dirty Side by side Compact Nema 1 IP 20 and IP 54 All Nema 1 IP 20 and IP 54 units in the above mentioned series can be installed side by side without any space between them since these units do not require cooling on the sides IP 00 VLT 5300 5500 380 500 V The IP 00 unit is designed for installation in a cabi net when installed according to th...

Page 381: ... at least 4 minutes if using VLT 5001 5006 and at least 15 minutes if using VLT 5008 5500 NB It is the user s or certified electrician s responsibility to ensure correct earthing and protection in accordance with applicable national and local norms and standards All terminals for the control cables are located under the protective cover of the VLT frequency converter The protective cover see drawi...

Page 382: ...200 240 V VLT 5001 5011 380 500 V Compact IP 20 VLT 5008 5027 200 240 V VLT 5016 5062 380 500 V Compact IP 20 IP 54 VLT 5001 5006 200 240 V VLT 5001 5011 380 500 V Compact IP 54 VLT 5008 5027 200 240 V VLT 5016 5062 380 500 V MG 51 A1 02 VLT is a registered Danfoss trade mark 48 ...

Page 383: ...0 IP 20 VLT 5032 5052 200 240 V VLT 5060 5100 380 500 V Compact IP 00 IP 20 VLT 5125 5250 380 500 V Compact IP 54 VLT 5032 5052 200 240 V VLT 5060 5100 380 500 V Compact IP 54 VLT 5125 5250 380 500 V MG 51 A1 02 VLT is a registered Danfoss trade mark 49 Installation ...

Page 384: ...llation power cables Compact IP 20 IP 54 without disconnector and mains fuses VLT 5300 5500 380 500 V Compact IP 20 IP 54 with disconnector and mains fuses VLT 5300 5500 380 500 V MG 51 A1 02 VLT is a registered Danfoss trade mark 50 ...

Page 385: ...0 240 V VLT 5001 5011 380 500 V Compact IP 20 VLT 5008 5027 200 240 V VLT 5016 5062 380 500 V Compact IP 20 VLT 5001 5006 200 240 V VLT 5001 5011 380 500 V Compact IP 54 VLT 5001 5006 200 240 V VLT 5001 5011 380 500 V MG 51 A1 02 VLT is a registered Danfoss trade mark 51 Installation ...

Page 386: ...4 VLT 5008 5027 200 240 V VLT 5016 5062 380 500 V Compact IP 00 VLT 5125 5250 380 500 V Compact IP 00 VLT 5032 5052 200 240 V VLT 5060 5100 380 500 V Compact IP 20 VLT 5032 5052 200 240 V VLT 5060 5100 380 500 V MG 51 A1 02 VLT is a registered Danfoss trade mark 52 ...

Page 387: ...installation enclosures Compact IP 20 VLT 5125 5250 380 500 V Compact IP 54 VLT 5125 5250 380 500 V Compact IP 54 VLT 5032 5052 200 240 V VLT 5060 5100 380 500 V MG 51 A1 02 VLT is a registered Danfoss trade mark 53 Installation ...

Page 388: ...VLT 5000 Series Electrical installation enclosures Compact IP 20 IP 54 VLT 5300 5500 380 500 V MG 51 A1 02 VLT is a registered Danfoss trade mark 54 ...

Page 389: ... high frequency impedance of the screen which reduces its effectiveness at high frequencies Use low impedance cable clamps or glands instead It is important to ensure good electrical contact between the mounting plate on which the VLT fre quency converter is installed and the metal chassis of the VLT frequency converter This however does not apply to IP54 units as they are designed for wall mounti...

Page 390: ...VLT 5000 Series MG 51 A1 02 VLT is a registered Danfoss trade mark 56 ...

Page 391: ...ng the physical design of the cable Transfer impedance ZT can be assessed on the basis of the following factors The conductibility of the screen material The contact resistance between the individual screen conductors The screen coverage i e the physical area of the cable covered by the screen often stated as a percentage value Screen type i e braided or twisted pattern Aluminium clad with copper ...

Page 392: ...If the earth potential between the VLT frequency converter and the PLC etc is different electric noise may occur that will disturb the whole system This problem can be solved by fitting an equalising cable to be placed next to the control cable Mini mum cable cross section 16 mm2 For 50 60 Hz earth loops If very long control cables are used 50 60 Hz earth loops may occur This problem can be solved...

Page 393: ...ains phases to terminals L1 L2 L3 High voltage test A high voltage test can be carried out by short circuiting terminals U V W L1 L2 and L3 and ener gizing by max 2 15 kV DC for one second between this short circuit and the chassis NB The RFI switch must be closed position ON when high voltage tests are carried out see section RFI Switch The mains and motor connection must be in terrupted in the c...

Page 394: ... operated with mains connected to the unit Check that the mains supply has been disconnected before operat ing the RFI switch NB Open RFI switch is only allowed at factory set switching frequencies NB The RFI switch discon nects the capacitors galvanically to ground The red switches are operated by means of e g a screwdriver They are set in the OFF position when they are pulled out and in ON posit...

Page 395: ... 200 240 V Compact IP 20 VLT 5027 5032 380 500 V VLT 5011 5016 200 240 V Compact IP 20 VLT 5042 5062 380 500 V VLT 5022 5027 200 240 V Compact IP 54 VLT 5001 5011 380 500 V VLT 5001 5006 200 240 V MG 51 A1 02 VLT is a registered Danfoss trade mark 61 Installation ...

Page 396: ...VLT 5000 Series Compact IP 54 VLT 5016 5027 380 500 V VLT 5008 5011 200 240 V Compact IP 54 VLT 5032 5062 380 500 V VLT 5016 5027 200 240 V MG 51 A1 02 VLT is a registered Danfoss trade mark 62 ...

Page 397: ...e HF impedance The frequency converter has been tested with a given length of cable and a given cross section of that cable If the cross section is increased the ca ble capacitance and thus the leakage current increases and the cable length must be reduced correspondingly Connection of motor All types of 3 phased asynchronous standard motors can be used with the VLT 5000 Series Normally small moto...

Page 398: ...tages up to 850 V DC may occur on the terminals Installation of relay terminals Torque 0 5 0 6 Nm Screw size M3 No Function 1 3 Relay output 1 3 break 1 2 make See parameter 323 of the Operat ing Instructions See also General technical data 4 5 Relay output 4 5 make See parameter 326 of the Operating In structions See also General technical data Installation of 24 Volt external DC supply Only exte...

Page 399: ...temperature of the brake resistor gets too high and the KLIXON switch drops out the VLT frequency converter will stop braking The motor will start coasting A KLIXON switch must be installed that can either be normally closed or normally open If this function is not used 106 and 104 must be short circuited together Bus connection The serial bus connection in accordance with the RS 485 2 conductor n...

Page 400: ... For the 24 V DC to be usable for the digital inputs switch 4 on the control card must be closed position ON 16 33 Digital inputs encoder inputs 20 Ground for digital inputs 39 Ground for analogue digital out puts 42 45 Analogue digital outputs for indi cating frequency reference current and torque 50 Supply voltage to potentiometer and thermistor 10 V DC 53 54 Analogue reference input volt age 0 ...

Page 401: ...VLT 5000 Series Electrical installation MG 51 A1 02 VLT is a registered Danfoss trade mark 67 Installation ...

Page 402: ...art 2 Jog by means of terminal 29 Parameter 305 Jog 5 Setup change Selection of setup using terminals 32 and 33 Parameter 306 Selection of setup lsb 10 Parameter 307 Selection of setup msb 10 Parameter 004 Multi setup 5 Digital speed up down Speed up and down using terminals 32 and 33 Parameter 306 Speed up 9 Parameter 307 Speed down 9 Parameter 305 Freeze reference 9 Potentiometer reference Param...

Page 403: ...meter 308 Feedback 2 Parameter 309 Terminal 53 min scaling Parameter 310 Terminal 53 max scaling Parameter 314 Reference 1 Parameter 315 Terminal 60 min scaling Parameter 316 Terminal 60 max scaling Encoder connection Parameter 306 Encoder input B 24 Parameter 307 Encoder input A 25 If an encoder is connected that only has one output to Encoder input A 25 Encoder input B 24 must be set to No funct...

