Westinghouse IQ-2000 User Manual Download Page 1

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Summary of Contents for IQ-2000

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Page 3: ...to be covered by these instructions If further information is desired by purchaser regarding his particular installation operation or maintenance of his equipment the local Westinghouse Electric Corporation representative should be contacted Effective April 1985 Copyright 0 1985 Westinghouse Electric Corporation Control Dlvism Asheville NC 28813 First Printing February 1986 ...

Page 4: ...Temperature Ground Fault Instantaneous Overcurrent Locked Rotor Current 1 Long Acceleration Jam Underload Start 1 Underload Run Ultimate Trip 4 2 1 4 2 2 4 3 4 3 1 4 3 2 4 4 4 5 4 6 5 5 0 5 1 5 1 1 5 1 2 Sequencing Checks 23 Power Off 23 Control Power Only 23 Entering Setpoints 23 Setpolnt Record Sheet 23 Value Entry 24 Initial Control Checkout 25 lmtlal Motor Startup 26 lnitlal Main Power on 26 A...

Page 5: ...rt Cycle Events Diagram 34 Motor Stop Cycle Events Chart 37 Three Wire Momentary Pushbutton Control with Time Delay Undervoltage Function 3 8 AC Interrupt Events Flow Chart 39 RTDWiring 4 3 Long Acceleration Events Diagram 48 Pre start Events Diagram 50 Pre run Events Diagram 51 Pre stop Events Diagram 52 Incomplete Sequence Events Diagram 52 Time Undervoltage Timing 53 Post start Events Diagram 5...

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Page 7: ...e switch l Allow for external warmng devices when approaching setpoint thresholds l Provides protection against program tampering while allowmg the monitonng of programmed setpoints l Communication data port l Mlmmizes shut downs for noncritical reasons l All metering data trip data status annunciation setpoints and dlagnostlc data is available for remote analysis Table 1 6 COMMUNICATION ARRANGEME...

Page 8: ...lrsted in Table 1 C 1 3 Hardware Familiarization The purpose of this Para graph is to familiarize the user with the main hardware features of the IQ 2000 A complete description of the Oper ator Panel and the functions of each pushbutton IS given in Chapter 4 The IQ 2000 mounts in an optional enclosure as shown in the typical installation of Figure 1 2 Observe the Figure and note the following expl...

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Page 11: ...s information about motor current line voltage and ground fault current as well as control inputs such as motor starting and stopping commands See Figure 2 1 Optionally RTD inputs supply temperature data The motor current is derived from 3 sepa rate current transformers which monitor each of 3 phases of the AC line to the motor Optionally 3 phase potential trans formers may be used to monitor the ...

Page 12: ...ection Par 2 22 2 2 1 Load Association Protection The value of the mo tor current is used to detect the instantaneous overcurrent jam and underload setpoint functions Information from the load bearing RTDs IS compared with the setpoint values to Initiate an alarm and or a trip condition Note all the setpoint functions are described in detail in Chapter 6 2 2 2 Rotor Temperature Protection Each mot...

Page 13: ...nal heating caused by the negative sequence With the use of a microprocessor the effects of both the posi tive and negative sequence are accurately taken into account Their combined effect is incorporated into a rotor protec tlon algorithm The algorithm is really a microprocessor based program which effectively keeps track of the tempera ture of the rotor It is not necessary to pick an arbitrary p...

Page 14: ...r bining the effects of time and RMS current positive and nega and coordinates the energizing and de energizing of the con tive sequence Into a single protective system The addition tactor and auxiliary control relays of the optional Resistance Temperature Detection RTD Module is also factored Into the rotor protective algorithm This results in a multi dimensional model allowing full motor utiliza...

Page 15: ...chine or process equipment Section 3 INSTALLATION 3 3 1 Wire Routing When routing wires between the Amp gard or other starter and the associated machine or process equipment follow these guidelines Insure that the lncommg AC power and all foreign power sources are turned OFF and locked out before per r 1 forming any work on the motor starter or IQ 2000 Failure to observe this practice can result i...

