Nederman FlexPAK Setting Manual Download

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PLC Settings Manual

Compact dust collectors

FlexPAK

Software #2168209-X

Original plc settings manual

PLC SETTINGS MANUAL

2021-05-12

2130258 (02)

Summary of Contents for FlexPAK

Page 1: ...PLC Settings Manual Compact dust collectors FlexPAK Software 2168209 X Original plc settings manual EN PLC SETTINGS MANUAL 2021 05 12 2130258 02 ...

Page 2: ...FlexPAK Trace back information Workspace Main version a43 Checked in 2021 05 12 Skribenta version 5 4 015 ...

Page 3: ...ages 16 3 2 1 Time For service 16 3 2 2 Warning Main Filter Clogged 16 3 2 3 Dustbin Full 16 3 2 4 Bag Replacement Switch Activated 17 3 2 5 Warning Low Vacuum 17 3 2 6 AUX Temp Limit Exceeded 1 17 3 2 7 AUX Temp Limit Exceeded 2 18 3 2 8 Rotary valve fault 18 3 2 9 Rotary rotation detection 18 3 3 Alarms 19 3 3 1 External Fire Alarm Explosion Detected 19 3 3 2 Frequency Conv Alarm 19 3 3 3 Emerge...

Page 4: ...4 4 2 24 FlushTmp 35 4 2 25 CoolTmp 35 4 2 26 TVFD Al Tmr 35 4 2 27 BRSTmr 36 4 2 28 Vac_Low 36 4 2 29 AEB TVFD 36 4 2 30 FlushCy1 37 4 2 31 VacLoTm 37 4 2 32 PSIFC 37 4 2 33 PresepTm 37 4 2 34 FlushTmr 38 4 2 35 FCDelay 38 4 2 36 IsoVDly 38 4 2 37 DuctIsoDamp 39 4 2 38 BLI Alarm 39 4 2 39 MFDPS Al 39 4 2 40 DPFClean 39 4 2 41 EmtyIdli 40 4 2 42 Clean cycle 40 4 2 43 Rot valve 40 4 2 44 Rot valve ...

Page 5: ... cleaning in Running mode 49 7 4 Filter cleaning valve function 49 8 ATEX Duct Isolation Valve settings 49 8 1 Flush Cycle settings 50 8 1 1 FlushCy1 T Timer 50 8 1 2 FlushCy2 T Timer Dual Function 50 8 2 Tuning Duct Isolation Damper sequence 50 8 2 1 FCDely T Parameter 50 8 2 2 FCDely T Parameter Calculation See Timing diagram 50 8 2 3 Default FCDely T Parameter Settings 50 8 3 IsoVDly T Paramete...

Page 6: ...C ESC OK FlexPak Hi Vacuum Unit IDLING Time To StandBy 05 33m PS PS ESC OK Running kPA 20 DIRTm 09 00 s OTTmr 00 00 h Exhaust Air Temp 60 C ESC OK FlexPak Hi Vacuum Unit IDLING Time To StandBy 00 00m PS Running P 5 à 20 35 kPa IDLING P 0 kPa PS PS Pilot signal OFF Pilot signal On DIRTm 10 00 s DIRTm 10 00 s ESC OK Running kPA 20 DIRTm 00 00 s OTTmr 00 00 h Exhaust Air Temp 60 C T 12 00m T 12 00m F...

Page 7: ...FlexPAK 2 7 ...

Page 8: ...2 Duct Isola on Damper SFV2 Duct Isola on Damper Mechanical status Closing Time Extra delay mer to FC TL 2s TL 3s TH 2s TH 1s TL 3s 15s TH 2s TL 3s TH 2s T Approximately 22 seconds Filter Cleaning IsoVDly T 4s Vacuum Equaliza on me Opening Time Timing Diagram FlexPAK 800 1000 ATEX Duct Isola on Damper So ware 2168079 1 2168209 X 3 8 ...

Page 9: ...f there are any damaged or missing parts when the product is de livered notify the carrier and the local Nederman rep resentative immediately 2 Safety 2 1 Classification of important informa tion This document contains important information that is presented either as a warning caution or note ac cording to the following examples WARNING Risk of personal injury Warnings indicate a potential hazard...

Page 10: ...cuum the FCV is closed and the unit is waiting for a pilot signal to go into Running mode ESC OK NEDERMAN FLEXPAK Standby Wai ng For Pilot Signal Mo 15 33 3 1 3 Running Running mode The unit in Running mode The pump motor is on and the unit generates a vacuum The FCV is closed The cur rent vacuum of the unit is shown on the display for example 20 kPa ESC OK Running kPA 20 DIRTm 00 00 s OTTmr 00 00...

