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Electrical Dokumentation

Jaw Crusher
and
Reciprocating Plate Feeder
Codelco El Teniente, Chile
Pipa Norte
2-443-20351
P.O.4500297631

07/2003

Year of manufacture 2002

ThyssenKrupp Frdertechnik GmbH


P.O. Box 1463 D - 59306 Ennigerloh
Schleebergstrasse 12 D - 59320 Ennigerloh
Phone: (02524) 30-0
Telefax: (02524) 2252
Internet: www.thyssenkrupp.com
www.eprocessingplants.com

This operating manual in all its parts is protected by copyright. All rights reserved including those of translation into
other languages. This manual as a whole or part of it is not allowed to be processed, reproduced or distributed in any
form, electronic systems included, without the written permission of ThyssenKrupp Frdertechnik.
2-443-20351

-1

File 1

Pipa Norte

1. Lists and Drawing


Motor and consumerlist
Switch list
Function diagram
One line diagram
P & I diagram
Installation of instrumente
Grease lubrication system jaw crusher
Grease lubrication system plate feeder
Installations instructions EASY 412-AC-R

Ident No. 4200 447


4200 446
4200 559
4200 454
4200 456
4200 457
4200 558
4200 560

Ind. 3
Ind. 4
Ind. 1
Ind. 4
Ind. 2
Ind. 6
Ind. 1

File 2
2. Medium Voltage Smart Starter
Medium voltage smart motor
controller Bulletin 1562 D
Construction diagram and technical data
SMC for crusher
Circuit diagram SMC for crusher
Medium voltage dialog plus TM motor
controller Bulletin 1562 D
Multifunctional motor management
Bulletin 825 smart motor

3. Crusher motor and hydraulic motor


Technical data sheet crusher motor
Motor dimension crusher motor
Test for asynchronous machines
Safety instructions crusher motor
Technical data for hydraulic motor
Motor dimension print for hydraulic motor
NEMA induction motor for hydraulic motor

Ident No. 4200 595 Ind. 2


Ident No. 7004 289-001-02 D
Page 1 - 6
7004 289-001-02E
Page 1 - 5

File 3
4. Video control jaw crusher inlet
Technical documents
Operating instructions camera
Operating instructions monitor

5. Ultrasonic measurement jaw crusher inlet


Operating instructions Prosonic FDU 81
Technical information FMU 860
Software instructions FMU 860

6. Hydraulical adjustment of jaw distance


Wiring diagram
Function discription

Ident No. 4200 712


4200 590

7. Control- and measurement system DALOG


Arragement drawing
Terminal drawing
Compoments dokumentation

8. Data sheets
Limit switch bal valve oil tanks
Limit switch plate feeder
Speed control jaw crusher

2
Revision

Date

Name

Date
Drawn.
Check.

Name
GAND
30.07.02

Datei name:

Client:

EL TENIENTE PIIPA NORTE

Description: DAGRAMA UNILINEAL

Pipa norte DAGRAMA UNILINEAL


Project no.:

Ident no.:

Page 1

2-4443-20351

4200 454

Sh

1
Revision

Date

Name

Date

Name

Drawn.

GAND

Check.

30.07.02

Datei name:

Client:

EL TENIENTE PIPA NORTE

Description: DAGRAMA UNILINEAL

Pipa norte DAGRAMA UNILINEAL


Project no.:

Ident no.:

Page 2

2-443-20351

4200 454

Sh

2
Revision

Date

Name

Revision 1

20.01.2003

Aufderheide

Date

Name

Drawn. 15.11.2002 Aufderheide


Check.

Datei name:

Client:

EL Teniente Pipa Norte

Description: title

22.01.2003
Project no.:

Ident no.:

Page 1

2-443-20351.01.01

4200 558

11

Sh

1
Revision

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Name

Revision 1

20.01.2003

Aufderheide

Date

Name

Drawn. 15.11.2002 Aufderheide


Check.

Datei name:

Client:

EL Teniente Pipa Norte

Description: title

17.11.2002
Project no.:

Ident no.:

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Revision

Date

Name

Revision 1

20.01.2003

Aufderheide

Date

Name

Drawn. 15.11.2002 Aufderheide


Check.

Datei name:

Client:

EL Teniente Pipa Norte

Description: Index

18.11.2002
Project no.:

Ident no.:

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Name

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20.01.2003

Aufderheide

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Datei name:

Client:

EL Teniente Pipa Norte

Description: primary circuit

20.01.2003
Project no.:

Ident no.:

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20.01.2003

Aufderheide

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Name

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Client:

EL Teniente Pipa Norte

Description: control unit

20.01.2003
Project no.:

Ident no.:

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Revision

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Name

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20.01.2003

Aufderheide

Date

Name

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Datei name:

Client:

EL Teniente Pipa Norte

Description: control unit

20.01.2003
Project no.:

Ident no.:

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20.01.2003

Aufderheide

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Client:

EL Teniente Pipa Norte

Description: cabinet

20.01.2003
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20.01.2003

Aufderheide

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Datei name:

Client:

EL Teniente Pipa Norte

Description: terminal strip

Project no.:

Ident no.:

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Client:

EL Teniente Pipa Norte

Description: terminal strip

18.11.2002
Project no.:

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Client:

EL Teniente Pipa Norte

Description: terminal strip

18.11.2002
Project no.:

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Gerteliste

19.11.2002

Description: spare parts list

Project no.:

Ident no.:

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Client:

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El Teniente Pipa Norte

Description: title

21.01.2003
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1
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Datei name:

Client:

El Teniente Pipa Norte

Description: title

push car
Project no.:

Ident no.:

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20.01.2003

Aufderheide

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Name

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Datei name:

Client:

El Teniente Pipa Norte

Description: Index

push car
Project no.:

Ident no.:

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Name

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20.01.2003

Aufderheide

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Name

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Datei name:

Client:

El Teniente Pipa Norte

Description: primary circuit

19.11.2002
Project no.:

Ident no.:

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Datei name:

Client:

El Teniente Pipa Norte

Description: control unit

20.01.2003
Project no.:

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Name

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Datei name:

Client:

El Teniente Pipa Norte

Description: control unit

20.01.2003
Project no.:

Ident no.:

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20.01.2003

Aufderheide

Date

Name

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Datei name:

Client:

El Teniente Pipa Norte

Description: cabinet

19.01.2003
Project no.:

Ident no.:

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Sh

7
Revision

Date

Name

Revision 1

20.01.2003

Aufderheide

Date

Name

Drawn. 15.11.2002 Aufderheide


Check.

Datei name:

Client:

El Teniente Pipa Norte

Description: terminal strip

push car
Project no.:

Ident no.:

Page 8

2-443-20351.07.82

4200 560

11

Sh

10

8
Revision

Date

Name

Revision 1

20.01.2003

Aufderheide

Date

Name

Drawn. 15.11.2002 Aufderheide


Check.

Datei name:

Client:

El Teniente Pipa Norte

Description: terminal strip

push car
Project no.:

Ident no.:

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2-443-20351.07.82

4200 560

11

Sh

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9
Revision

Date

Name

Revision 1

20.01.2003

Aufderheide

Date

Name

Drawn. 15.11.2002 Aufderheide


Check.

Datei name:

Client:

El Teniente Pipa Norte

Description: terminal strip

push car
Project no.:

Ident no.:

Page 10

2-443-20351.07.82

4200 560

11

Sh

10
Revision

Date

Name

Revision 1

20.01.2003

Aufderheide

Date

Name

Drawn. 15.11.2002 Aufderheide


Check.

Datei name:

Client:

El Teniente Pipa Norte

Description: spare parts list

push car
Project no.:

Ident no.:

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u2e.fm Seite 1 Dienstag, September 8, 1998 4:38 PM

Manual bsico
Mdulo de control
EASY 412-DC-R...
EASY 412-AC-R...