Page 404: ...eset reference msb PRESET REF MSB 6 8 6 Freeze reference FREEZE REFERENCE 7 7 9 7 7 Freeze output FREEZE OUTPUT 8 8 10 8 8 Speed up SPEED UP 9 11 9 Speed down SPEED DOWN 9 12 9 Choice of Setup lsb SETUP SELECT LSB 10 13 10 Choice of Setup msb SETUP SELECT MSB 10 14 10 Choice of Setup msb speed up SETUP MSB SPEED UP 11 Choice of Setup lsb speed down SETUP LSB SPEED DOWN 11 Catch up CATCH UP 11 15 1...

Page 405: ... of 4 alpha numeric lines together with a box that shows the direction of rotation arrow and the chosen Setup as well as the Setup in which programming is taking place if that is the case 12345678 SETUP 1 12345678901234567890 12345678901234567890 12345678901234567890 175ZA443 10 1st line 2nd line 3rd line 4th line 1st line shows up to 3 measurements continuously in normal operating status or a tex...

Page 406: ... parameters STOP RESET is used for stopping the motor connected or for resetting the VLT frequency converter after a drop out trip Can be selected via parameter 014 to be active or inactive If stop is activated line 2 will flash and START must be activated JOG overrides the output frequency to a preset frequency while the key is kept down Can be se lected via parameter 015 to be active or inactive...

Page 407: ...unit Frequency Hz Frequency x scaling Motor current A Torque Power kW Power HP Output energy kWh Motor voltage V DC link voltage V Motor thermal load VLT thermal load Hours run Hours Input status dig Input Binary code Input status analogue terminal 53 V Input status analogue terminal 54 V Input status analogue terminal 60 mA Pulse reference Hz External reference Status word Hex Brake effect 2 min ...

Page 408: ...nverter This function is acti vated in parameter 005 Programming Setup MOTOR IS RUNNING 50 0 Hz 24 3 30 2 13 8A The selected programming setup number will flash to the right of the active setup Parameter Setup The VLT 5000 Series can be used for practically all assignments which is why the number of parame ters is quite large Also this series offers a choice between two programming modes a Menu mo...

Page 409: ...e control 13 003 Local reference Menu mode The Menu mode is started by pressing the MENU key which produces the following read out on the display 50 0 Hz FREQUENCY 0 KEYB DISPLAY Line 3 on the display shows the parameter group number and name Parameter selection In the Menu mode the parameters are divided into groups Selection of parameter group is effected by means of the keys The following param...

Page 410: ...a value is indicated by the digit flash ing The bottom display line shows the data value that will be entered saved when signing off with OK Infinitely variable change of numericdatavalue If the chosen parameter represents a numeric data value a digit is first selected by means of the keys 50 0 HzSETUP 1 FREQUENCY 130 START FREQUENCY 09 0 HZ Then the chosen digit is changed infinitely variably by ...

Page 411: ... of the parameter select the indexed value and press the CHANGE DATA key Using the and keys the value to be changed will flash To accept the new setting press OK to abort press CANCEL Manual initialisation Disconnect from mains and hold the following keys down Display status Change data OK while at the same time reconnecting the mains sup ply Release the keys the VLT frequency converter has now be...

Page 412: ...data value Choice of group VAR 2 STATUS VAR 1 1 VAR 1 2 VAR 1 3 50 0 HZ FREQUENCY 0 KEYB DISPLAY 50 0 HZ 001 LANGUAGE ENGLISH FREQUENCY 001 LANGUAGE ENGLISH 50 0 HZ FREQUENCY 001 LANGUAGE ENGLISH 50 0 HZ 001 LANGUAGE ENGLISH DATA CHANGE MODE 50 0 HZ QUICK MENU 1 OF 13 QUICK MENU 1 OF 13 MG 51 A1 02 VLT is a registered Danfoss trade mark 78 ...

Page 413: ...rol open loop 0 200 Output frequency range direction 201 Output frequency low limit Only if 0 or 2 in par 200 202 Output frequency high limit 203 Reference feedback range 204 Minimum reference Only if 0 in par 203 205 Maximum reference Select Speed control closed loop if the application has a feedback signal and the accuracy in Speed control open loop is not sufficient or a full holding torque is ...

Page 414: ...tegration time 442 Process PID differentiation time 443 Process PID diff gain limit 444 Process PID lowpass filter Select Torque control open loop if PI control is re quired to change the motor frequency in order to maintain the torque reference Nm This is relevant for winding and extrusion applica tions Torque control open loop is to be selected if the speed direction is not to be changed during ...

Page 415: ...orque control speed feedback has been selected the VLT frequency converter should be cal ibrated to ensure that the current torque equals the torque of the VLT frequency converter For this to be ensured a torque gauge must be fitted to the shaft so as to enable accurate adjustment of parameter 447 Torque compensation and parameter 449 Friction loss It is recommended to run an AMA be fore torque ca...

Page 416: ...t the following parameters in order shown Special motor characteristics Parame ter Setting Data value 101 Torque characteristics Special motor characteristics 5 or 15 432 431 F5 frequency U5 voltage 430 429 F4 frequency U4 voltage 428 427 F3 frequency U3 voltage 426 425 F2 frequency U2 voltage 424 423 F1 frequency U1 voltage 422 U0 voltage MG 51 A1 02 VLT is a registered Danfoss trade mark 82 ...

Page 417: ...le to control the VLT frequency converter as follows Digital inputs 1 Local reference set in parameter 003 can be changed via the keys 2 Reset via digital terminal 16 17 29 32 or 33 3 Stop inverse via digital terminal 16 17 27 29 32 or 33 4 Choice of Setup lsb via digital terminal 16 29 or 32 5 Choice of Setup msb via digital terminal 17 29 or 33 6 Ramp 2 via digital terminal 16 17 29 32 or 33 7 Q...

Page 418: ...ake resistor the appli cation must be known through and through i e it must be known how often to brake and by how much power braking is effected The resistor ED which is often used by motor suppliers when stating the permissible load is an in dication of the duty cycle at which the resistor is working The resistor ED is calculated as follows ED dutycycle tb t2 0 t1 in which t2 t1 cycle time in se...

Page 419: ...is a risk that the VLT 5000 Series will cut out for safety reasons For further information please consult Brake Instructions MI 50 Dx xx NB If a short circuit in the brake transistor occurs power dissipation in the brake resistor can only be prevented by using a mains switch or con tactor to disconnect the mains for the VLT The contactor can be controlled by the VLT MG 51 A1 02 VLT is a registered...

Page 420: ...er 100 Speed control open loop External U f on terminal 53 54 or 60 f pulse on terminal 17 or 29 binary serial port Single ref Preset references par 215 218 Setting Parameter Setting Data value 100 Configuration Speed control open loop 0 308 Funct of analogue input Reference 1 309 Min reference signal Min 1 V 310 Max reference signal Max 5 V 203 Reference range Reference range Min Max 0 204 Minimu...

Page 421: ...9 Min reference signal Min 0 V 310 Max reference signal Max 10 V 203 Reference range Reference range Max Max 1 205 Max reference 100 Hz 214 Reference type Sum 0 215 Preset reference 50 200 Output frequency range direction Both directions 0 132 Hz 1 The following can be used Catch up slow down via digital input terminals 16 17 29 32 or 33 Freeze reference via digital input terminals 16 17 29 32 or ...

Page 422: ...e connected either in the form of external or preset reference signals Via parameter 214 these can be combined in three different ways Sum Multi ref Relative External preset In the following each reference type sum relative and external preset is shown SUM MG 51 A1 02 VLT is a registered Danfoss trade mark 88 ...

Page 423: ...VLT 5000 Series RELATIVE EXTERNAL PRESET MG 51 A1 02 VLT is a registered Danfoss trade mark 89 Special functions ...

Page 424: ...nditions For AMA to be able to determine the motor pa rameters optimally the correct nameplate data for the motor connected to the VLT frequency con verter must be entered in parameters 102 to 106 For the best adjustment of the VLT frequency converter it is recommended to carry out AMA on a cold motor Repeated AMA runs may lead to a heating of the motor that will result in an in crease of the stat...