Page 11: ...own when TVFD advanced is activated ESC OK Open Upper Slide Valve Remaing time 06 00s Remaining Time The remaining time for the valve to open before the alarm is activated 3 1 8 Close Upper Slide Valve V12 The message appears when the TVFD Upper Solenoid Valve is expected to close The timer is set with TVFDC Al see Section 4 2 26 TVFD Al Tmr If the timer elapses the TVFD Alarm Upper Slide Not Clos...

Page 12: ...3 1 12 Isolation Damper Closing Duct When the parameter Softkey DuctIsoDamp On FlexPAK is configured to control a damper that separates the filter from the factory s channel system The message appears before filter cleaning starts The display shows the time delay set for opening the damper after filter cleaning ESC OK Isolation Damper Closing Duct Delay Open Time 04 00s RemaningTm 02 00s 3 1 13 Em...

Page 13: ...lter Sensor Stat On Activated sensor input for Analog sensor 0 10V Stat Off Activated sensor input for Dp Switch input configuration Displayed when only Main Filter is installed ESC OK Ppump 20 kPa Total System Pressure Dropp SystdP 3 1 kPa Duct P 16 9 kPa MaxdP 5 0 kPa ESC MFdP Setting Set ON CFdP Setting Set OFF Press OK button to close display Ppump 20 kPa Pressure readings from the pump pressu...

Page 14: ...ensor MFdP 1 8 kPA Main Filter dp pressure CFdP 0 8 kPA Control Filter dp pressure MF Lim 5 0 kPA Main Filter Max dp pressure Limit setting CF Lim 5 0 kPA Control Filter Max dp pressure Limit setting See MFdP Setting and CFdP Setting for more information 3 1 16 Emptying bin by rotary valve When the system is configured for a simple TVFD without the limit mode sensor the message below will be dis p...

Page 15: ...C Min 0 C AUX Temperature Min Temperature Limit setting Default 0 C See AUX Setting for more information 3 1 18 Vibration Sensor Display The Vibration Sensor Reading display is manually activated Toggle with arrow key UP or Down until Date Window is visible Toggle with arrow key Left or Right until Arrow Window is visible Press the ESC button simultaneously while pressing the arrow key Down to vie...

Page 16: ...ual fil ter cleaning button for 10 seconds ESC OK FlexPak Hi Vacuum Unit Time for Service Th 15 01 Reset OK à EMERGENCY STOP 3 2 2 Warning Main Filter Clogged This Warning is only shown when the Main Filter Delta Pressure Switch MFDPS is installed This message is dis played if the Differential Pressure switch DP switch is installed and the Dp switch detects a high differential pressure across the ...

Page 17: ...ime allowed to replace the dust bag 3 2 5 Warning Low Vacuum Function to warn when the vacuum is too low in the system When the vacuum is too low Vac_Low activates the delay timer VacLoTm function when the message expires When the vacuum rises above the set limit value the message disappears automatically The Vac_Low parameter default setting is 15kPa The VacLoTm parameter default setting is 1 min...

Page 18: ...the actual temperature value MaxTemp 50 C Shows Max Temperature limit setting MinTemp 0 C Shows Min Temperature limit setting Time To Unit Stop 25 00 s Shows the remaining time until the unit stops 3 2 8 Rotary valve fault This message is displayed if parameter Rot valve ERR ON and the rotary valve control unit indicates a fault The time until the unit stops is also displayed 3 2 9 Rotary rotation...

Page 19: ...ection problem to the main power supply Motor cable problem Power supply fault There is a problem with the frequency converter PTC temp monitor detects an overheated motor ESC OK PTC Detect Hi Motor Temp or Inverter Fault Th 12 23 Unit is stopped Reset OK à 3 3 3 Emergency Stop Activated If this message appears in the display one or more emergency stops have been activated and the machine has been...

Page 20: ... OK to reset the alarm ESC OK Alarm Hi Vacuum Level 36 kPA Th 12 23 Unit is Stopped Reset OK 3 3 6 Exhaust Air Temp High The temperature of the air exiting the pump has exceeded the maximum allowable limit of 135ºC 275ºF When the Current Value has become lower than 90 C 194ºF press OK to reset the alarm Check for the cooling air valve or PT100 sensor values ESC OK Max Temp Exhaust Air Exceeded Uni...