04/98 AWB 2528-1316-E


Primera edicin 04/98
Klckner-Moeller GmbH, Bonn
Autor:

Dieter Bauerfeind

Editor:

Jrg Eiserloh, Thomas Kracht

Traductor:Parlamon, Traductors i Intrprets, s.l.

SICH_E.FM5 Seite 1 Mittwoch, September 9, 1998 9:23 AM

Cuidado!
Peligro. Alta tensin.
Antes de instalar:
Conecte los dispositivos con la
alimentacin elctrica desconectada.
Asegrese de que los dispositivos no
puedan conectarse de forma accidental.
Verifique el estado del aislamiento desde la
fuente de alimentacin.
Conecte la puesta a tierra y proteja la
instalacin contra cortacircuitos.
Cubra o proteja las dems unidades
activas.
Siga las instrucciones tcnicas (AWA) del
dispositivo.
Slo el personal tcnico cualificado est
autorizado a manipular los dispositivos/el
sistema.
Antes de instalar o tocar el dispositivo,
asegrese de estar libre de carga
electroesttica.
Los cables de conexin y de transmisin de
seales deben instalarse de modo que las
interferencias inductivas o capacitivas no
interfieran en las funciones automticas.
Instale los dispositivos automticos y los
correspondientes elementos operativos de
modo que se prevenga la puesta en marcha
involuntaria de los mismos.
Tome las medidas de seguridad
adecuadas, tanto en hardware como en
software, para el interface I/O, de modo que
una ruptura de lnea o cable en la fuente no
cause estados indefinidos en los
dispositivos conectados.
Aplique un aislamiento elctrico fiable a la
fuente de 24 V de baja tensin.

IBM un marchio registrato della


International Business Machines
Corporation.
Tutti gli altri marchi o nomi di prodotto sono
marchi registrati dai rispettivi costruttori.

Utilice nicamente fuentes de alimentacin


que cumplan con la norma IEC 364-4-41 o
HD 384.04.41 (VDE 0100 Parte 40-1).
Las desviaciones de los valores nominales
del voltaje principal no deben exceder los
lmites de tolerancia descritos en las
especificaciones, ya que podran causar un
mal funcionamiento y representan un modo
de operar peligroso.
Todos los dispositivos de parada de
emergencia que cumplan la norma EN
60204 / IEC 204 (VDE 0113) deben ser
efectivos en todos los modos operativos de
los dispositivos automticos. La
desconexin de dichos dispositivos de
seguridad no debe causar la puesta en
marcha accidental o no controlada.
Los dispositivos montados en cajas o en
cajas de control slo deben activarse y
manejarse despus de su debida
instalacin y con la caja cerrada. Las
unidades fijas y porttiles slo deben
activarse y manejarse con la caja cerrada.
Tome medidas para volver a poner en
marcha de modo adecuado los programas
que han sido interrumpidos por un bajn o
fallo de tensin. Evite en todo momento
cualquier situacin de peligro y, en caso de
necesidad, instale dispositivos de parada
de emergencia.

Tutti i diritti, ancfhe la traduzione sono riservati.


Nessuna parte di questo manuale pu essere
riprodotta in alcuna forma (stampa, fotocopia,
microfilm o altro sistema), elaborata o diffusa con
lutilizzo di sistemi di elaborazione elettronica,
senza lautorizzazione scritta della KlcknerMoeller di Bonn.

1316e.bk : 1316e.IVZ Seite 1 Donnerstag, September 10, 1998 12:01 PM

ndice

04/98 AWB 2528-1316 E

1 Mdulo de control easy

Ms fcil con easy

Montaje del easy

Conexin del easy

Funciones del easy

2 El cableado con easy

15

Manejo easy

15

Establecer el idioma del men

16

Configurar hora

16

Seleccionar el modo de funcionamiento


del easy

17

Elementos del esquema de contactos


del easy

18

Ejemplo: Crear un esquema de contactos

20

Rels de funcin

24

Ejemplo: Utilizar rels de funcin

30

Circuitos principales

33

3 Interface easy

35

4 Caractersticas tcnicas

37

Caractersticas tcnicas

37

Gama easy

38

ndice alfabtico

39

04/98 AWB 2528-1316 E

1316e.bk : 1316e.IVZ Seite 2 Donnerstag, September 10, 1998 12:01 PM

1316e.bk : 1316e01.fm Seite 3 Donnerstag, September 10, 1998 12:01 PM

Mdulo de control easy

Indicaciones tcnicas de seguridad


Voltaje elctrico peligroso!
Los trabajos de instalacin que se describen a
continuacin deben realizarse nicamente por
personal tcnico cualificado.
No realice trabajos elctricos con la corriente
conectada.
Siga las instrucciones siguientes :
Desconecte todos los aparatos
Asegrese de que no se pueden conectar de
nuevo
Asegrese de que no tienen tensin

04/98 AWB 2528-1316 E

Recubra las partes cercanas que tengan corriente

1316e.bk : 1316e01.fm Seite 4 Donnerstag, September 10, 1998 12:01 PM

Mdulo de control easy


Ms fcil con easy

Conmutacin y control inteligente


easy es un mdulo de control de control para
instalaciones pequeas de forma cmoda. easy es
adecuado para la domtica y en la fabricacin de
mquinas y aparatos. Easy se suministra con
funciones de uso ergonmicas y eficientes.
Conecte el easy e introduzca su esquema de
contactos simplemente pulsando las teclas. easy
utiliza contactos a la apertura, contactos y rels.
Con easy implementar su esquema elctrico en
tamao real. easy dispone de las funciones
bsicas y especiales de controles por rels y por
contactores, aparte de muchas ms posibilidades.
Las modificaciones y ampliaciones pueden
realizarse simplemente pulsando una tecla. El
aparatoso recableado se hace prescindible.

Aplicacin universal
mbito domstico, sistemas de control de
iluminacin, marquesinas y persianas.
Extractores, puertas giratorias, invernaderos,
instalaciones de iluminacin exterior, accionamiento
de ventanas, iluminacin de escaparates.

04/98 AWB 2528-1316 E

Mquinas e instalaciones, prensas, cintas


transportadoras, transportadores vibrantes,
clasificadoras, bombas.

1316e.bk : 1316e01.fm Seite 5 Donnerstag, September 10, 1998 12:01 PM

Ms fcil con easy


Vista general del easy

alimentacin
entradas

DEL

ALT

Teclas de
funcin
Pantalla

ESC

OK

Interface para
la conexin de
la tarjeta de
memoria PC

04/98 AWB 2528-1316 E

salidas

1316e.bk : 1316e01.fm Seite 6 Donnerstag, September 10, 1998 12:01 PM

Mdulo de control easy


Montaje del easy

Montaje en carril DIN


Colocar el easy en el
borde superior
del carril y encajarlo.

.1

El mecanismo de muelle
permite que el easy
encaje automticamente.

.2

04/98 AWB 2528-1316 E

Montaje con tornillos


El montaje con tornillos
puede realizarse utilizando
los clips de fijacin que se
suministran como
accesorios.