Page 425: ...e cause to the fault related to the alarm message given The figure after the text is the error code which can be seen in the fault log in parameter 615 Automatic motor adaptation does not update param eters You may choose to run a reduced automatic motor adaptation CHECK P 103 105 0 AUTO MOT ADAPT FAIL Parameter 102 103 or 105 has a wrong setting Correct the setting and start AMA all over LOW P 10...

Page 426: ...probably wrong Check the setting and choose Continue or Stop WARNING 40 CHECK P 103 105 The setting of parameter 102 103 or 105 is probably wrong Check the setting and choose Continue or Stop WARNING 41 MOTOR TOO BIG The motor used is probably too big for AMA to be carried out The setting in parameter 102 may not match the motor Check the motor and choose Continue or Stop WARNING 42 MOTOR TOO SMAL...

Page 427: ...etting 7 Open the saved file and select On line 8 Send the file to the VLT frequency converter s that is are to run the automatic motor adaptation programme 9 End Parameter Setup Start of automatic motor adaptation AMA 1 Start Test run 2 Scan for VLT frequency converters and select the relevant frequency converter that has been prepared for automatic motor adaptation 3 Press the Start button in Te...

Page 428: ...rent can be selected which is approx 70 of the magnetising current Parameter 225 Warning Low frequency states the frequency during ramp down at which the mechani cal brake is to close again If Extended mechanical brake control 34 is selected the mechanical brake is closed voltage free during start until the output current is above the level se lected in parameter 223 Warning Low Current During sto...

Page 429: ...VLT 5000 Series MG 51 A1 02 VLT is a registered Danfoss trade mark 95 Special functions ...

Page 430: ...y voltage clockwise3 3 130 Start frequency Set to slip frequency 131 Extra voltage at start Set to rated motor current IM N not higher than 160 of IM N 1 During start and stop the current limit in parame ter 223 decides the switching level 2 This value indicates the frequency during ramp down at which the mechanical brake is to be closed again This assumes that a stop signal has been given 3 It mu...

Page 431: ...6 Relative references can be programmed A relative reference is a percentage value Y of the sum of the external references X This percentage value is added to the sum of the external references which produces the active reference X XY See section Handling of multi references If relative references are to be used parameter 214 is to be set to Relative 1 This makes the preset references relative Fur...

Page 432: ... stabilised Now lower the proportional gain by 40 60 3 Set parameter 441 integration time to 20s and reduce the value until the feedback signal again begins to vary continuously Increase the integra tion time until the feedback signal stabilises followed by an increase of 15 50 4 Only use parameter 442 for very fast acting sys tems only differentiation time The typical value is four times the set ...

Page 433: ...r If are oscillations of the current voltage on the feed back signal these can be dampened by means of a lowpass filter Set a suitable lowpass filter time constant This time constant represents the limit fre quency of the ripples occurring on the feedback signal If the lowpass filter has been set to 0 1s the break frequency will be 10 RAD sec corresponding to 10 2 x 1 6 Hz This will mean that all ...

Page 434: ...ure which is selected in parameter 407 If no function is selected the mains failure procedure will not be car ried out If Controlled ramp down 1 is selected the VLT frequency converter will take the motor down to 0 Hz If Enable 1 has been selected in parameter 408 a quick discharge of the intermediate circuit voltage will be carried out after the motor has stopped Using a digital input it is possi...

Page 435: ...See procedure on previous page Function no 5 The digital input activates the mains failure function regardless of whether the unit receives any supply voltage See the different functions in parameter 407 Function no 6 The mains failure function is activated when the in termediate circuit voltage has dropped to a given value The selected function in case of mains failure is selected in parameter 40...

Page 436: ...find the spinning motor during the search sequence it will carry out a DC braking so as to try to bring the speed of the spin ning motor down to 0 rpm This requires that the DC brake is active via parameters 125 and 126 If Both directions is selected the VLT frequency converter will first find out in which direction the motor rotates and then search for the frequency If the motor is not found the ...

Page 437: ...t be active until the VLT fre quency converter has moved away from the current limit Please note that the motor will not use the ramp down time since terminal 27 must be programmed for Coasting stop inverse 0 or Reset and coasting stop inverse 1 Programming of Torque limit and stop In applications with an external electro mechanical brake such as hoisting applications it is possible to stop the VL...

Page 438: ... 3 has been made 4 Via parameter 003 the local reference can be controlled by means of the Arrow up and Arrow down keys 5 An external control command that can be con nected to terminal 16 17 19 27 29 32 or 33 However 2 or 4 must be selected in parameter 013 See also section Shift between local and remote control 003 003 Local reference LOCAL REFERENCE Value Par 013 set for 1 or 2 0 fMAX 000 000 Pa...

Page 439: ...gardless of the Setup selected as the active Setup and thus controlling the functions of the VLT fre quency converter NB If a general change of data or a copying to the active Setup is effected this immediately affects the functioning of the unit 006 006 Copying of Setups SETUP COPY Value No copying NO COPY 0 Copy to Setup 1 from COPY TO SETUP 1 1 Copy to Setup 2 from COPY TO SETUP 2 2 Copy to Set...

Page 440: ...D HEX 26 Control word Hex CONTROL WORD HEX 27 Warning word 1 Hex WARNING WORD 1 HEX 28 Warning word 2 Hex WARNING WORD 2 HEX 29 Communication option card warning COMM OPT WARN HEX 30 RPM min 1 MOTOR RPM RPM 31 RPM x scaling MOTOR RPM X SCALE 32 Function This parameter allows a choice of the data value to be displayed in line 2 of the display Parameters 010 012 enable the use of three addi tional d...

Page 441: ...ni cation in the Design Guide Warning word 1 Hex indicates one or more warnings in a Hex code See page 160 for further in formation Warning word 2 Hex indicates one or more sta tus states in a Hex code See page 160 for further information Communication option card warning Hex gives a warning word if there is a fault on the communica tion bus Is only active if communication options have been instal...

Page 442: ...p to Re mote control The selected configuration parameter 100 will be active Shifts are effected without any abrupt move ment Shift from Remote control to LCP control as parame ter 100 or LCP digital control as parameter 100 The present reference will be maintained If the ref erence signal is negative the local reference will be set at 0 Shift from LCP control as parameter 100 or LCP re mote contr...

Page 443: ...Forced stop use saved ref LOCAL STOP 1 Forced stop set ref to 0 LOCAL STOP REF 0 2 Function Setting of the desired operating mode when the mains voltage is reconnected This function can only be active in connection with Local control 1 in parameter 002 Description of choice Auto restart use saved ref 0 is selected if the unit is to start up with the same local reference set in parameter 003 and th...

Page 444: ... signal since VLT 5000 accurately calculates the torque on the basis of the current measurement See also connection ex amples in the Design Guide If Torque control speed feedback 5 is selected an encoder speed feedback signal must be connected to the digital terminals 32 33 Parameter 205 Maximum reference and parameter 415 Maximum feedback must be adapted to the ap plication if 1 3 4 or 5 is selec...

Page 445: ... 37 kW 0 37 KW 37 0 55 kW 0 55 KW 55 0 75 kW 0 75 KW 75 1 1 kW 1 10 KW 110 1 5 kW 1 50 KW 150 2 2 kW 2 20 KW 220 3 kW 3 00 KW 300 4 kW 4 00 KW 400 5 5 kW 5 50 KW 550 7 5 kW 7 50 KW 750 11 kW 11 00 KW 1100 15 kW 15 00 KW 1500 18 5 kW 18 50 KW 1850 22 kW 22 00 KW 2200 30 kW 30 00 KW 3000 37 kW 37 00 KW 3700 45 kW 45 00 KW 4500 55 kW 55 00 KW 5500 75 kW 75 00 KW 7500 90 kW 90 00 KW 9000 110 kW 110 00...

Page 446: ... Hz Function This is where the rated motor frequency fM N is se lected nameplate data Description of choice Select a value that equals the nameplate data on the motor Alternatively it is also possible to set the value for motor frequency infinitely variably see procedure on page 53 If a value different from 50 Hz or 60 Hz is selected it is necessary to correct parameters 108 and 109 For 87 Hz oper...