Page 21: ...ot been activated as it should Something can be stuck in the upper slide valve The compressed air pressure hose has either been disconnected or the compressed air pressure is too low This message is only shown when TVFD advanced is activated ESC OK TVFD Alarm Lower slide not closed Th 11 23 Unit is Stopped Reset OK 3 3 10 TVFD Alarm Upper Slide Not Open The TVFD Upper Solenoid Valve does not open ...

Page 22: ...It can be caused by the following The lower slide valve has not been activated as it should Something can be stuck in the lower slide valve The compressed air pressure hose has either been disconnected or the compressed air pressure is too low This message is only shown when TVFD advanced is activated ESC OK TVFD Alarm Lower slide not closed Th 11 23 Unit is Stopped Reset OK 3 3 13 TVFD Alarm Slid...

Page 23: ... display and the Start Stop button starts to flash The unit is stopped Fix the problem with the clogged filter Press the OK button to reset the Alarm ESC OK Alarm Main Filter Clogged Th 12 23 Unit is Stopped Reset OK 3 3 16 AUX Hi Temp Limit Exceeded This message is displayed when AUX temperature exceeds the Max Set temperature limit setting and stop delay timer is elapsed See AUX Setting When the...

Page 24: ... s MaxS 10 0 mm s MaxR 10 0 mm s MaxS Default 10mm s MaxR Default 10mm s Delay Tmr Default 10s Level 3 8 mm s Shows the actual vibration value DelayTmr 09 00 s Shows the remaining time of the Stop delay timer MaxS 10 mm s Shows Max SET vibration limit setting MaxR 10 mm s Shows Max RESET vibration limit setting If this alarm activates do not reset and restart the FlexPAK It is very inappropriate a...

Page 25: ...FlexPAK 3 3 19 Rotary valve fault This alarm is displayed if parameter Rot valve ERR ON and the rotary valve control unit has indicated a fault for longer than parameter Rot fault Al 25 ...

Page 26: ... the down arrow to go to the date and time screen 2 Press Escape to go to the main menu 3 Press the Down arrow to go to Program Press OK to confirm 4 Select Set Parameter Press OK to confirm 5 Use the Up or Down arrows to find the parameter Press OK to confirm 6 Use the Left and Right arrows to select a value 7 Use the Up or Down arrows to set the value Press OK to confirm 8 Press Escape to go to ...

Page 27: ...er value Press OK to confirm 7 Use the Up or Down arrows to set Time or Date Press OK to confirm Weekday is automatically set by the date 8 Press Escape 3 times to go to the time screen 9 Press the Up arrow to exit There are several other input menus on the same level as the date and time screen If pressing the Down arrow takes the PLC to one of those menus use the Left arrow to get to the date an...

Page 28: ...e Down arrow takes the PLC to one of those menus use the Left arrow to get to the date and time screen Daily AM setting ESC OK WeekTmr 1 2 D1 On1 Off1 D2 On2 D1 MTWTF Default setting Monday Tuesday Wednesday Thursday and Friday On1 Time the unit is set to Standby at chosen D1 days The default set ting is no preset time Off1 The time the unit is set to Off on chosen D1 days The default set ting is ...

Page 29: ...e display to show only dashes However it is recommended that the timer function is used as this ensures that the unit is switched off even when a valve remains open for example overnight NOTE If the weekly timer has been activated the amount of time the unit can be used during the day before it automatically goes into Off mode can be extended if the optional external standby button accessory is us...

Page 30: ...s TL 00 00s Ta 00 00 TH 5 seconds the Cleaning Valve V1in is opened for 5 seconds TH 0 is the default settting To activate CoolTM set CoolTM TH 0 seconds e g TH 5 TL 0 seconds The default setting do not change TA Ta 00 00 The elapsed time since the Cooling cycle was activated 4 2 6 FltClean Menu for setting time between automatic filter cleanings If TH 0 no filter cleaning is performed TH may not ...

Page 31: ...hen the Main Filter pressure sensor monitoring detect High dP across Main Filter MFDPS FC is activated and the delay timer for MFDPS FC has expired it activates automatic filter cleaning if DPFClean is activated see Sec tion 4 2 40 DPFClean If PSIFC is set to On the filter cleaning sequence will not be activated ESC OK MFDPS FC 1 1 T 01 00m Ta 00 00m T 01 00m Time before MFDPS FC is activated The ...

Page 32: ...t setting of 1 second TL 60 00m The amount of time between emptying cycles The default setting is 60 minutes Ta 00 00 The elapsed time since the last AEB was activated 4 2 15 BinOpnTm Menu for AEB Flap Valve simple TVFD and pre separator opening cycle settings The values for TL and TH de pend on which function is being used See Section 4 2 46 Vibr Setting ESC OK BinOpnTm 1 1 TH 05 00s TL 03 00s Ta...