1316e.bk : 1316e01.fm Seite 7 Donnerstag, September 10, 1998 12:01 PM

Conexin del easy

04/98 AWB 2528-1316 E

Conexin del easy

Conexiones de entrada y salida del easy de


24 V DC

1316e.bk : 1316e01.fm Seite 8 Donnerstag, September 10, 1998 12:01 PM

Mdulo de control easy


Conexiones de entrada y salida del easy de
115/230 V AC
264 V

l1-I6 = 0,5 mA, 230 V


= 0,25 mA, 115 V
I7, I8 = 6 mA, 230 V
4 mA, 115 V

"1" 79 V
"0" 40 V
L
N

> 1A
e = 115/230 AC
50 / 60 Hz
(97...264 V AC)
e = 40 mA 115 V
20 mA 230 V

0.5 Nm
3.5 mm
L

1
Q1

l1

1
Q2

I2

I4

I3

2
Q3

I5

I6

I7

I8

Q4

10 000 000

0 V DC
N

24 V DC
115 V AC
230 V AC

8A
8A
8A

2A
2A
2A

8 A / B 16
L1, L2, L3 ( 115/230 AC )
+ 24 V DC

10 58 W

25 000

04/98 AWB 2528-1316 E

1000 W

1316e.bk : 1316e01.fm Seite 9 Donnerstag, September 10, 1998 12:01 PM

Funciones del easy


Funciones del easy

Teclas de funcin
DEL: Eliminar del esquema de contactos
ALT: Funciones especiales en el
esquema de contactos
Teclas de cursor    :
Mover cursor
Seleccionar opciones de men
Establecer nmeros, contactos y valores
OK: Seguir, guardar
ESC: Ir atrs, cancelar

Gestin de mens y entrada de valores


Llamar men especial
y
Pasar al siguiente nivel de men
Llamar opcin de men
Guardar entradas
Pasar al nivel de men anterior
Deshacer entradas efectuadas desde el
ltimo OK
Saltar entre opciones de men

Modificar valor
  Cambiar posicin

Funciones de la tecla P:
entrada P1,  entrada P2
 entrada P3,
 entrada P4

04/98 AWB 2528-1316 E

1316e.bk : 1316e01.fm Seite 10 Donnerstag, September 10, 1998 12:01 PM

Mdulo de control easy


Pantalla de estado
Entradas
 On /  Off

Salidas
 On /  Off






 

Da de la semana
Hora
Modo de funcionamiento
RUN/STOP

Pantalla del men


Seleccin actual
parpadea en el
men easy

 """











 !"!#

 !"!#

Men principal con o sin proteccin por


contrasea

Pantalla del cursor

Cursor / 
Mover cursor con  
o tambin con en el
esquema de contactos
Valor / 
Cambiar posicin con  
Cambiar valores con 
En el manual, los valores
parpadeantes se representan en
color gris

10

$"%


!

$&

$"%


!

$

04/98 AWB 2528-1316 E

El cursor parpadea
alternativamente

1316e.bk : 1316e01.fm Seite 11 Donnerstag, September 10, 1998 12:01 PM

Funciones del easy


Pantalla del esquema de contactos

Campo de bobina

Campos de

Vas de
corriente


 



Conexiones

Elementos del esquema de contactos




Contacto: Tecla P

Contacto: Entrada

Contacto/bobina: Salida

Contacto/bobina: Marcador

Contacto/bobina: Temporizador

Contacto/bobina: Contador

Contacto: Reloj programable

Contacto: Comparador de valores


analgicos
Campo de bobina

'(')
'*+&&&&&
&&&&&&&&&

04/98 AWB 2528-1316 E

&&&&&&&&&

Va de corriente 1
Va de corriente 2
Va de corriente 3
...

Va de corriente 41

11

1316e.bk : 1316e01.fm Seite 12 Donnerstag, September 10, 1998 12:01 PM

Mdulo de control easy


Estructura del men
Men principal sin proteccin por contrasea
STOP: Pantalla del esquema de contactos
RUN: Pantalla del flujo de corriente

Men



 



Esquema de
contactos

RUN
STOP

Pantalla de
parmetros
Registro de
parmetros


 

  


 

  

   


 

  

  

   


 
 

  


 



 






 






 




 


Pantalla de
parmetros
Registro de
parmetros




 

  

 

Pantalla de
configuracin
del reloj

 






 

 

  




 




 

12

   

04/98 AWB 2528-1316 E



   

 


1316e.bk : 1316e01.fm Seite 13 Donnerstag, September 10, 1998 12:01 PM

Funciones del easy


Men principal con proteccin por contrasea
Men principal




cuatro
entradas
errneas

Introducir
contrasea

entrar en el
easy

Contrasea

 

entrada
correcta




Visualizzazione
di stato



   



Men especial
Introducir
contrasea

Men


Establecer contrasea
Contrasea

 
 


impostazione
password

  
   

Cambiar

  



 
 

  
   

Contrasea

 
 
 
 
 


  
 

 



 
 

  
   

 
  



 
 

  

04/98 AWB 2528-1316 E

   

 
  
   
  

 

Las funciones de men se


describen en el manual
AWB 2528-1304 E.

13

14

04/98 AWB 2528-1316 E

1316e.bk : 1316e01.fm Seite 14 Donnerstag, September 10, 1998 12:01 PM

1316e.bk : 1316e02.fm Seite 15 Donnerstag, September 10, 1998 12:01 PM

Manejo easy

El cableado con easy

Teclas para editar el esquema de contactos


Eliminar conexin, contacto, rel o
conexin que no se utilicen
Abrir/Cerrar contactores
Cablear contactos y rels
Insertar conexiones
 Modificar valor
Mover cursor hacia arriba/
abajo

Cambiar posicin
Mover cursor hacia la
izquierda/derecha
Asignar teclas P:
entrada P1,  entrada P2
 entrada P3,
 entrada P4


Deshacer entradas efectuadas


desde el ltimo OK
Salir de la pantalla actual

04/98 AWB 2528-1316 E

Modificar/insertar nuevo contacto


rel
Guardar configuracin

15

1316e.bk : 1316e02.fm Seite 16 Donnerstag, September 10, 1998 12:01 PM

El cableado con easy


Establecer el idioma del
men

Conectar easy por primera vez


Establecer el idioma del men
selezionare con i tasti cursore
 la lingua prescelta
!

GB Ingls
D

Alemn

Francs

Espaol

Italiano

-.""

Confirmar configuracin con OK..

El easy pasa a la pantalla de


estado .



!

 

Configurar hora

La configuracin de la hora slo es posible en los


modelos easy, versin ...-C.
Pasar a la pantalla de configuracin del reloj



 """

!



  



 

 
!"!#
"""


 !"!#

$"%

16

04/98 AWB 2528-1316 E

 !"!#

1316e.bk : 1316e02.fm Seite 17 Donnerstag, September 10, 1998 12:01 PM

Seleccionar el modo de
funcionamiento del easy
Configurar da de la semana y hora
 !"!#

$"%

$"%

 !
$ 

  seleccionar posicin
  modificar valor
Guardar configuracin
o
mantener valores anteriores

Salir del men

Cambio de horario verano/invierno


 !"!#
$"%

Indicacin: HOR.VERANO
establecido horario de invierno
Indicacin: HOR.INVIERNO
establecido horario de verano
cambiar configuracin
salir del men

Seleccionar el modo de
funcionamiento del
easy

El easy dispone de dos modos de funcionamiento :


RUN o STOP.
RUN: El easy ejecuta el esquema de contactos.
STOP: Puede crearse un esquema de contactos

04/98 AWB 2528-1316 E

ILa opcin de men conmutable


RUN/STOP siempre indica el posible  """
cambio de modo de funcionamiento: 
Modo de funcionamiento STOP:
Indicacin: RUN


"

Modo de funcionamiento RUN: Indicacin: STOP

17

1316e.bk : 1316e02.fm Seite 18 Donnerstag, September 10, 1998 12:01 PM

El cableado con easy


Elementos del
esquema de contactos
del easy

Contactos de conmutacin
Contacto de conmutacin

Contacto Contacto rea


cerrado abierto

Conexin de entrada easy

...

Tecla de cursor

...

Rel de salida easy

...

Rel auxiliar (marcador)

...

Rel de funcin Contador

...

Rel de funcin Temporizador

...

Rel de funcin Reloj programable 

...

...

Rel de funcin para el


procesamiento de valores
analgicos

Tipo de rel

Smbolo rea
easy

Funcin Parmetro
de bobina

Rel de salida

...

...

Rel auxiliar (marcador) 

18

Rel de funcin
Temporizador

...

Rel de funcin
Contador

...

Rel de funcin Reloj


programable

...

Rel de funcin para el 


procesamiento de
valores analgicos

...