Page 16: ...IQ 2000 CT TD 11 720 B 73 Figure 3 1 Ampgard Schematic Model B typical 14 ...

Page 17: ...y at the RTD Module Use shrink tubing or electrical tape to Insure that the shields do not make accidental contact with ground or other terminals at the RTD end 3 3 3 Grounding A typical grounding plan for a starter is 15 shown n Figure 3 5 Note carefully these guldeline before maklng grounding connections Guideline 7 Install an equipment grounding conductor between the motor starter s ground stud...

Page 18: ... shielded cable s conductors must be connected on IQ 2000 as shown 3 Use of 3 lead RTDs is recommended 3i RTDs must not be grounded at the motor and no common connections between RTDs should be made at the IQ 2OOt or the motor 4 If motor or load bearing RTDs are used they must be the same ohmic value and material During the monitoring operation the load bearing and motor beanng temperatures are di...

Page 19: ...to remove AC power to the IQ 2000 and the low voltage control circuit of the motor starter Verify that all foreign external power sources are dis connected from the starter cabinet Open the access door to the low voltage compartment Examine the wmng terminals of the draw out panel Look for foreiqn material pieces of wire screws Check screws Verify that unused RTD Module inputs if any are jum pered...

Page 20: ...tch etc nections Note if the control device is a programmable controller I If a field device as shown in dashed lines is to bs its signal must energize a control relay and its dry con installed remove the associated jumpers as shown in tact wired to the 02000 solid lines during installation Figure 3 6 Jumper and Field Wiring Typical 18 ...

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Page 22: ...associated with these selected functions WIII be displayed When monitonng characteristics the RUN PROGRAM keyswitch must be In the RUN position Refer to Chapter 7 for a complete description 4 1 Operator Panel Description The Operator Panel is primarily controlled by the RUN PROGRAM keyswitch which provides 2 modes of operation Run Mode When the keyswltch is in the RUN posItIon normal operation of ...

Page 23: ...run mode Error and status messages A complete listing of mes sages is given in Chapter 7 Troubleshooting l Trip alarm and time setpoint values that cause the trip alarm condrtion to be displayed in the run mode In thus Instance the SET POINTS LED indicator on the Operator Panel lights to Indicate that the values displayed are setpoint values 4 1 3 VALUES Windows There are 3 numerical VALUES window...

Page 24: ...ushbutton De press the appropriate ADJUST pushbutton immediately to modify the value l Monitoring When in the run mode depress the CYCLE SELECT pushbutton to cause the IQ 2000 to sequence through each electrical characteristic Each of these will be dlsplayed for approximately 6 seconds After all charactenstics have been displayed the sequencing stops 4 1 7 RUN PROGRAM LEDs The red RUN and PRO GRAM...

Page 25: ...present Alternately with a motor starter other than Ampgard tem porarily connect 120 VAC 150 a power to the IQ 2000 This action insures that the low voltage control circuit also has 120 VAC applied Note the low voltage control circuit refers to any low voltage circuitry associated with the coil of the motor s contactor 4 2 2 Control Power Only These checks are to be per formed when control power i...

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Page 27: ...usly entered ac tually function as anticipated before enabling high voltage or main power to the motor starter If this test can be success fully completed the control wiring can be assumed to be cor rect If the test cannot be completed for example BAD REPORTBACK one possible cause is incorrect control wiring II Initiate the run sequence Note If the IO 2000 displays PHASE ERROR program the potentia...

Page 28: ...IQ 2000 control checkout wlthout any high voltage being applied 4 5 Initial Motor Startup Depending on the motor type specific application and completeness of the installation it may be a good practice to disconnect the load from the mo tor before applying power for the first time Consult the appli cation engineer for suggestlons Always keep in mind the cautions listed in Paragraphs 4 2 and 4 3 wh...