Page 33: ... for activating the Automatic Emptying of collector Bin interval Timer AEBTme see Section 4 2 14 AEBT me ESC OK BinAuto 1 1 Switch Off Switch Off is the default setting the BinAuto timer is off To activate the AEBTme timer set Switch On 4 2 20 LiAuto Menu for activating Bin Level Indicator Automatic Emptying of Bin BLI Empt see Section 4 2 12 BLI Empt ESC OK LIAuto 1 1 Switch Off Switch Off is the...

Page 34: ...he external standby button less than 2 seconds puts the unit into Standby mode for the time set in T for example two hours See the figure below If the unit is in Standby mode and the weekly timer is not used quickly pressing the external standby button less than 2 seconds puts the unit into Off mode after the time set in T for example two hours See the figure below If the weekly timer is being use...

Page 35: ...10 C 230ºF Off 97 207ºF The temperature limit that is set to close the flush valve The default setting is 97 C 207ºF Ax 00 00 The current temperature of air exiting the system 4 2 25 CoolTmp Menu for setting CoolTmp See Section 4 2 5 CoolTmr The default settings for CoolTmp ESC OK CoolTmp 1 1 On 97 Off 96 On 97 The default temperature limit that is set to open Cleaning Valve V1 SCV The default set...

Page 36: ...mit is set to 15kpa and the pressure in the system is 14kPa the alarm will be activated when the VacLoTm delay timer has expired Warning Message Activated Warning Low Vacuum Limit setting Vaccum 15kPa Pressure 15kPa Default setting On 15 kPa Default setting Off 15 kPa On and Off must have the same limit value ESC OK Vac_Low 1 1 On 15 Off 15 4 2 29 AEB TVFD Menu for choosing between the AEB Flap Va...

Page 37: ...short term vacuum variations in the system When the timer expires the mes sage Warning Low Vacuum is displayed ESC OK VacLoTm 1 1 T 01 00m Ta 00 00m T 01 00m default setting 1 minute delay Ta 00 00m shows the lukewarm delay time 4 2 32 PSIFC Menu for activating Pilot Signal Interlock Filter Cleaning PSIFC Filter cleaning does not take place until the pi lot signal has disappeared and DIR_Time has ...

Page 38: ...ion Damper in order to isolate the pipe system before filter cleaning and minimize the risk that it accidentally closes For more information see Section 8 2 Tuning Duct Isolation Damper sequence ESC OK FCDely 1 1 TH 01 00s TL 02 00s Ta 00 00s TH 1s Default setting Do not change this parameter value TL 2s Default setting Ta Elapsed time since Filter Cleaning Start Impulse was activated 4 2 36 IsoVD...

Page 39: ...DPS Al Menu for setting the Main Filter Differential Pressure Sensor Alarm MFDPS Al delay timer When the Main Filter pressure sensor monitoring detect High dP across Main Filter MFDPS Al is activated When the delay timer has expired the Alarm Main Filter Clogged message is activated See Section 3 2 2 Warning Main Filter Clogged When the timer has expired the unit stops ESC OK MFDPS Al 1 1 T 20 00m...

Page 40: ...nds On Number of cleaning pulses Default is 1 pulse Note Minimum value 1 Cnt 0 Elapsed cleaning cycles Note If On is set to 0 no filter cleaning is performed 4 2 43 Rot valve Enab On if rotary valve installed Dete On if rotation detection installed Trun Length of time during which the rotary valve runs T1 Time between rotary valve operations Err Fault detection from rotary valve control unit insta...

Page 41: ... elapsed T the unit stops MaxR Reset Vibration Threshold If Vibration Alarm is activated and the Vibration Alarm Delay Timer is not elapsed T 0 and the Vibration signal pass below MaxR the alarm is reset and FlexPAK is not stopped Always set MaxR MaxS Ax Vibration Sensor Signal If FlexPAK is equipped with a vibration sensor the input signal value is 0 mm s 2Volt signal and 24mm s 10V Volt signal I...

Page 42: ...m activates When the Temperature Alarm Delay Timer is elapsed TDly the unit stops MinR Reset Temperature Threshold If the temperature alarm is activated and Temperature Alarm Delay Timer is not elapsed TDly 0 and the tem perature is higher than MinR the alarm is reset and FlexPAK is not stopped Always set MinR MinS Larm Larm Activation If Stat off AUX Sensor Activation The Warning and Alarm functi...