X
04/98 AWB 2528-1316 E

Rels

1316e.bk : 1316e02.fm Seite 19 Donnerstag, September 10, 1998 12:01 PM

Elementos del esquema


de contactos del easy
Rels con activacin por estado


on

on

Rels de impulso


on

on

04/98 AWB 2528-1316 E

, 

Rels enclavados

19

1316e.bk : 1316e02.fm Seite 20 Donnerstag, September 10, 1998 12:01 PM

El cableado con easy


Ejemplo: Crear un
esquema de contactos

Cablear contactos y rels


Cableado fijo

Cableado easy

Entrada I1 al cerrar el contacto S1


Entrada I2 al cerrar el contacto S2
Carga H1 a contacto de salida Q1
Esquema de contactos easy

 

Pasar a la pantalla del esquema de contactos


Punto de partida: Pantalla de estado



 """

!



 


 
 !"!#
"

 

#"""
&

Introducir contacto I1
Pantalla del esquema de contactos



&

20

04/98 AWB 2528-1316 E

&

1316e.bk : 1316e02.fm Seite 21 Donnerstag, September 10, 1998 12:01 PM

Ejemplo: Crear un
esquema de contactos
Introducir contacto I2
&





'&

Conectar los campos de contacto y de bobina


'&

'/
''''/
''''&

Seleccionar bobina de rel Q1


''''&

'''')

04/98 AWB 2528-1316 E

'''')
''''')
&

21

1316e.bk : 1316e02.fm Seite 22 Donnerstag, September 10, 1998 12:01 PM

El cableado con easy


Seleccionar el modo de funcionamiento
Esquema de contactos easy
''''')

 
"
 """


 ""
 !"!#


 !"!#

easy trabaja en modo de funcionamiento RUN

Comprobar el funcionamiento del esquema de


contactos

 """

 """









 !"!#

 !"!#

Pantalla de flujo de conexiones

22

04/98 AWB 2528-1316 E

''''')

1316e.bk : 1316e02.fm Seite 23 Donnerstag, September 10, 1998 12:01 PM

Ejemplo: Crear un
esquema de contactos
Conectar los conmutadores S1 y S2
S1 on

'''')

)

S2 on

)

La bobina de rel 01 opera

Volver a la pantalla de estado con ESC

)



!

  

En el siguiente ejemplo se ampla la funcin del


esquema de contactos con un rel de funcin

04/98 AWB 2528-1316 E

Inicio desde la pantalla de estado


Seleccionar el
modo de
funcionamiento
STOP:

 ""


 !"!#

23

1316e.bk : 1316e02.fm Seite 24 Donnerstag, September 10, 1998 12:01 PM

El cableado con easy


Rels de funcin

Representacin en el
esquema de contactos

Rels de funcin

Rel de temporizacin, retardo a la


conexin, por flanco o por nivel
Rel de temporizacin, retardo a
desconexin, por flanco o por nivel
Rel de temporizacin, pulso retentivo
Rel de temporizacin, parpadeante
R

Rel contador, reversible


Reloj programable, da de la semana/hora
(slo en las versiones del easy con reloj
en tiempo real
Rel para la comparacin de valores
analgicos (slo en las versiones del
easy de 24 V DC)

Rels de temporizacin

Rel de temporizacin, con o sin


retardo a conexin por flanco

on

TRG

on

on

24

04/98 AWB 2528-1316 E

RES

1316e.bk : 1316e02.fm Seite 25 Donnerstag, September 10, 1998 12:01 PM

Rels de funcin

Rel de temporizacin, con o sin


retardo a desconexin por flanco

on
TRG

on
RES

on

En el caso del rel de temporizacin con retardo por


flanco, easy determina un tiempo de retardo entre
cero y el tiempo nominal fijado.
Rel de temporizacin, pulso
retentivo


on
TRG

on
RES

on

04/98 AWB 2528-1316 E

25

1316e.bk : 1316e02.fm Seite 26 Donnerstag, September 10, 1998 12:01 PM

El cableado con easy


Rel de temporizacin, parpadeante

Frecuencia
1
di inter=
2 veces tiempo nominal
mitencia

on
TRG

on
RES

on

Pantalla de parmetros para rels temporizador


Funcin de
conmutacin



Margen de tiempo

 

Bobina de activacin

   N.

26

Tempo
nominal

   Pantalla de

parmetros

04/98 AWB 2528-1316 E

Bobina de
reinicializacin

Tiempo real

1316e.bk : 1316e02.fm Seite 27 Donnerstag, September 10, 1998 12:01 PM

Rels de funcin
Rel contador
on
CNT
on
DIR
on
RES

8
6
4
2
0

7
5
3
1

on

Pantalla de parmetros para rels contadores


Valor nominal
Direccin
Contaje

04/98 AWB 2528-1316 E

Bobina de
reinicializacin

 Valor real


  
    

N.
Pantalla de

    parmetros

27

1316e.bk : 1316e02.fm Seite 28 Donnerstag, September 10, 1998 12:01 PM

El cableado con easy


Reloj programable

Ejemplo de programacin: El reloj programable


(1 conecta de lunes a viernes de 6.30 h a 9.00 h y de
17.00 h a 22.30 h.
0!'%1

0!'%1

23*

23*

4 2

4 2-

..5867

..567

LU

MA

MI

JU

VI

DO

A on
B on
on

Pantalla de parmetros para el reloj programable

28

!" 

Hora

# 

N.

Hora de conexin

$ # %

Canal

Hora de
desconexin

$&&# 

Pantalla de
parmetros

04/98 AWB 2528-1316 E

Da(s) de la
semana de ... a

1316e.bk : 1316e02.fm Seite 29 Donnerstag, September 10, 1998 12:01 PM

Rels de funcin
Comparador de valores analgicos
Opciones de comparacin
I7 I8, I7 I8
I7 valor nominal, I7 valor nominal
I8 valor nominal, I8 valor nominal

Los valores nominales y reales de 0.0 a 10.0


corresponden a los valores de tensin medidos.
Las oscilaciones de seales analgicas son milivolticas. En lo relativo a los valores nominales de
configuracin y reconfiguracin, procure mantener una
diferencia de potencial mnima de 0,2 V para evitar
vibraciones del rel de salida. No utilice rels con las
funciones de bobina de contactor y de impulsin.
Pantalla de parmetros para del comparador de
valores analg
Comparar las entradas I7 y I8

% %!$
Entrada I7

' ( )

Valores
reales

Comparacin

 * %

N.

Entrada I8

( + ) 

Pantalla de
parmetros

Comparar la entrada con los valores nominales

% %!$
04/98 AWB 2528-1316 E

Entrada I7

' ( )

Valor real

Comparacin

 , % N.

Valor nominal

   Pantalla de

parmetros

29

1316e.bk : 1316e02.fm Seite 30 Donnerstag, September 10, 1998 12:01 PM

El cableado con easy


Ejemplo: Utilizar rels
de funcin

Cableado fijo

Cableado easy
easy conecta H1
con un retardo de 10
segundos
Esquema de
contactos easy
''''')
'''''''
''''''')

Seleccionar rel de salida Marcador


Punto de partida: Esquema de
contactos del primer ejemplo
''''')

Situar el cursor sobre Q


''''')
''''')

2x

''''')
&

''''')

''''')

&


''''')

2x

30

2x

3x

'''''')

04/98 AWB 2528-1316 E

Seleccionar contacto de marcador, conectar con


salida

1316e.bk : 1316e02.fm Seite 31 Donnerstag, September 10, 1998 12:01 PM

Ejemplo: Utilizar rels de


funcin
Seleccionar rel de disparo para el tiempo
''''')

''''')

'''''')

'''''''

2x

''''')
'''''''
&

Introducir contacto para rel de temporizacin


''''')

''''')

'''''''

'''''''

&



2x

''''')
'''''''


Llamar pantalla de parmetros


''''')

2x

9:1

'''''''

2"2



)4 3

04/98 AWB 2528-1316 E

567

31

1316e.bk : 1316e02.fm Seite 32 Donnerstag, September 10, 1998 12:01 PM

El cableado con easy


Establecer 10 segundos
9:1

9:1

2"2

2"2

)4 3

)4 3

567

567

2x

9:1
2"2
)4 3
567

2x

volver al esquema de
contactos

Cableado de la salida
''''')

''''')

'''''''

'''''''

&

/

3x

3x

''''')
'''''''
''''''')
&

Para comprobar el esquema de contactos, pase al


modo de funcionamiento RUN.
Haga una prueba del esquema de contactos

Adems, podr ver el parmetro del tiempo y


modificar el valor nominal:
Site el cursor sobre la T de T1 en el esquema

del conjunto de circuitos y pulse OK.