Page 29: ...th a heating and a cooling cal culation To do this a mrcroprocessor located in the Processor Mod ule maintains a short term history of the motor s operation A rotor protection algorithm mamtains the history See Fig ure 5 1 The following variables are used as Input data for the hrstory l Motor current I the posrtrve sequence current l Motor current lz the negative sequence current or un balanced cu...

Page 30: ...r protection curve defines the motor versus time relationship that exists as a direct re sult of the IQ 2000 s hardware and the programmed setpoint 28 values See Figure 5 2 Ideally this curve is located as close as possible to the motor damage curve thus allowing maxi mum utilization of the motor and at the same time fully pro tecting the motor from damage The motor damage curve is defined as that...

Page 31: ...TD 11 720 B IQ 2 00 Instantaneous overcurrent 5 1 2 4 6 8 10 20 100 muhples of full load amps Figure 5 2 Motor Protection Curve 29 ...

Page 32: ...f this factor this situatron shifts the ultimate curve to the right on the ttme current graph and has an ef feet where the VT curve Intersects the ultimate trip curve Note that the VT curves are a combination of the positive cur rent and negative sequence current with the negative se quence current weighted to reflect the additional rotor heating It causes Figure 5 2 shows the curves that result f...

Page 33: ...e 15 seconds cold start l Ultimate trip 100 of full load amps l Acceleration of motor loaded 10 seconds l Motor running loaded at 90 of full load amps l Underload protectton set at 60 of full load amps for a 5 second duration l Jam protection 180 full load amps for a 5second du ratlon The basic dtfference wtth the addition of RTDs is shown in Figure 5 5 In the time period after 60 seconds With RTD...

Page 34: ... pre run timer Underload protection set point 60 of full load amps for 5 sec duration Motor running with load Maximum allowable locked rotor amps Instantaneous overcurrent 12 times full load amps I Motor starting current 6 1 times full load amps 5 1 2 4 6 6 10 20 100 multiples of full load amps Figure 5 4 Motor Protection Curve without RTDs 32 ...

Page 35: ...tron combination of setpoint 60 of positive I and full load amps for negative sequence 12 5 sec duration motor currents Motor running with load Underload start setpoint time of 25 sec Jam protection setpoints l 180 of full load amps for 5 sec 1 duration l 15 sec delay pre run timer 5 1 2 multiples of full load amps 4 6 6 10 20 100 Inherent i cycle delay IIILI Figure 5 5 Motor Protection Curve with...

Page 36: ...ergized it initiates the pre run timing function In reactor or autotransformer applications the momentary contactors are energized during the pre run timing interval It is also used in conjunction with the JAM function Refer to Paragraph 5 1 3 5 When the post start timing is completed the Post start Relay is energized The run sequence is the normal or steady state of the contactors 0 The star sequ...

Page 37: ...e pre start time After the pre start function is timed out the PRE START REPORT BACK terminal has no effect on the run sequence If the pre start timer function times out before the PRE START REPORT BACK terminal TBAIO is energized the starting cycle is aborted At this time the message BAD START RESET is displayed in the FUNCTION window In a multi step application where for example the Class 11 502...

Page 38: ...lso the message BAD STOP RESET IS dis played in the FUNCTION window 36 Note however that the pre stop timing function can be drsabled if it is not required by the application See Para graph 6 16 After the stop sequence is complete the post stop tim ing function is enabled It is programmable from 0 to 60 seconds A Pre stop Relay is energized when the pre stop timer setpoint function is active It ma...

Page 39: ...the Pre stop Relay is energized The PRE STOP REPORT BACK terminal must be energized before the pre stop timer func tion timeS o t I gK r Terminal TB A6 energized I stop I sequence m Opens the contactor Post stop timer function 0 to 60 c L When the post stop timer functron is actrve SK the Post stop Relay is active I A n gzz gq initiated Prevents the start cycle from being I The mcltorstop sequence...

Page 40: ...omentary is not required the IQ 2000 should be wired as pushbutton control is wired as shown in Figure shown in Figure 3 1 Schematic TypIcal r A7 RUN ENABLE CR2 I Iy Ag L ENTARY IQ 2000 Processor Terminals X Y 2 Three wire pushbutton control Figure 5 8 Three wire momentary pushbutton control with Time Delay Undervoltage function 38 ...