Page 447: ...play will read ALARM 21 Press the STOP RESET key The VLT frequency converter is now ready for opera tion Description of choice Select Enable RS and XS 1 if the VLT frequency converter is to be able to carry out automatic motor adaptation of both the stator resistance RS and the stator reactance XS Select Optimisation on RS 2 if a reduced test is to be carried out in which only the ohmic resistance...

Page 448: ...lculated by connecting a motor to mains and measuring the phase to phase voltage UL as well as the idling current I Alternatively these values can be recorded dur ing operation in idle running state at the rated motor frequency fM N slip compensation par 115 0 and load compensation at high speed par 114 100 XS UL p3xl8 4 The factory settings of XS selected by the VLT frequency converter itself on ...

Page 449: ...ensation at low speed stopped working to max frequency This function is active for Motor size Change over 0 5 kW 7 5 kW 10 Hz 11 kW 45 kW 5 Hz 55 kW 355 kW 3 4 Hz 115 115 Slip compensation SLIP COMPENSAT Value 500 500 100 Function Slip compensation is calculated automatically i e on the basis of the rated motor speed nM N In parameter 115 slip compensation can be ad justed in detail which compensa...

Page 450: ...rt frequency voltage clockwise CLOCKWISE OPERATION 3 Start frequency voltage in reference direction HORIZONT AL OPERATION 4 VVC p l u s clockwise VVC CLOCKWISE 5 Function This is where the desired state during start delay parameter 120 is selected Description of choice Select DC hold in the start delay time 0 so as to energize the motor with a DC holding current pa rameter 124 in the start delay t...

Page 451: ...r closed Select DC hold 1 when a DC holding current set in parameter 124 is to be activated Select Motor check 2 if the VLT frequency con verter is to check whether or not a motor has been connected Select Pre magnetizing 3 The magnetic field is built up in the motor while it remains stopped This ensures that the motor can produce torque as quickly as possible on starting 123 123 Min frequency for...

Page 452: ...ble to monitor the motor temperature in two different ways Via a thermistor sensor connected to one of the analogue inputs terminals 53 and 54 parame ters 308 and 311 Calculation of the thermal load based on the cur rent load and the time This is compared with the rated motor current IM N and the rated motor fre quency fM N The calculations made take into account the need for a lower load at lower...

Page 453: ... g for hoist applications cone rotor motors Description of choice Set the desired start frequency It is assumed that the start function in parameter 121 has been set to 3 or 4 and that a start delay time has been set in parameter 120 also a refer ence signal must be present 131 131 Initial voltage INITIAL VOLTAGE Value 0 0 parameter 103 0 0 Volt Function Some motors such as cone rotor motors need ...

Page 454: ... Hz 1 or Both directions 0 1000 Hz 3 is selected the output frequency will be limited to the range fMAX the minimum frequency is of no significance Example Parameter 200 Output frequency range direction both directions 201 201 Output frequency low limit FMIN OUT FREQ LOW LIM Value 0 0 fMAX 0 0 Hz Function In this parameter a minimum motor frequency limit can be selected that corresponds to the min...

Page 455: ...ax 0 Set the desired value The unit follows the choice of configuration in param eter 100 Speed control open loop Hz Speed control closed loop rpm Torque control open loop Nm Torque control speed feedback Nm Process control closed loop Process units par 416 Special motor characteristics activated in parameter 101 use the unit selected in parameter 100 205 205 Maximum reference MAX REFERENCE Value ...

Page 456: ... 222 Description of choice Program the desired ramp down time 209 209 Ramp up time 2 RAMP UP TIME 2 Value 0 05 3600 sec depends on unit Function See description of parameter 207 Description of choice Program the desired ramp up time Switching from ramp 1 to ramp 2 is effected via a signal on digital input terminal 16 17 29 32 or 33 210 210 Ramp down time 2 RAMP DOWN TIME 2 Value 0 05 3600 sec depe...

Page 457: ...unction to select whether a shift between external references and pre set references is desired Description of choice If Sum 0 is selected one of the adjusted preset references parameters 215 218 is added as a per centage of the maximum possible reference If Relative 1 is selected one of the adjusted preset references parameters 215 218 is added to the ex ternal references as a percentage of the a...

Page 458: ...etween RefMAX and RefMIN following which the value is added to RefMIN Description of choice Set the fixed reference s that is are to be the op tions To use the fixed references it is necessary to have selected Preset ref enable on terminal 16 17 29 32 or 33 Choices between fixed references can be made by activating terminal 16 17 29 32 or 33 see the table below Terminals 17 29 33 preset ref msb Te...

Page 459: ...e max torque depends on the unit and the motor size selected Function This function is relevant for all application configura tions speed process and torque control This is where to set the torque limit for generating operation The torque limiter is active in the fre quency range up to the rated motor frequency parameter 104 In the oversynchronous range where the frequency is higher than the rated...

Page 460: ...Value parameter 225 parameter 202 132 0 Hz Function When the motor frequency is above the limit pro grammed in this parameter fHIGH the display will indicate FREQUENCY HIGH The signal outputs can be programmed to transmit a status signal via terminal 42 or 45 and via relay out put 01 or 04 parameter 319 321 323 or 326 Description of choice The upper signal limit of the motor frequency fHIGH must b...

Page 461: ... 5 Hz and 100 5 Hz i e 1 of 100 Hz 230 230 Frequency bypass 1 FREQ BYPASS 1 231 231 Frequency bypass 2 FREQ BYPASS 2 232 232 Frequency bypass 3 FREQ BYPASS 3 234 234 Frequency bypass 4 FREQ BYPASS 4 Value 0 0 parameter 200 0 0 Hz Function Some systems call for some output frequencies to be avoided because of resonance problems in the system Description of choice Enter the frequencies to be avoided...

Page 462: ...F MSB 6 8 6 Freeze reference FREEZE REFERENCE 7 7 9 7 7 Freeze output FREEZE OUTPUT 8 8 10 8 8 Speed up SPEED UP 9 11 9 Speed down SPEED DOWN 9 12 9 Choice of Setup lsb SETUP SELECT LSB 10 13 10 Choice of Setup msb SETUP SELECT MSB 10 14 10 Choice of Setup msb speed up SETUP MSB SPEED UP 11 Choice of Setup lsb speed down SETUP LSB SPEED DOWN 11 Catch up CATCH UP 11 15 12 Slow down SLOW DOWN 11 16 ...

Page 463: ... only stop if terminal 42 45 01 or 04 has been connected to terminal 27 The data choice on terminal 42 45 01 or 04 must be Torque limit and stop 27 Start is selected if a start stop operating com mand group 2 command is desired Logic 1 start logic 0 stop 002 Latched start if a pulse is applied for min 3 ms the motor will start provided no stop command op erating command group 2 The motor stops if ...

Page 464: ...ed down the reference or the output frequency will be reduced Follow ramp 2 parameter 210 in the range 0 fMIN Pulses logic 1 minimum high for 3 ms and a mini mum pause of 3 ms will lead to a change of speed of 0 1 reference or 0 1 Hz output frequency Example Terminal Freeze ref 16 17 Freeze output No speed change 0 0 1 Speed down 0 1 1 Speed up 1 0 1 Speed down 1 1 1 The speed reference frozen via...

Page 465: ...erminal 17 is 5 kHz Description of choice See parameter 300 302 302 Terminal 18 Start input DIGITAL INPUT 18 Value See parameter 300 Function This parameter allows a choice between the different options on terminal 18 The enabled functions are shown in the table on page 102 Maximum frequency for terminal 18 is 5 kHz Description of choice See parameter 300 303 303 Terminal 19 input DIGITAL INPUT 19...

Page 466: ...ired option on terminal 53 Scaling of the input signal is effected in parameters 309 and 310 Description of choice No operation Is selected if the VLT frequency con verter is not to react to signals connected to the terminal Reference Is selected to enable change of refer ence by means of an analogue reference signal If other inputs are connected these are added up taking account of their signs Fe...