32

04/98 AWB 2528-1316 E

segn detallado en el primer ejemplo.

1316e.bk : 1316e02.fm Seite 33 Donnerstag, September 10, 1998 12:01 PM

Circuitos principales
Circuitos principales

Significado de los valores lgicos


0 contacto abierto, contacto a la apertura
cerrado, bobina no excitada
1 contatto NA chiuso, contatto NC aperto,
bobina eccitata
Negacin
I1

Q1

1
0

0
1

;''''''')

Contacto permanente
---

Q1

''''''''')

Conmutador de impulso
I1

Estado Q1

Q1

0
1
0
1

0
0
1
1

0
1
1
0

'''''''<

04/98 AWB 2528-1316 E

Conexin serie
I1

I2

I3

Q1

Q2

0
1
0
1

0
0
1
1

0
0
0
0

0
0
0
0

1
0
0
0

0
1
0
1

0
0
1
1

1
1
1
1

0
0
0
1

0
0
0
0

''')
;';';')

33

1316e.bk : 1316e02.fm Seite 34 Donnerstag, September 10, 1998 12:01 PM

El cableado con easy


Conexin en paralelo

('''''')

I1

I2

I3

Q1

Q2

0
1
0
1

0
0
1
1

0
0
0
0

0
1
1
1

1
1
1
1

+

0
1
0
1

0
0
1
1

1
1
1
1

1
1
1
1

1
1
1
0

;4

4

;('''''')
;+

Conexin de tres vas (XOR)


I1

I2

Q1

0
1
0
1

0
0
1
1

0
1
1
0

';(''')
;'+

Autoenclavamiento
I2

Contatto Bobina
Q1
Q1

0
1
0
1

0
0
1
1

0
0
0
0

0
0
0
1

1
0
1

0
1
1

1
1
1

0
1
1

('''')
+

alternativ
'''''''
;'''''''

04/98 AWB 2528-1316 E

34

I1

1316e.bk : 1316e03.fm Seite 35 Donnerstag, September 10, 1998 12:01 PM

Interface easy

A travs de la interface easy, los esquemas de


contactos pueden transferirse a una tarjeta de
memoria, o a un PC en que se haya instalado
previamente el programa EASY-SOFT, mediante un
cable de transmisin de datos .
Tarjeta de memoria
Ogni scheda di memoria - disponibile come
accessorio easy M-8K - memorizza uno schema
elettrico di easy.
La informacin guardada en la tarjeta de memoria se
conserva an sin corriente, lo cual le permite utilizar
la tarjeta para archivar, transportar y copiar
esquemas de contactos.
En la tarjeta de memoria se
guardan:

04/98 AWB 2528-1316 E

el esquema de contactos
todos los registros de
parmetros del esquema
de contactos
las configuraciones del
sistema

Cargar o almacenar un esquema de contactos


El intercambio de datos debe efectuarse en el modo
de funcionamiento STOP.
EASY > TARJ.: Guardar el
=>#"
esquema de contactos easy
#">=
en la tarjeta,
"#
TARJ. > EASY: Cargar el
esquema de contactos de la
tarjeta en la memoria del easy,
SUPRIM. TARJ: Borrar el contenido de la tarjeta de
memoria
35

1316e.bk : 1316e03.fm Seite 36 Donnerstag, September 10, 1998 12:01 PM

Interface easy
EASY-SOFT
EASY-SOFT es un programa de PC que le permite
crear, comprobar y gestionar esquemas de
contactos easy. Los esquemas de contactos
pueden transferirse directamente desde el PC al
easy y viceversa.
Para la transferencia de datos entre el PC y el easy
debe utilizarse exclusivamente el cable de PC
easy, el cual puede adquirirse como accesorio
easy-PC-CAB.
Para comprobar un esquema de contactos creado
en el PC con cableado real, el esquema debe
transferirse al easy y seleccionar el modo de
funcionamiento RUN del easy.
EASY-SOFT le ofrece una
completa ayuda para aprender a
trabajar con el programa.

36

04/98 AWB 2528-1316 E

Inicie EASY-SOFT, haga


simplemente clic sobre
Contenido y ver toda la informacin necesaria
acerca de EASY-SOFT.

1316e.bk : 1316e04.fm Seite 37 Donnerstag, September 10, 1998 12:01 PM

Caractersticas
tcnicas

50

10.75

Caractersticas tcnicas

Peso

200 g

Temperatura ambiente

de 0 a 55 C

Grado de proteccin

IP20

Inmunidad a
interferencias

Grado de lmite B, EN55011, EN55022

Normas
Aprobaciones

EN50178
UL, CSA

56.5
47.5

10.75

45
58

M4
35.75
04/98 AWB 2528-1316 E

90

100
110

4.5

71.5

37

1316e.bk : 1316e04.fm Seite 38 Donnerstag, September 10, 1998 12:01 PM

Caractersticas tcnicas
Gama easy

EASY 412-DC-R
24 V DC
8 entradas digitales (2 de ellas pueden funcionar
como analgicas tambin)
4 salidas de rel
Pantalla LCD
Teclas de funcin
EASY 412-DC-RC
igual que EASY 412-DC-R, con reloj programable
EASY 412-AC-R
115/230 V AC
8 entradas digitales
4 salidas de rel
Pantalla LCD
Teclas de funcin
EASY 412-AC-RC
igual que EASY 412-AC-R, con reloj programable

Equipamiento adicional
Software EASY-SOFT
Tarjeta de memoria EASY-M-8K
Cable de conexin EASY-PC-CAB
Clips de fijacin ZB4-101-GF1
Documentacin
Manual bsico AWB 2528-1316 E

38

04/98 AWB 2528-1316 E

Manual de instrucciones AWB 2528-1304 E

1316e.bk : 1316e.SIX Seite 39 Donnerstag, September 10, 1998 12:01 PM

ndice alfabtico

B
Bobina, funcionnes de 19
C
Cable de transmisin 35
Circuito AND 33
Circuito NOT 33
Circuito OR 34
Circuito principal
autoenclavamiento 34
conexin de tres vas
(XOR) 34
conexin en paralelo 34
conexin serie 33
conmutador de
impulsin 33
contacto permanente 33
negacin 33
Circuito XOR 34
Comparador de valores
analgicos 29
Conectar el easy AC 7, 8
Conectar entradas 7, 8
Conectar salidas 7, 8
Configurar 19
Configurar da de la
semana 17
Contactor, funciones de 19
Contactos de
conmutacin, tipos 18

04/98 AWB 2528-1316 E

D
Dimensiones easy 37

E
easy vista general 5
Ejemplo de
circuitos principales 33
contactos y rels 20
rel de funcin 30
Encajar 19
Esquema de contactos
cargar 36
comprobar 22
contacto, introducir 20
ejemplos 20, 30, 33
elementos 11
funciones de las
teclas 15
guardar 35, 36
llamar pantalla 20
llamar pantalla de
parmetros 31
seleccionar bobina de
rel 21
seleccionar marcador 30
utilizar rels de
funcin 31
Estructura del men 12
G
Gestin de mens 9
H
Hora, configurar 17
Horario de invierno 17
Horario de verano 17
I
Idioma del men 16