Page 41: ...e motor remains stopped If the TUV function has not been exceeded a normal start cycle will occur Note circuitry contained in the Processor Module continues to time the TUV even after the AC line power IS removed Figure 5 9 AC Interrupt Events Flow Chart Table 5 A INPUT CIRCUIT CHARACTERISTICS Characteristic Opt0 isolation Input impedance Input current drain ON Input current drain OFF max Specific...

Page 42: ...00 IS supplied In an Amp 28 VDC at 6 amperes Table 5 B INPUT TERMINAL DESCRIPTION Terminal Designation Description TB A21 E STOP Hard wired to the lock out stop reset switch It is used to inform the IQ 2000 when a lock out stop IS Initiated Highest priority in IQ 2000 logic TB A9 FWDlSLOW FWD MOM TB A3 RVSlSLOW RVS MOM See Table 5 C for a description of the input terminal functions as they relate ...

Page 43: ...re se 5 4 3 Interposing Relays The term interposing relays when used with the 10 2000 refers to the relays located between l Output contacts of the IQ 2000 and the main contactor of the motor starter l Start stop contacts or pushbuttons and the input terml nals of the IQ 2000 When Westinghouse supplies the Ampgard starter certain in terposing relays are factory wired as listed In Paragraph 54 2 Fo...

Page 44: ...n Table 5 D of fer a convenient means of monitorma the various ooerat 5 5 1 RTD Wiring If the optional RTD Module IS used it must be wired as shown in Figure 5 10 Also note the follow mg requirements mg states of the IQ 2000 These contacts can be hardwired into conventional relay control wiring schemes Also any 1 of these contacts can be wired as inputs to a programma ble controller in order to be...

Page 45: ...Wire routing IS divided into 2 types high voltage 440 VAC and higher and low voltage 120 VAC and VDC signals Low voltage tends to be control and RTD wlrlng Note the following guldelines when developing a wire plan Separation Maintain a separation of at least 1 to 2 ft 45 to 60 cm between high and low voltage conductors Never route high and low voltage lines in the same raceway Low Voltage Lines It...

Page 46: ...for value entry The IQ 2000 displays its setpoint functions in a fixed sequence that IS dupli cated on the Setpoint Record Sheet Thus the sheet minimtzes programming time Specific entry procedures are described in Paragraph 4 3 2 Each of the 26 setpomt functions IS described separately in the following paragraphs To easily understand the timing functions explained between Paragraph 6 14 and 6 22 r...

Page 47: ...pere5 in 1 amp increments l Time 0 to 5 seconds In 1 set increments Ground fault trip conditions can be initiated by motor suppression devices or power factor correction devices Capa citors in these devices offer low impedance to the voltage when it is first applied to the motor Increase the ground fault setpoint Time as needed NOTE With certain suppression or power factor correction devices and m...

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Page 50: ... of time The available value range is l Time 0 to 99 seconds in 1 sec increments If this function is not used zero must be entered as a time value If the function is used it must be initiated by a contact closure input to the L ACCEL PERM terminal TB A12 See Figure 6 1 The contact is typically an external zero speed switch 6 6 Jam The jam setpoint function active after the start cycle is completed...

Page 51: ...e application A setpoint for o oof full load amperes is entered in the TRIP window The function is displayed as ULTIMATE TRIP 49 The available value range is l Amps 85 to 125 full load amps in 1 increments In cases when a value from 101 to 125 is programmed the permissible motor full load amps will be greater than the pro grammed full load current setpoint value This can occur when the motor manuf...

Page 52: ...g pumps A setpoint may be entered for the time duration The func tion is displayed as PRE START TIMER During a pre start condition in the run mode this message also appears The available value range is l Time 0 to 255 seconds in 1 sec increments In summary the motor start sequence begins only when the following conditions exist l A pre start timing function is active l The PRE START REPORT BACK te...