Page 467: ...01 to Output fre quency high limit parameter 202 309 309 Terminal 53 min scaling AI 53 SCALE LOW Value 0 0 10 0 Volt 0 0 Volt Function This parameter is used for setting the signal value that corresponds to the maximum reference value set in parameter 204 Description of choice Set the desired voltage value See also section Handling of single references 310 310 Terminal 53 max scaling AI 53 SCALE H...

Page 468: ...AI 60 SCALE HIGH Value 0 0 20 0 mA 20 0 mA Function This parameter sets the value of the reference signal that is to correspond to the maximum reference value set in parameter 205 Description of choice Set the desired current value See also section Handling of single references 317 317 Time out LIVE ZERO TIME O Value 0 99 sec 10 sec Function If the signal value of the reference signal connected to...

Page 469: ...VE CURRENT LOW 13 13 13 13 Under I high BELOW CURRENT HIGH 14 14 14 14 Out of frequency range OUT OF FREQ RANGE 15 15 15 15 Over f low ABOVE FREQUENCY LOW 16 16 16 16 Under f high BELOW FREQUENCY HIGH 17 17 17 17 Out of feedback range OUT OF FDBK RANGE 18 18 18 18 Over feedback low ABOVE FDBK LOW 19 19 19 19 Under feedback high BELOW FDBK HIGH 20 20 20 20 Thermal warning THERMAL WARNING 21 21 21 2...

Page 470: ...20 mA 48 48 0 IMAX 4 20 mA 0 IMAX 4 20 mA 49 49 0 IMAX 0 32000 p 0 IMAX 0 32000P 50 50 0 TLIM 0 20 mA 0 TLIM 0 20 mA 51 51 0 TLIM 4 20 mA 0 TLIM 4 20 mA 52 52 0 TLIM 0 32000 p 0 TLIM 0 32000P 53 53 0 TNOM 0 20 mA 0 TNOM 0 20 mA 54 54 0 TNOM 4 20 mA 0 TNOM 4 20 mA 55 55 0 TNOM 0 32000 p 0 TNOM 0 32000P 56 56 0 PNOM 0 20 mA 0 PNOM 0 20 mA 57 57 0 PNOM 4 20 mA 0 PNOM 4 20 mA 58 58 0 PNOM 0 32000 p 0 ...

Page 471: ...he feedback signal is out side the range programmed in parameters 227 and 228 Over feedback low the feedback signal is higher than the value set in parameter 227 Under feedback high the feedback signal is lower that the value set in parameter 228 Thermal warning above the temperature limit in ei ther the motor the VLT frequency converter the brake resistor or the thermistor Ready no thermal warnin...

Page 472: ...the interval FBMIN FBMAX parameters 414 415 is obtained 0 IVLT MAX 0 20 mA or 0 IVLT MAX 4 20 mA and 0 IVLT MAX 0 32000 p an output signal propor tional to the output current in the interval 0 IVLT MAX is obtained IVLT MAX depends on the settings in pa rameter 101 and 103 and can be seen from the Technical data IVLT MAX 60 s 0 MLIM 0 20 mA and 0 MLIM 4 20 mA and 0 MLIM 0 32000 p an output proporti...

Page 473: ...led Activation deactivation can be delayed in parameter 324 325 Description of choice See description of parameter 319 Connections see the below drawing 324 324 Relay 01 ON delay RELAY 1 3 ON DL Value 0 00 10 00 min 0 00 sec Function This parameter allows a delay of the cut in time of relay 01 terminals 01 02 Description of choice Enter the desired value can be set at intervals of 0 02 sec 325 325...

Page 474: ...only available in Speed control closed loop and in Torque control speed feedback parameter 100 Description of choice Read the correct value from the encoder Pay atten tion to the speed limitation rpm for a given number of pulses rpm see the drawing below The encoder used is to be of the Open Collector PNP 0 24 V DC type max 20 kHz or a Push Pull circuit 0 24 V DC max 65 kHz 330 330 Freeze referenc...

Page 475: ...llowing priority to the time out function 1 Parameter 318 Function after time out 2 Parameter 346 Function after encoder loss 3 Parameter 514 Bus time interval function Description of choice The output frequency of the VLT frequency converter can be frozen at the present value overruled to jog frequency overruled to max frequency overruled to stop with subsequent trip overruled to Setup 4 357 357 ...

Page 476: ... the desired output current at a value be tween 0 100 of the full scale output program the percentage value in the parameter i e 50 20 mA If a current between 4 and 20 mA is desired at maxi mum output 100 the percentage value to program in the drive is calculated as 0mA desired maximum c urrent 3 100 i e 0mA 20 10 3 100 200 factory setting display text value for use in communication via serial com...

Page 477: ...requency converter will not stop in the case of a stop command when the overvolt age control is active Select Overvoltage control and stop 3 if the over voltage control function is not required during ramp down after stop has been pressed Warning If Overvoltage control 2 is used at the same time as the supply voltage to the VLT frequency converter is close to or above the maximum limit there is a ...

Page 478: ...ontinue the brake check 2 If the intermediate circuit voltage is unstable dis continue the brake check 3 Carry out a brake test 4 If the intermediate circuit voltage is lower than the starting voltage discontinue the brake check 5 If the intermediate circuit voltage is unstable dis continue the brake check 6 If the braking power is higher than 100 discon tinue the brake check 7 If the intermediate...

Page 479: ...back up have lim ited perfomance above 70 load Description of choice Select No function 0 if this function is not required If Controlled ramp down 1 is selected the motor will ramp via the quick stop ramp set in parameter 212 If the supply voltage is re established during ramp down the VLT frequency converter will start up again If Controlled ramp down and trip 2 is se lected the motor will ramp v...

Page 480: ...actory setting the unit may report a fault when the mains voltage is turned on 411 411 Switching frequency SWITCH FREQ Value Depends on the unit output Function The set value determines the switching frequency of the inverter If the switching frequency is changed this may help to minimise possible acoustic noise from the motor NB The output frequency of the VLT frequency converter can never assume...

Page 481: ...ed together with Speed control closed loop Pro cess control closed loop and Torque control speed feedback parameter 100 Description of choice Is only active when parameter 203 has been set to Min Max 0 Set the value to be shown on the display when Mini mum feedback is obtained on the selected feedback input parameter 308 or 314 The minimum value can be limited by the choice of configuration parame...

Page 482: ...LCP control and open loop or LCP digital control and open loop the ref erence will be given in Hz regardless of the choice made in parameter 416 A feedback or process sig nal connected to terminal 53 60 or 33 pulse will however be displayed in the form of the unit se lected in parameter 416 If parameter 013 is chosen as LCP control as par 100 or LCP digital control as par 100 the unit will be as d...

Page 483: ... TIME Value 5 200 ms 10 ms Function Oscillations on the feedback signal are dampened by a lowpass filter so as to reduce their influence on control This might be an advantage e g if there is a great amount on noise on the system See draw ing Used together with Speed control closed loop and Torque control speed feedback parameter 100 Description of choice If a time constant e g of 100 ms is program...

Page 484: ...n parameter 426 See drawing for parameter 422 426 426 F 2 frequency F2 FREQUENCY Value par 424 par 428 Factory setting of par 104 Function This parameter sets the X value of the 2nd break point Description of choice Set the frequency desired at the U2 voltage set in parameter 425 See drawing for parameter 422 427 427 U 3 voltage U3 VOLTAGE Value 0 0 UVLT MAX Factory setting of par 103 Function Thi...

Page 485: ...ter is not limited by parameter 200 Description of choice Set the frequency desired at the U5 voltage set in parameter 431 See drawing for parameter 422 433 433 Torque control open loop proportional gain TOR OL PROP GAIN Value 0 Off 500 100 Function The proportional gain indicates how many times the error the deviation between feedback signal and set point is to be applied Used together with Torqu...

Page 486: ...ge again until either the error is zero or its sign has changed Select Disable 0 if the integrator is to continue integrating on an error even if it is not possible to re move the fault by such control NB If Disable 0 is selected it will mean that when the error changes its sign the integrator will first have to integrate down from the level ob tained as a result of the former error before any cha...