39

1316e.bk : 1316e.SIX Seite 40 Donnerstag, September 10, 1998 12:01 PM

ndice alfabtico

P
Pantalla de estado 10
Pantalla de parmetros
comparador de valores
analgicos 29
rel contador 27
rel de temporizacin 26
reloj programable 27
Pantalla del cursor 10
Potencial, diferencia 29
R
Reiniciar 19
Rel contador 27
Rel de impulsin 19

40

Rel de
temporizacin 2426
Rels de funcin
comparador de valores
analgicos 29
rel de temporizacin 24
reloj programable 28
tipos de rels 24
Rels, tipos de rels 18
Reloj programable 28
S
Seleccionar modo de
funcionamiento 17
T
Tablas lgicas 3334
Tarjeta de memoria 35
Teclas de funcin 9

04/98 AWB 2528-1316 E

M
Men especial 13
Montaje 6

Data sheet Sach Nr.: 4200 595 (4) rev. 02 19.12.02


Page 1-3

Page 1

Medium Voltage Smart Motor Controller Allen-Bradley Bulletin


1562D

Qty.:
Type:
Voltage:
Power:
Load profile:
Cooling method:
Ambient temp.:
Enclosure:
Rel. humidity:
Dimensions:
Weight:

1
1562D-TJEY
4160V, 50/60Hz
500HP
Variable torque
Air
0-40C
NEMA Type 12
max. 95%, non condensing
(W)915 x (D)915 x (H)2315mm
636kg

Accessories included:
Motor Protection Relais Bulletin 825
with RTD input
Set of Lamps and push buttons
Set of Lamps and push buttons

Bulletin 1562D

L:\Dokumentationen-FrameMaker\A - Unterlieferanten fr Auftrge\2-443-20351-01 El Teniente\Elektrodokumentation\Brennen Pipa Norte\Datenblatt Kund_ Bulletin 1562D


Sach_Nr_4200 595 Re_02.doc

... / 2

Datenblatt Sach Nr.: 4200 595 (4) rev. 02


Blatt 1-3

19.12.02

Blatt 2

Specials of Bulletin 1560 / 1562 :

SMC Dialog Plus controller, fully programmable, communication adapters


heat sink profile optimized for soft starter applications without fans or ventilation
compact self powered gate drivers, no control transformer, no heat losses after soft
start
redesigned compact structure: height 2315 mm, depth 915 mm, width: 660 - 2540 mm
depending on kV and nominal current

Bulletin 1562 = Bulletin 1560 + Input Starter:

3-pole gang-operated, non load break isolating switch with an


external operating handle, fully interlocked with isolation contactor
and power cell doors
3 R-rated current limiting power fuses
3 bar type current transformers
Fixed mounted ISOLATION vacuum contactor
Control power transformer

Bulletin 1560 :

M
3~

SMC Dialog Plus control module with 4 modes of starting


Electronic overload protection
Low voltage and power cell doors with a viewing window
2-line, 16 character backlit LCD display
Metering without additional CPT or PT
Built-in SCAN-port communications
Programmable adjustments for setup
Power SCRs with fibre optic isolated gate logic
Fixed mounted vacuum BYPASS contactor
Motor Protection Relais Bulletin 825

Technical Discription Medium Voltage Smart Motor Controller


MV SMC Dialog Plus, Solid State Reduced Voltage Controller Unit with Bypass Contactor
Codes and Standards:

Each controller shall be designed, manufactured and tested to meet or exceed the
requirements of the latest published standards of:

L:\Dokumentationen-FrameMaker\A - Unterlieferanten fr Auftrge\2-443-20351-01 El Teniente\Elektrodokumentation\Brennen Pipa Norte\Datenblatt Kund_ Bulletin 1562D


Sach_Nr_4200 595 Re_02.doc

... / 3
Datenblatt Sach Nr.: 4200 595 (4)ev. 02
Blatt 1-3

19.12.02

Blatt 3

Canadian Standards Association (CSA) Industrial Control Equipment C22.2 No. 14


American National Standards Institute (ANSI) Instrument Transformers C57.13
National Electrical Manufacturers Association (NEMA) Medium Voltage Controllers Rated
1501 to 7200 volts AC ICS 3-2 (formerly ICS 2-324)
Underwriters Laboratories, Inc. (UL) High Voltage Industrial Control Equipment 347

Standard Features :
Fixed mounted 400 amp "BYPASS" vacuum contactor
SMC Dialog Plus control module with four modes of starting: Soft Start with
selectable Kickstart, Current Limit, Dual Ramps or Full Voltage.
Programmable adjustments for setup.
Power SCRs with fiber optic isolated gate logic.
Viewing window in low voltage door to view the LCD display on the control
module.
Low voltage and power cell doors.
Metering (does not require additional CPT or PTs)
Electronic motor overload protection.
Bulletin 825-NCM-20 converter module(mounted in cabinet)
Built-in SCANport communications.

2-line, 16 character backlit LCD display.

Additional Features for Bulletin 1562D (is quoted) :


Non Load Line Breaker with viewing window
3 phase line vacuum contactor interlocked with non load breaker
3 phase line power fuses

1 selector switch
local remote
1 push button color green
on local
1 push button color red
off local
1 push button color green
Resetl
1 potential-free contact on / off remote
1 potential-free contact UTS (soft start completed)
1 potential-free contact FAULT
1 potential-free contact Reset
1 lamp FAULT, in low-voltage unit, colour red
1 lamp UTS (soft start completed), in low-voltage unit, colour green
Colour of switch cabinet, standard colour RAL 7005
Motor- and power supply cables connected from top
Software for soft starter(DriveExplorer Lite) provided as CD-Rom including
connection cable 1203-SSS

L:\Dokumentationen-FrameMaker\A - Unterlieferanten fr Auftrge\2-443-20351-01 El Teniente\Elektrodokumentation\Brennen Pipa Norte\Datenblatt Kund_ Bulletin 1562D


Sach_Nr_4200 595 Re_02.doc

Medium V
oltage
Voltage
Dialog Plus
Motor Controller
Bulletin 1503D, 1560D
and 1562D

User Manual

Important User Information

Because of the variety of uses for the products described in this publication,
those responsible for the application and use of this control equipment must
satisfy themselves that all necessary steps have been taken to assure that each
application and use meets all performance and safety requirements, including
any applicable laws, regulations, codes and standards.
The illustrations, charts, sample programs and layout examples shown in this
guide are intended solely for purposes of example. Since there are many
variables and requirements associated with any particular installation,
Rockwell Automation does not assume responsibility or liability (to include
intellectual property liability) for actual use based upon the examples shown
in this publication.
Rockwell Automation publication SGI-1.1, Safely Guidelines for the Application, Installation, and Maintenance of Solid-State Control (available from
your local Rockwell Automation office), describes some important differences between solid-state equipment and electromechanical devices that
should be taken into consideration when applying products such as those
described in this publication.
Reproduction of the contents of this copyrighted publication, in whole or in
part, without written permission of Rockwell International Corporation, is
prohibited.
Throughout this manual we use notes to make you aware of safety
considerations:

ATTENTION: Identifies information about practices or


circumstances that can lead to personal injury or death,
property damage or economic loss.

Attention statements help you to:


identify a hazard
avoid the hazard
recognize the consequences
Important: Identifies information that is critical for successful application
and understanding of the product.

SMC Dialog Plus, SCANport, and Accu-Stop are trademarks of Rockwell Automation.
DeviceNet is a trademark of the Open DeviceNet Vendors Association (O.D.V.A.).