Page 53: ...s may be closed just before the motor turns off As shown in Figure 6 4 the pre stop timer function and the Pre stop Re lay are enabled when a stop command occurs When the PRE STOP REPORT BACK terminal TB A8 is ener gized the stop sequence is initiated 51 In terms of hardware contacts of the Pre stop Relay control the auxiliary functions These contacts are enabled for the programmed time while the ...

Page 54: ...mer function Pre stop report back signal must be energized before a pre stop timing function is completed terminal energized r contactor The stop sequence de energizes the motor Figure 6 4 Pre stop Events Diagram Events Description Start command _ I INCOMPL EJ energized Initiated by an external contact closure This energizes a terminal such as FWDlSLOW FWD MAINTAINED TBAG Incomplete sequence timer...

Page 55: ... example is the backspin of a pump and motor caused by the descent of a column of water after pumping is ter minated A setpoint may be entered for the time value The function is displayed as ANTI BACKSPIN The available value IS l Time 0 to 255 seconds In 1 sec increments If It ISdesired to disable the anti backspin function enter zero for the time value 6 19 Anti recycle Min The anti recycle setpo...

Page 56: ...ered for the time value The function IS displayed as POST START TIMER The available value range is l Time 0 to 255 seconds in 1 sec increments If it is desired to disable the post start timer function program a zero for the time value 6 22 Post stop Timer The post stop timer setpomt func tion initiated immediately after the stop sequence is complete can be used to disable auxiliary functions after...

Page 57: ...ogrammed time the red ALARM LED on the Operator Panel flashes and a warnmg message is displayed This function however does not cause a trip condition since the phase unbalance is already incorporated into the motor rotor protection algorithm Should the calculated temperature become too high due to a combination of current and phase 55 unbalance the trip condition results LOCKED ROTOR CUR Setpoint ...

Page 58: ...use the IQ 2000 to receive incorrect motor current data Motor damage could result 6 27 Potential Transformer Ratio The potential transform er PI ratio setpoint function defines the turns ratio of the optional PT The turns ratio is entered in the TIME window although only the first factor of the ratio is used Thus the entry of 35 represents 35 l This value is used internally by the IQ 2000 and thus...

Page 59: ...tage reversing 1l 902 Reserved for future use 11 912 Reserved for future use 13 202 Wound rotor non reversing 13 212 Wound rotor reversing 14 202 Synchronous full voltage non reversmg 14 212 Synchronous full voltage reversing 14 502 Synchronous primary reactor reduced voltage non reversing 14 512 Synchronous pnmary reactor reduced voltage reversing 14 602 Synchronous auto transformer reduced volta...

Page 60: ...GE 14 612 m FWD RVS FWDlRVS FULL VOLTAGE MOM m The closure time of the Forward Momentary C3 relay IS determined by the pre run timer setpant tunctlon See Paragraph 6 15 0 The Post start Relay when used IS energized Immediately after the pre run timer function tmles out q When used with a reactor or autotransformer the pre run tmw setpolnt should be set 2 seconds longer than the longest passable t ...

Page 61: ...erator Panel provides a reporting function that occurs during the normal operation of the IQ 2000 Com mands such as START SEQUENCE and POST STOP are used to report the various sequences involved with starting running and stopping the motor Figure 7 1 shows the rela tionship among the displays and the various operations of the IQ 2000 7 1 2 Reviewing Setpoints The setpoint value reviewing operation...

Page 62: ...escrip certain trip conditions such as tlon of these electrical charactenstics is given in Table 7 A l Instantaneous overcurrent NOTE As long as the RESET pushbutton IS not reset the state of the metering functions just prior to the occurrence of the trip are retained by the IQ 2000 for diagnostic purposes Even if AC power is removed the last states of the meter ing functions are retained for a mi...

Page 63: ...power factor is lagging POWER FACTOR q The actual power factor ranging from 0 to lOO is displayed in the A window of the Operator Panel Note When the power factor is lagging the value displayed will be negative and the display will be prefixed with a dash symbol FREQUENCY HZ The frequency of the incoming AC line is displayed to the closest whole number of Hertz second MEGAWATT HOURS q E The actual...