Page 487: ...meter 100 Description of choice Quick control is obtained with a long differentiation time However this time may become too long which can make the process unstable 443 443 Process PID diff gain limit PROC DIFF GAIN Value 5 0 50 0 5 0 Function It is possible to set a limit for the differentiator gain The differentiator gain will increase if there are fast changes which is why it can be beneficial ...

Page 488: ...with cali bration of the VLT frequency converter By adjusting parameter 447 Torque compensation the output torque can be calibrated See section Setting of parameters torque regulation speed feedback Description of choice Set the required value 448 448 Torque speed feedback Gear ratio with en coder TOR SF GEARRATIO Value 0 001 100 000 1 000 Function This parameter is only used if Torque control spe...

Page 489: ... 1 00 Please note that this parameter only has influence on the encoder loss function Description of choice Set the required value 454 454 Dead time compensation DEADTIME COMP Value Off OFF 0 On ON 1 Function The active inverter dead time compensation which is part of the VLT 5000 control algorithm VCC is causing instability at standstill when working in closed loop control The purpose of this par...

Page 490: ... Warning has been selected the life expectancy of the drive will be reduced when the mains failure persists NB At phase loss the internal cooling fans of some drive types cannot be powered In or der to avoid overheating an external power supply can be connected to VLT 5032 5052 200 240 V and VLT 5075 5500 380 500 V see Electrical in stallation factory setting display text value for use in communic...

Page 491: ...ssion time proper which is determined by the set baud rate is only part of the total commu nication time 502 502 Coasting COASTING SELECT 503 503 Quick stop Q STOP SELECT 504 504 DC brake DC BRAKE SELECT 505 505 Start START SELECT 507 507 Selection of Setup SETUP SELECT 508 508 Selection of speed PRES REF SELECT Value Digital input DIGIT AL INPUT 0 Bus SERIAL PORT 1 Logic and LOGIC AND 2 Logic or ...

Page 492: ...a fixed speed jog that is acti vated via the serial communication port This function is the same as in parameter 213 Description of choice The jog frequency fJOG can be selected in the range between fMIN parameter 201 and fMAX pa rameter 202 510 510 Bus jog 2 BUS JOG 2 FREQ Value 0 0 parameter 202 10 0 Hz Function This is where to set a fixed speed jog that is acti vated via the serial communicati...

Page 493: ... reaction of the VLT frequency converter when the set time for bus timeout parameter 513 has been exceeded If choices 1 to 5 are activated relay 01 and relay 04 will be de activated If more time outs occur at the same time the VLT frequency converter will give the following priority to the time out function 1 Parameter 318 Function after time out 2 Parameter 346 Function after encoder loss 3 Param...

Page 494: ...2 MIN kW 536 Brake power sec BRAKE ENERGY S kW 537 Heat sink temperature HEATSINK TEMP C 1 2 sec 538 Alarm word ALARM WORD HEX Hex code 20 msec 539 VLT control word CONTROLWORD HEX Hex code 2 msec 540 Warning word 1 WARN WORD 1 Hex code 20 msec 541 Extended status word Hex EXT STATUS WORD Hex code 20 msec 557 Motor RPM MOTOR RPM RPM 80 msec 558 Motor RPM x scaling MOTOR RPM X SCALE 80 msec Functio...

Page 495: ...ed for con trolling the motor DC link voltage parameter 525 The value shown is a measured value The value is filtered which means that approx 1 3 seconds may pass from an input value changes until the data read out changes values Motor temp parameter 526 VLT temp parameter 527 Only whole numbers are displayed Digital input parameter 528 The value shown indicates the signal status from the 8 digita...

Page 496: ...orma tion Warning word 1 parameter 540 States in Hex format whether there is a warning on the VLT frequency converter See section Warning word 1 Extended status word and Alarm word for further information Extended status word Hex parameter 541 States in Hex format whether there is a warning on the VLT frequency converter See section Warning word 1 Extended status word and Alarm word for further in...

Page 497: ...there has been on the VLT frequency converter No of overvoltages parameter 605 States the number of overvoltages there has been on the VLT frequency converter Parameter no Description Data log Display text Unit Range 606 Digital inputs LOG DIGITAL INP Decimal 0 255 607 Control word LOG CONTROL WORD Decimal 0 65535 608 Status word LOG BUS STAT WD Decimal 0 65535 609 Reference LOG REFERENCE 0 100 61...

Page 498: ...he value of the DC link voltage is stated as Volts in the interval 0 0 999 9 V 615 615 Fault log Error code F LOG ERROR COD Value Index 1 10 Error code 0 44 Function This parameter makes it possible to see the reason why a trip occurs 10 0 10 log values are stored The lowest log number 1 contains the latest most recently saved data value the highest log number 10 contains the oldest data value Des...

Page 499: ...3 605 can be initialised This function will not become active until the mains supply to the VLT frequency converter has been turned off and then turned on again Description of choice Normal function 0 is selected for normal operation with the motor in the selected application Function with deactivated inverter 1 is selected if control is desired over the influence of the control signal over the co...

Page 500: ...umber LCP ID NO 626 Database identification number PARAM DB ID 627 Power section identification number POWER UNIT DB ID 628 Application option type APP OPTION 629 Application option ordering number APP ORDER NO 630 Communication option type COM OPTION 631 Communication option ordering number COM ORDER NO Function The key data of the unit can be read out via the dis play or the serial communication...

Page 501: ...pplication option ordering number parameter 629 This gives the ordering number for the application option Communication option type parameter 630 This gives the type of communication options fitted with the VLT frequency converter Communication option ordering number parame ter 631 This gives the ordering number for the communica tion option factory setting display text value for use in communicat...

Page 502: ...4 Relay 7 ON delay RELAY7 ON DELAY 707 707 Relay 8 ON delay RELAY8 ON DELAY 710 710 Relay 9 ON delay RELAY9 ON DELAY Value 0 600 sec 0 sec Function This parameter allows a delay of the cut in time of relays 6 7 8 9 terminals 1 2 Description of choice Enter the required value 702 702 Relay 6 OFF delay RELAY6 OFF DELAY 705 705 Relay 7 OFF delay RELAY7 OFF DELAY 708 708 Relay 8 OFF delay RELAY8 OFF D...

Page 503: ...VLT 5000 Series factory setting display text value for use in communication via serial communication port MG 51 A1 02 VLT is a registered Danfoss trade mark 169 Programming ...

Page 504: ...back low ABOVE FDBK LOW 19 19 19 19 Under feedback high BELOW FDBK HIGH 20 20 20 20 Thermal warning THERMAL WARNING 21 21 21 21 Ready no thermal warning READY NOTHERM WARN 22 22 22 22 Ready remote control no therm warn REM RDY NO THERMWAR 23 23 23 23 Ready mains voltage within range RDY NO OVER UNDERVOL 24 24 24 24 Reversing REVERSE 25 25 25 25 Bus ok BUS OK 26 26 26 26 Torque limit and stop TORQU...

Page 505: ...anfoss for assistance If no check if the control card is overloaded If so disconnect all control signal plugs on the control card and check if the fault disappears If yes make sure that the 24 V supply is not short circuited If no call Danfoss for assistance 5 Motor stopped light in display but no fault report Start the VLT by pressing START on the control panel Check if the display is frozen ie t...

Page 506: ...AX The brake is functioning Optimum braking is effected when the value in pa rameter 402 Braking power limit KW is exceeded Braking BRAKING The brake is functioning Ramp operation REM RAMPING Remote has been selected in parameter 002 and the output frequency is changed in accordance with the ramps set Ramp operation LOCAL RAMPING Local has been selected in parameter 002 and the output frequency is...

Page 507: ...e terminal in question 16 17 29 32 or 33 has been activated or possibly via the serial com munication port Jog operation local LOCAL RUN JOG Local has been selected in parameter 002 and Jog in parameter 300 301 305 306 or 307 and the ter minal in question 16 17 29 32 or 33 has been activated or possibly via the serial communication port Overvoltage control OVER VOLTAGE CONTROL The intermediate cir...

Page 508: ...ended units supplied with a 24 V DC supply the message also comes up when there is not mains supply Bus jog remote controlled REM RUN BUS JOG1 Remote control has been selected in parameter 002 and the Fieldbus has been selected in parameter 512 Bus Jog has been selected by the fieldbus or serial bus Bus jog remote controlled REM RUN BUS JOG2 Remote control has been selected in parameter 002 and Fi...