Page 43: ...essure DucP Duct Pressure Dirty side of Main Filter Pump Side Channel Fan MFP Main Filter Pressure Sensor signal CFP Control Filter Pressure Sensor signal PP Pump Pressure Sensor signal MFPP Calculated dP Across System MFP PP MFPP System Pressure drop from the duct to pump MFCF MFdP Calculated dP Across Main Filter MFP CFP MFCF Pressure Drop across Main Filter CFPP Calculated dP Across Control Fil...

Page 44: ...ter dP PP Pump Pressure Setting high dP limit Max dP limit across Control Filter Maximum accepted dp across Control Filter if dp pass above parameter on the Alarm Control Filter Clogged alarm activates and the FlexPAK stops Parameter On Off ESC OK CFdP Se 1 2 On 50 Oﬀ 50 CFP 190 PP 200 CFdP 10 ESC OK CFdP Se 2 2 Stat Oﬀ 50hPa 5KPa Always set On Off On 50 Max dp Set Alarm Default 50hPa Off 50 Max d...

Page 45: ...ross Main Filter Default 50hPa MFPP 30 Calculated dP Across Filter System hPa MFCF 30 Calculated dP Across Main Filter hPa MFP 30 Main Filter Pressure Sensor signal hPa Stat Of Set Analog Sensor monitoring on off Default Off The Analog Sensor uses ambient pressure as a reference to the measured pressure To get the Main filter dP pressure with a positive sign calculate it with the formulas Filter S...

Page 46: ...noid Lower Valve The duct isolation valve controlled by the V12 TVFD SUV Solenoid Upper Valve 5 1 2 PLC Settings 1 Presep Switch Off standard setting 2 AEB TVFD Switch On standard setting 3 TVFDAdv Switch Off standard setting Presep overrides 2 above If TVFDAdv is activated Switch On TVFDAdv overrides 1 and 2 above 5 1 3 Timer Settings BinOpnTm TL Delay time to let the motor decrease speed and the...

Page 47: ...tarts to open The default is 5 seconds TH Time delay to the next possible emptying sequence The default is 5 seconds 5 3 Pre Separator Settings 5 3 1 Hardware Pre Separator 1 controlled by the V11 TVFD SLV Solenoid Lower Valve Pre Separator 2 controlled by the V12 TVFD SUV Solenoid Upper Valve 5 3 2 PLC Settings 1 Presep Softkey On standard setting Off 2 AEB TVFD Softkey Off standard setting On 3 ...

Page 48: ...e the unit goes into Off mode TVFDO Al T sets the maximum time that you can accept it will take to perform the slide valve opening sequences of the upper and lower slide The default setting is 15 seconds If the slide valves do not perform this sequence within the set time the unit goes into Off mode 5 5 Rotary valve settings 5 5 1 Hardware The rotary valve is started by a 24VDC signal Rotation det...

Page 49: ...the unit will stop its motor and go into Standby mode To perform a new filter cleaning in Idling mode activ ate the pilot signal and enter Running mode or toggle the Standby Running button to go to Standby mode and press the filter cleaning button again 7 3 Filter cleaning in Running mode Perform filter cleaning in Running mode as follows 1 Put the system into Standby mode by pressing the Standby ...

Page 50: ...uence 8 2 1 FCDely T Parameter Filter cleaning delay time is used to ensure that the Duct Isolation Damper is closed before the first filter cleaning FC pulse To set FCDely T parameter it is necessary to know how long time it takes for Duct Closing Damper to go from Open to Closed Test the time it takes for the Duct Closing Damper to close at the default Vacuum set point for the system Vacuum set ...

Page 51: ...hird FC pulse is executed when vacuum reading is more than 5kPa higher than the setpoint in this case when vacuum reading is above 40kPa Solution Increase Parameter TL 5 To long TL time FlexPAK 800 35kPa After the first FC pulse and the FC valve has opened and closed again the motor runs at high speed until the vacuum reading has passed the setpoint 35Pa After a while the motor speed slows down an...

Page 52: ... etcetera Message Larm Message Warning Message Parameter settings Other parameters s also available Running time Timer settings etcetera 9 1 Preset IP Addresses for FlexPAK IOT Units Siemens Logo 8 10 5 3 91 Vacon VFD 10 5 3 92 eWon Router 10 5 3 93 Contact a Nederman Sales company for more informa tion 52 ...

Page 53: ...FlexPAK 10 Appendix A PLC settings protocol Copy the PLC settings protocol fill it in and save it as a service record PLC setting Default value Customer specific value 53 ...

Page 54: ...FlexPAK PLC setting Default value Customer specific value 54 ...

Page 55: ...www nederman com ...

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