Table of Contents
Preface

Service Procedure

Product Overview

Chapter 1

Page

Manual Objectives ............................................................................ 1-1


Documentation .................................................................................. 1-1
Description ........................................................................................ 1-1
1503D Chassis Mount Retrofit Controller ............................... 1-1
1560D Retrofit Controller........................................................ 1-1
1562D Combination Controller ............................................... 1-2
Starting Modes .................................................................................. 1-3
Soft Start ..................................................................................... 1-3
Selectable Kickstart .................................................................... 1-4
Current Limit Start ...................................................................... 1-4
Dual Ramp Start.......................................................................... 1-5
Full Voltage Start ........................................................................ 1-5
Protection and Diagnostics ................................................................ 1-6
Overload...................................................................................... 1-6
Stall Protection and Jam Detection ............................................. 1-8
Open Gate ................................................................................... 1-9
Line Faults .................................................................................. 1-9
Underload ................................................................................... 1-9
Excessive Starts/Hour ............................................................... 1-10
Overtemperature ....................................................................... 1-10
Metering .......................................................................................... 1-10
Communication ............................................................................... 1-11
Programming ................................................................................... 1-11
Status Indication .............................................................................. 1-12
Control Options ............................................................................... 1-12
Soft Stop Option ....................................................................... 1-12
Pump Control Option ................................................................ 1-13
Application Considerations .................................................. 1-13
Preset Slow Speed Option ........................................................ 1-15
SMB Smart Motor Braking Option ...................................... 1-15
Slow Speed with Braking Option ............................................. 1-16
Hardware Description ..................................................................... 1-17
Power Module ........................................................................... 1-17
Self-Powered Silicon-Controlled Rectifier Gate Driver Board ..... 1-17
Interface Board ......................................................................... 1-18
System Diagram Figure 1.17 ........................................................ 1-19
Functional Description .................................................................... 1-20
Bulletin 1562D Basic Control Standard Module ................ 1-20
Bulletin 1562D Basic Control Soft Stop or Pump Control ... 1-20
Bulletin 1562D SCANport Control Standard Module ........ 1-21
Bulletin 1562D SCANport Control Soft Stop or Pump Control... 1-21
Bulletin 1560D Basic Control Standard Module ................ 1-22
Bulletin 1560D Basic Control Soft Stop or Pump Control ... 1-22

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Table of Contents MV Dialog Plus Medium Voltage Controller User Manual

Installation

Chapter 2

Page

Receiving ........................................................................................... 2-1


Safety and Codes ............................................................................... 2-1
Unpacking and Inspection ................................................................. 2-1
General Precautions........................................................................... 2-2
Transportation and Handling ............................................................. 2-2
Installation Site .................................................................................. 2-3
Power Connections ............................................................................ 2-5
Power Wiring .................................................................................... 2-8
Interlocking ....................................................................................... 2-8
Installation ......................................................................................... 2-9
Surge Arrestor Protection Devices .................................................. 2-12
Motor Overload Protection.............................................................. 2-13
Human Interface Module................................................................. 2-14
Communication Modules ................................................................ 2-18
Converter Modules .......................................................................... 2-19
Control Terminal Designations ....................................................... 2-21

Commissioning Procedure

Chapter 3
Preliminary Set-Up ............................................................................ 3-1
System Characteristics ...................................................................... 3-2
Preliminary Check ............................................................................. 3-3
Programming ..................................................................................... 3-3
Hi-Pot and Megger Test .................................................................... 3-4
Power Supply Tests ........................................................................... 3-6
Control Function Tests ...................................................................... 3-9
Resistance Checks ........................................................................... 3-10
Start-Up ........................................................................................... 3-10

Programming

Chapter 4
Overview ........................................................................................... 4-1
Keypad Description ........................................................................... 4-1
Programming Menu ........................................................................... 4-1
Password ............................................................................................ 4-5
Search ................................................................................................ 4-5
Parameter Management ..................................................................... 4-6
Parameter Modification ..................................................................... 4-8
Soft Start ............................................................................................ 4-9
Current Limit Start ............................................................................ 4-9
Dual Ramp Start .............................................................................. 4-10
Full Voltage Start ............................................................................ 4-10
Basic Setup ...................................................................................... 4-11
Advanced Setup ............................................................................... 4-12
Example Settings ............................................................................. 4-13

1560D-5.1 February 2000

iii

Table of Contents MV Dialog Plus Medium Voltage Controller User Manual

Calibration

Chapter 5

Page

Overview ........................................................................................... 5-1


Motor Data Entry .............................................................................. 5-1

Metering

Chapter 6
Overview ........................................................................................... 6-1
Viewing Metering Data ..................................................................... 6-1

Options

Chapter 7
Overview ...........................................................................................
Human Interface Module...................................................................
Programming Parameters ..................................................................
Control Wiring for SCANport Control .............................................
Soft Stop Option ................................................................................
Pump Control Option ........................................................................
SMB Smart Motor Braking Option ...................................................
Preset Slow Speed Option .................................................................
Slow Speed with Braking Option ......................................................

Serial Communications

7-1
7-1
7-3
7-4
7-5
7-6
7-7
7-8
7-9

Chapter 8
Overview ........................................................................................... 8-1
Logic Control Data ............................................................................ 8-1
Control Wiring .................................................................................. 8-1
Control Enable................................................................................... 8-2
SMC Status Data ............................................................................... 8-3
Reference/Feedback .......................................................................... 8-3
Parameter Listing .............................................................................. 8-3
Scale Factor Conversion .................................................................... 8-3
Display Unit Equivalents .................................................................. 8-4
Datalinks/SLC Block Transfers ........................................................ 8-4
Interfacing ......................................................................................... 8-4
Processing Time ................................................................................ 8-4
Remote I/O Examples........................................................................ 8-5
Example #1 SLC 500 Controller without Block Transfer ....... 8-5
Example #2 SLC 500 Controller with Block Transfer .......... 8-10
Example #3 PLC 5/20, 5/40, 5/60 and 5/80 ........................... 8-20
DeviceNet Examples ....................................................................... 8-27
Example #1 SLC 500 Controller with Explicit Messaging ... 8-27
1203-GK5 Communication Module Switch Settings ............... 8-28
Explicit Messaging ................................................................... 8-33

1560D-5.1 February 2000

iv

Table of Contents MV Dialog Plus Medium Voltage Controller User Manual

Diagnostics

Chapter 9

Page

Overview ...........................................................................................
Fault Display .....................................................................................
Clear Fault .........................................................................................
Fault Buffer .......................................................................................
Fault Auxiliary Contact .....................................................................
Fault Definitions ................................................................................

Troubleshooting

9-1
9-1
9-1
9-2
9-3
9-3

Chapter 10
General Notes and Warnings ........................................................... 10-1
Fault Identification .......................................................................... 10-2
Control Module Removal ................................................................ 10-7
Voltage Feedback Circuit Tests ...................................................... 10-8
Circuit Board Replacement ............................................................. 10-8
Power Circuit Troubleshooting ....................................................... 10-9
Thyristor Testing ...................................................................... 10-9
SCR Replacement Procedure .................................................. 10-10
Snubber and Resistor Circuit Testing ........................................... 10-24
Snubber Resistor Replacement ....................................................... 10-26

Maintenance

Chapter 11
Safety and Preventative ................................................................... 11-1
Periodic Inspection .......................................................................... 11-1

Appendix A

Parameter Information .................................................................... A-1

Appendix B

Spare Parts ............................................................................... B-1

Appendix C

Accessories .............................................................................. C-1

1560D-5.1 February 2000

Table of Contents MV Dialog Plus Medium Voltage Controller User Manual

Figures

Page

Figure 1.1
Figure 1.2
Figure 1.3
Figure 1.4
Figure 1.5
Figure 1.6
Figure 1.7
Figure 1.8
Figure 1.9
Figure 1.10
Figure 1.11
Figure 1.12
Figure 1.13
Figure 1.14
Figure 1.15
Figure 1.16
Figure 1.17
Figure 1.18a
Figure 1.18b
Figure 1.18c
Figure 1.18d
Figure 1.19a
Figure 1.19b

Soft Start ...................................................................................................... 1-3