Page 509: ...being ready Wherever a cross is placed under both Warning and Alarm this can mean that a warning precedes the alarm It can also mean that it is possible to program whether a given fault is to result in a warning or an alarm This is possible e g in parameter 404 Brake check After a trip alarm and warning will flash but if the fault is removed only alarm will flash After a reset the VLT frequency co...

Page 510: ... CARD X 21 Auto optimisation OK AUTO MOTOR ADAPT OK X 22 Auto optimisation not OK AUTO MOT ADAPT FAIL X 23 Brake test failed BRAKE TEST FAILED X X 25 Brake resistor short circuited BRAKE RESISTOR FAULT X 26 Brake resistor power 100 BRAKE POWER 100 X X 27 Brake transistor short circuited BRAKE IGBT FAULT X 29 Heat sink temperature too high HEAT SINK OVER TEMP X X 30 Motor phase U missing MISSING MO...

Page 511: ...too high This mesage can also appear if there is a fault in the input rectifier on the VLT frequency converter Check the supply voltage and supply currents to the VLT frequency converter WARNING 5 Voltage warning high DC LINK VOLTAGE HIGH The intermediate circuit voltage DC is higher than the overvoltage limit of the control system The VLT frequency converter is still active WARNING 6 Voltage warn...

Page 512: ...nverter is to give a warning or an alarm when the counter reaches 100 The fault is that the motor is overloaded by more than 100 for too long Check that motor pa rameters 102 106 have been set correctly WARNING ALARM 11 Motor thermistor MOTOR THERMISTOR The thermistor or the thermistor connection has been disconnected Parameter 128 allows a choice of whether the VLT frequency converter is to give ...

Page 513: ...isplay indicates a fault message The figure after the text is the error code which can be seen in the fault log in parameter 615 CHECK P 103 105 0 See section Automatic motor adaptation AMA LOW P 105 1 See section Automatic motor adaptation AMA ASYMMETRICAL IMPEDANCE 2 See section Automatic motor adaptation AMA MOTOR TOO BIG 3 See section Automatic motor adaptation AMA MOTOR TOO SMALL 4 See sectio...

Page 514: ...verter and motor is missing Turn off the VLT frequency converter and check mo tor phase U ALARM 31 Motor phase V missing MISSING MOT PHASE V Motor phase V between VLT frequency converter and motor is missing Turn off the VLT frequency converter and check mo tor phase V ALARM 32 Motor phase W missing MISSING MOT PHASE W Motor phase W between VLT frequency converter and motor is missing Turn off the...

Page 515: ...OO SMALL The motor used is probably too small for AMA to be carried out The setting in parameter 102 may not match the motor Check the motor and choose Continue or Stop ALARM 43 Brake fault BRAKE FAULT A fault has arisen on the brake The text shown in the display indicates a fault message The figure af ter the text is the fault code that can be seen in the fault log parameter 615 Brake check faile...

Page 516: ...2000 Voltage warning high 004000 Phase fault 008000 No motor 010000 Live zero fault 4 20 mA current signal low 020000 10 Volts low 040000 080000 Brake resistor power 100 100000 Brake resistor fault 200000 Brake transistor fault 400000 Out of frequency range 800000 Fieldbus communication fault 1000000 2000000 Mains failure 4000000 Motor too small 8000000 Motor too big 10000000 Check P 103 and P 105...

Page 517: ...it 002000 Motor thermistor 004000 Motor overload 008000 Inverter overload 010000 Undervoltage 020000 Overvoltage 040000 Phase fault 080000 Live zero fault 4 20 mA current signal low 100000 Heat sink temperature too high 200000 Motor phase W missing 400000 Motor phase V missing 800000 Motor phase U missing 1000000 Quick discharge not ok 2000000 Fieldbus communication fault 4000000 Mains failure 800...

Page 518: ...versing Jog and Freeze output Group 1 functions are called Start disable com mands The difference between group 1 and group 2 is that in group 1 all stop signals must be cancelled for the motor to start The motor can then be started by means of a single start signal in group 2 A stop command given as a group 1 command re sults in the display indication STOP A missing stop command given as a group ...

Page 519: ...detachable and may as an alternative be installed up to 3 metres away from the frequency converter i e in a front panel by means of the installation kit option VVCp l u s If compared with standard voltage frequency ratio control VVCp l u s improves the dynamics and the sta bility both when the speed reference is changed and in relation to the load torque Slip compensation Normally the motor speed ...

Page 520: ...tion Automatic motor adjustment AMA Automatic motor adjustment algorithm which deter mines the electrical parameters for the connected motor at standstill On line off line parameters On line parameters are activated immediately after the data value is changed Off line parameters are not activated until OK has been entered on the con trol unit VT characteristics Variable torque characteristics used...

Page 521: ...0 5 017 Local reset of trip Possible Yes Yes 0 5 018 Lock for data change Not locked Yes Yes 0 5 019 Operating state at power up local control Forced stop use saved ref Yes Yes 0 5 Changes during operation Yes means that the parameter can be changed while the VLT frequency converter is in operation No means that the VLT frequency converter must be stopped before a change can be made 4 Setup Yes me...

Page 522: ... speed 100 0 300 Yes Yes 0 6 114 Load compensation at high speed 100 0 300 Yes Yes 0 6 115 Slip compensation 100 500 500 Yes Yes 0 3 116 Slip compensation time con stant 0 50 s 0 05 1 00 s Yes Yes 2 6 117 Resonance dampening 100 0 500 Yes Yes 0 6 118 Resonance dampening time constant 5 ms 5 50 ms Yes Yes 3 6 119 High starting torque 0 0 sec 0 0 0 5 s Yes Yes 1 5 120 Start delay 0 0 sec 0 0 10 0 s ...

Page 523: ... Yes Yes 0 5 215 Preset reference 1 0 00 100 00 100 00 Yes Yes 2 3 216 Preset reference 2 0 00 100 00 100 00 Yes Yes 2 3 217 Preset reference 3 0 00 100 00 100 00 Yes Yes 2 3 218 Preset reference 4 0 00 100 00 100 00 Yes Yes 2 3 219 Catch up slow down value 0 00 0 00 100 Yes Yes 2 6 220 221 Torque limit for motor mode 160 0 0 xxx Yes Yes 1 6 222 Torque limit for regenerative operation 160 0 0 xxx ...

Page 524: ...60 max scaling 20 0 mA 0 0 20 0 mA Yes Yes 4 5 317 Time out 10 sec 1 99 sec Yes Yes 0 5 318 Function after time out Off Yes Yes 0 5 319 0 IMAX Þ 0 20 mA Yes Yes 0 5 320 Terminal 42 output pulse scal ing 5000 Hz 1 32000 Hz Yes Yes 0 6 321 Terminal 45 output 0 fMAX Þ 0 20 mA Yes Yes 0 5 322 Terminal 45 output pulse scal ing 5000 Hz 1 32000 Hz Yes Yes 0 6 323 Relay 01 output Ready no thermal warning ...

Page 525: ...ation function On Yes Yes 1 5 414 Minimum feedback 0 000 100 000 000 FBHIGH Yes Yes 3 4 415 Maximum feedback 1500 000 FBLOW 100 000 000 Yes Yes 3 4 416 Process unit Yes Yes 0 5 417 Speed PID proportional gain 0 015 0 000 0 150 Yes Yes 3 6 418 Speed PID integration time 8 ms 2 00 999 99 ms Yes Yes 4 7 419 Speed PID differentiation time 30 ms 0 00 200 00 ms Yes Yes 4 6 420 Speed PID diff gain ratio ...

Page 526: ...ain 0 01 0 00 10 00 Yes Yes 2 6 441 Process PID integral time 9999 99 sec OFF 0 01 9999 99 sec Yes Yes 2 7 442 Process PID differentiation time 0 00 sec OFF 0 00 10 00 sec Yes Yes 2 6 443 Process PID diff gain limit 5 0 5 0 50 0 Yes Yes 1 6 444 Process PID lowpass filter time 0 01 0 01 10 00 Yes Yes 2 6 445 Flying start Disable Yes Yes 0 5 446 Switching pattern SFAVM Yes Yes 0 5 447 Torque compens...