Page 64: ...itions Par 721 1 l Trip conditions Par 7 2 1 2 7 2 1 1 Alarm Conditions An alarm condition occurs when one of the electrical characteristics exceeds the programmed setpoint value Note however that some alarm characteris tics must exceed the setpoint value for a programmed time value before the alarm condition occurs When this condition happens the red ALARM and SETPOINT LED lights Also a message i...

Page 65: ... IQ 2000 as described In Paragraph 7 1 3 Note Depressing the RESET pushbutton clears the elec trical charactertstics stored when the trip condition oc curred If after depressing the RESET pushbutton the OVERLOAD WARNING message appears wait until the motor cools before restarting The internal Trip Relay is actuated when the condition occurs The form C relay contacts available at the interface TB A...

Page 66: ...ed at the correct time in the stop cycle Monitor terminal TB A8 during an actual stop cycle BAD START RESET The PRE START REPORT BACK terminal TBAlO failed to be ener gized at the correct time in the start cycle Monttor terminal TBAIO during an actual start cycle REMOTE TRIP The REMOTE TRIP terminal TB A13 was energized Monrtor terminal TBA13 PHASE ERROR 1 Check to see if voltage is availa ble bet...

Page 67: ...to determine prop er phase relationship is recommended Without such an instrument it is possible through trial and error to correct Leave the Potential Transformer Connections as is and roll the Current Transformer connections Example TB B4 to B6 B6 to B8 and 88 to 84 This may have to be tried twice two rolls to obtain proper phase relationship Make a fmal calculation check reviewing the Volts Amp...

Page 68: ...n the FUNCTION window OPT0 COUPLER BAD IS displayed in the FUNCTION window Probable Cause lncomrng AC deficient Blown fuse Check the fuse located on the Processor Module Processor Chassts or Operator Panel malfunction A display sequence as described in Par 7 1 2 IS completed Data transfer loss Processor Module malfunctron Solution Verify that 120 VAC 15 exists between ter minals TB P2 and TB P3 Re...

Page 69: ...R If a Processor Module IS replaced it is necessary to re program all setpoint values that apply to the specific IQ 2000 application Do not attempt to restart the motor until all values are entered and validated Use the appli cation s Setpoint Record Sheet and Paragraph 4 3 Per sonnel injury and or damage to the equipment may occur if this procedure is not followed 8 1 Processor Module Replacement...

Page 70: ... pulling the draw out panel as far forward as it will travel Step 3 Verify that all wires connecting to the terminals of terminal block TB R are clearly marked and it is clear which terminal relates to the designations See Figure 8 1 Step 4 Loosen each screw terminal and remove the wires from them Step 5 Remove the screw securing the chassis door of the IQ 2000 and open the door Step 6 Remove the ...

Page 71: ...START REPORT BACK FAST FWD MOMENTARY L ACCEL PERM Input REMOTE TRIP input INCOMPL SEC REPORT BACK Cl REPORT BACK C2 REPORT BACK C3 REPORT BACK C4 REPORT BACK For future use For futyre use E STOP input p22Jr Common to TB PP Trip relay contacts Alarm relay contacts Unused for future use Pre stop relay contacts Pre start relay contacts Post stop relay contacts Figure 8 2 Terminal Designations 69 ...

Page 72: ...t xfmr B input Current xfmr A COMM Current xfmr A input For future use Potential xfmr COMM Potential xfmr input VCB Potential xfmr input VAB Inactive Terminal For future use E stop relay contacts Relay Cl coil 1 Relay C2 coil 2 Relay C3 coil 3 Relay C4 coil 4 Post start relay contacts Note for terminal designations on the optional RTD Module see Figure 3 3 Figure 8 2 Terminal Designations 70 ...

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Page 76: ... Westinghouse Westinghouse Electric Corporation Control Division Asheville NC 28813 TD 11 720 6 ...

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