Page 527: ...rent No No 2 7 521 Data read out Torque No No 1 3 522 Data read out Power kW No No 1 7 523 Data read out Power HP No No 2 7 524 Data read out Motor voltage No No 1 6 525 Data read out DC link voltage No No 0 6 526 Data read out Motor temp No No 0 5 527 Data read out VLT temp No No 0 5 528 Data read out Digital input No No 0 5 529 Data read out Terminal 53 analogue input No No 2 3 530 Data read out...

Page 528: ...urrent No No 2 3 614 Data log DC link voltage No No 0 6 615 Fault log Error code No No 0 5 616 Fault log Time No No 1 7 617 Fault log Value No No 0 3 618 Reset of kWh counter No reset Yes No 0 5 619 Reset of hours run counter No reset Yes No 0 5 620 Operating mode Normal function Normal function No No 0 5 621 Nameplate VLT type No No 0 9 622 Nameplate Power section No No 0 9 623 Nameplate VLT orde...

Page 529: ...ion Motor running Yes Yes 0 5 704 Relay 7 ON delay 0 sec 0 00 600 sec Yes Yes 2 6 705 Relay 7 OFF delay 0 sec 0 00 600 sec Yes Yes 2 6 706 Relay 8 function Mains ON Yes Yes 0 5 707 Relay 8 ON delay 0 sec 0 00 600 sec Yes Yes 2 6 708 Relay 8 OFF delay 0 sec 0 00 600 sec Yes Yes 2 6 709 Relay 9 function Fault Yes Yes 0 5 710 Relay 9 ON delay 0 sec 0 00 600 sec Yes Yes 2 6 711 Relay 9 OFF delay 0 sec...

Page 530: ... speed up down 68 Direction of motor rotation 63 Display 71 Display mode 72 Display mode selection of read outstate 73 Display read out state 72 E Earthing of braided screened armouredcontrol cables 58 Electrical installation 47 67 Electrical installation enclosures 51 52 53 54 Electrical installation power cables 48 49 50 Enclosure protection 41 Encoder connection 69 External 24 volt dc supply 11...

Page 531: ...of indexed parameters 77 Relay outputs 11 11 RFI switch 60 S Safety earthing 59 Safety regulations 4 Selection of brake resistor 84 Setting of parameters 79 Setup change 68 Shift between local and remote control 83 Status messages 172 Structure for the Quick menu mode versusthe Menu mode 74 Switches 1 4 66 T Tightening up torques and screw sizes 59 Torque characteristics 8 8 Two wire transmitter 6...

Page 532: ...Niro Soavi S p A SECTION 7 SUPPLIERS CATALOGUE INDEX 7 1 SUB SUPPLIERS AND COMPONENTS CATALOGUE 7C001E0C DOC 7 1 0 ...

Page 533: ...e included copies of the suppliers catalogues and of components installed in the machine In addition to the maintenance guidelines provided in this USE AND MAINTENANCE MANUAL you should refer to the specific instructions of any installed components 7C001E0C DOC 7 1 1 ...

Page 534: ...ons in industrial areas additional protection measures if necessary for different employs must be adopted and assured by the person responsible for the installation IMPORTANT the components supplied by ROSSI MOTORIDUTTORI must be incorporated into machinery and should not be commis sioned before the machinery in which the components have been incorporated conforms to Machinery directive 98 37 EEC ...

Page 535: ...ot use motor eyebolts when lifting the gearmotors Position the gear reducer or gearmotor so as to allow a free passage of air for cooling both gear reducer and motor especially at their fan side Avoid any obstruction to the air flow heat sources near the gear re ducer that might affect the temperature of cooling air and of gear re ducer for radiation insufficient air recycle and applications hinde...

Page 536: ...ical catalogues When installing and removing gear reducers with hollow low speed shaft incorporating a circlip groove whether with keyway or shrink disc proceed as per fig 4a and 4b respectively on page 16 In order to remove the hol low low speed shaft of the parallel and right angle shaft gear reducers this is the first operation to per form when disassembling the gear reducer turn the shaft unti...

Page 537: ... having the ISO viscosity grade given in the table FILLED WITH SYNTHETIC GREASE SHELL Tivela Compound A IP Telesia Compound A MOBIL Glygoyle Grease 00 Filler drain plug only for coaxial FILLED WITH SYNTHETIC OIL KLÜBER Klübersynth GH 6 220 MOBIL Glygoyle 30 Filler drain plug 2 filler drain plugs for sizes 80 81 WITHOUT OIL except different statement on lubrication name plate Filler plug with valve...

Page 538: ... shaft gear reducers cat G and L an for non continuous duties R I R 2I MR 2I R 3I MR 3I MR 4I Parallel B31 B7 B6 B31 B62 B7 B31 B6 B7 B31 B6 B7 V53 size B8 V5 V6 B8 V5 V6 B8 V53 V6 B8 V6 50 0 6 0 9 0 8 0 7 1 05 0 9 63 64 0 7 0 8 1 0 9 1 4 1 2 1 1 5 1 3 1 1 1 8 1 4 1 3 80 1 2 1 5 1 9 1 5 2 7 2 3 1 7 2 9 2 5 1 9 3 2 2 7 2 5 Right R CI MR CI R ICI MR ICI MR C3I angle B31 B8 V5 B31 B6 B8 V5 B31 B6 B8 ...

Page 539: ...equently according to environment and use a all external surfaces are clean and air passages to the gear reducer or gearmotor are free in order that cooling remains fully effective b normal running conditions oil level and deterioration degree check with cold gear reduc er at rest noise level vibrations sealings correct fastening screws tightening etc Attention After a running period gear reducer ...

Page 540: ... TORI Inefficient or out of service oil cooling system obstructed filter insufficient oil exchanger or water coil flow rate pump out of service etc Check the pump the pipes the oil filter and safety devices effi ciency manostats thermo stats etc One or more teeth with dents or spallings excessive flanks roughness Consult ROSSI MOTORIDUT TORI Bearings failure defect or bad lubrication Consult ROSSI...

Page 541: ...ng fig 4b Axial fastening Fitting with key and locking rings fig 4e with key and locking bush fig 4f Fitting with shrink disk fig 4g fig 4a fig 4c fig 4e fig 4g Worm sizes 32 50 Parallel and right angle shaft size 50 Worm sizes 32 50 Parallel and right angle shaft size 50 Parallel and right angle shafts size 63 Parallel and right angle shaft sizes 50 125 Parallel and right angle shaft sizes 140 36...

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Page 545: ...14kg Grommet style Weight Bracket DXT152 25 1A with screws Accessories options Effective area mm2 3 Cv 4 Port size P A 3 9 0 21 3 9 0 21 A R 3 9 0 21 4 0 0 22 A P 3 5 0 19 4 2 0 23 R A 3 6 0 20 3 8 0 21 Rc PT Rc PT Option Note 1 Based on dynamic performance test JIS B8374 1981 Coil temperature 20Co at rated voltage without surge voltage suppressor Note 2 Impact resistance No malfunction resulted f...

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Page 552: ...round GND To1 kjground FG Cables to be used Use 0 5 1 5 mm2 2 core 3 core or 4 core shielded cables far power supply signal output and monitoring according to the required number of cores The shielded cable should be connected to the ground either on the signal generator side or on the electropneumatic regulator side Basically the electropneumatic regulator should be installed in a noiseless or sh...

Page 553: ...ltd SINGAPORE SMC Pneumatics S E A Pte ltd PHILIPPINES SMC Pneumatics Philippines Inc MALAYSIA SMC Pneumatics S E A Sdn Bhd Oceania AUSTRALIA SMC Pneumatics Australia Pty ltd NEW ZEALAND SMC Pneumatics N l ud ENGLAND SMC Pneumatics U K Ltd GERMANY SMC Pneumatik GmbH ITALY SMC Italia S R L FRANGE SMC Pneumatique SA HOLLAND SMC Controls BV SWEDEN SMC Pneumatics Sweden A B SWITZERLAND SMC Pneumatik A...

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