Selectable Kickstart...................................................................................... 1-4
Current Limit Start ....................................................................................... 1-4
Dual Ramp Start ........................................................................................... 1-5
Full Voltage Start ......................................................................................... 1-5
Overload Trip Curves ................................................................................... 1-7
Restart Trip Curves after Auto Reset ........................................................... 1-7
Stall Protection ............................................................................................. 1-8
Jam Detection ............................................................................................... 1-8
SCANport Location ................................................................................... 1-11
Built-in Keypad and LCD .......................................................................... 1-11
Soft Stop Option ......................................................................................... 1-12
Pump Control Option ................................................................................. 1-14
Preset Slow Speed Option .......................................................................... 1-15
SMB Smart Motor Braking Option ............................................................ 1-15
Slow Speed with Braking Option ............................................................... 1-16
System Diagram ......................................................................................... 1-19
Bul. 1562D Basic Control Circuit Standard Module ................................. 1-23
Bul. 1562D Basic Control Circuit Soft Stop or Pump Control .................. 1-24
Bul. 1562D with SCANport Control Standard Module ............................ 1-25
Bul. 1562D with SCANport Control Soft Stop or Pump Control ........... 1-26
Bul. 1560D Basic Control Circuit Standard Module ............................... 1-27
Bul. 1560D Basic Control Circuit Soft Stop or Pump Control ............... 1-28

Figure 2.1
Figure 2.2
Figure 2.3
Figure 2.4

Power Connections 1560D 400A, 2400V to 4160V .............................. 2-5


Power Connections 1560D 400A, 6900 V ............................................. 2-6
Power Connections 1560D 800A, 2400V to 6900V .............................. 2-7
Typical One-Line Diagram Showing 2 Different Styles
of Power Factor Capacitor Connections ............................................... 2-11
SMC Dialog Plus Controller with Human Interface Module .................... 2-15
SMC Dialog Plus Controller with Communication Module ...................... 2-18
Converter Module Connection Interface .................................................... 2-19
Current Transformer Connection to Converter Module .............................. 2-20
SMC Dialog Plus Controller Control Terminals ....................................... 2-21

Figure 2.5
Figure 2.6
Figure 2.7
Figure 2.8
Figure 2.9

1560D-5.1 February 2000

vi

Table of Contents MV Dialog Plus Medium Voltage Controller User Manual

Figures (cont.)

1560D-5.1 February 2000

Page

Figure 3.1
Figure 3.2
Figure 3.3
Figure 3.4a
Figure 3.4b

Connection and Test Information for Interface Board ................................. 3-5


Interface PCB ............................................................................................... 3-6
Test Power Application ................................................................................ 3-7
Gate Pulse Detail .......................................................................................... 3-8
Gate Pulse Test Waveform .......................................................................... 3-8

Figure 4.1
Figure 4.2

Menu Structure Hierarchy ............................................................................ 4-2


Memory Block Diagram ............................................................................... 4-6

Figure 7.1
Figure 7.2
Figure 7.3
Figure 7.4
Figure 7.5

Soft Stop Option Sequence of Operation ..................................................... 7-5


Pump Control Option Sequence of Operation ............................................. 7-6
SMB Smart Motor Braking Sequence of Operation .................................... 7-7
Preset Slow Speed Option Sequence of Operation ...................................... 7-8
Slow Speed with Braking Option Sequence of Operation ............................. 7-9

Figure 9.1

Fault Display ................................................................................................ 9-1

Figure 10.1
Figure 10.2
Figure 10.3
Figure 10.4
Figure 10.5
Figure 10.6
Figure 10.7
Figure 10.8
Figure 10.9
Figure 10.10
Figure 10.11
Figure 10.12
Figure 10.13
Figure 10.14
Figure 10.15
Figure 10.16
Figure 10.17
Figure 10.18
Figure 10.19
Figure 10.20
Figure 10.21

Low Voltage Panel & Power Cell Detail (1562D) .................................. 10-14
1000/1300/1500/2400 Volt Heatsink Assembly, 180/360 A ................... 10-15
Heatsink Clamp ........................................................................................ 10-15
Removal of SCR1 ..................................................................................... 10-16
Removal of SCR2 ..................................................................................... 10-16
3300/4160 Volt Heatsink Assembly, 180/360 A ..................................... 10-17
Heatsink Clamp ........................................................................................ 10-17
Removal of SCR1 ..................................................................................... 10-18
Removal of SCR1 or SCR2 ...................................................................... 10-18
6900V Module, 180/360 A ...................................................................... 10-19
6900V Module with Gate Driver Boards Removed, 180/360 A .............. 10-19
6900V Module with Boards and Frame Removed, 180/360 A ................ 10-20
6900V Heatsink Assembly, 180/360 A .................................................... 10-21
6900V SCR Replacement, 180/360 A ..................................................... 10-21
Removing and Replacing SCRs ............................................................... 10-22
2300V Heatsink Module, 800A ............................................................... 10-22
3300 and 4160V Heatsink Module, 800A ............................................... 10-23
6900V Heatsink Module, 800A ............................................................... 10-23
1500/2400V Module Wiring .................................................................... 10-27
3300/4160V Module Wiring .................................................................... 10-28
6900V Module Wiring ............................................................................. 10-29

Table of Contents MV Dialog Plus Medium Voltage Controller User Manual

Tables

vii

Page

Table 4.A

Parameter Linear List ................................................................................... 4-4

Table 5.A

Motor Codes ................................................................................................. 5-2

Table 8.A
Table 8.B

Logic Control Data ....................................................................................... 8-1


SMC Status Data .......................................................................................... 8-3

Table 9.A

Fault Code Cross-Reference ........................................................................ 9-2

Table 10.A
Table 10.B
Table 10.C
Table 10.D
Table 10.E

Fault Display Explanation .......................................................................... 10-3


Motor Will Not Start No Output Voltage to Motor ................................ 10-5
Motor Rotates (but does not accelerate to full speed) .............................. 10-5
Motor Stops While Running ...................................................................... 10-5
Miscellaneous Situations ........................................................................... 10-6

Table A.1
Table A.2

Parameter List ............................................................................................. A-1


Parameter Text/Display Unit Cross-Reference ........................................... A-5

Table B.1
Table B.2
Table B.3
Table B.4
Table B.5
Table B.6
Table B.7
Table B.8
Table B.9
Table B.10

Bulletin 1503D 1500V, 200/400A, 6-device ............................................ B-1


Bulletin 1503D, 1560D/1562D 2300V, 200/400A, 6-device ................... B-2
Bulletin 1503D, 1560D/1562D 2300V, 800A, 6-device .......................... B-3
Bulletin 1503D, 1560D/1562D 3300V, 200/400A, 12-device ................. B-4
Bulletin 1503D, 1560D/1562D 3300V, 800A, 12-device ........................ B-5
Bulletin 1503D, 1560D/1562D 4160V, 200/400A, 12-device ................. B-6
Bulletin 1503D, 1560D/1562D 4160V, 800A, 12-device ........................ B-7
Bulletin 1503D, 1560D/1562D 6900V, 200/400A, 18-device ................. B-8
Bulletin 1503D, 1560D/1562D 6900V, 800A, 18-device ........................ B-9
Accessories Control Modules and Fans.................................................. B-10

Table C.1

Accessories .................................................................................................. C-1

1560D-5.1 February 2000

viii

Table of Contents MV Dialog Plus Medium Voltage Controller User Manual

1560D-5.1 February 2000

Preface

Service Procedure

For your convenience, the Rockwell Automation Global Technical Services


(GTS), provides an efficient and convenient method of servicing medium
voltage products.
Contact your local area support office to make arrangements to have a qualified service representative come to your facility.
A complete listing of Area Support Offices may be obtained by calling your
local Rockwell Automation Distributor or Sales Office.

For MV Dialog Plus technical support on start-up or existing installations, contact your Rockwell Automation
representative. You can also call 1-519-623-1810 for assistance Monday through Friday from 7:30 a.m.
to 5:15 p.m. (Eastern time zone).

1560D-5.1 February 2000

Preface

1560D-5.1 February 2000

Chapter

Product Overview
Manual Objectives

This manual is intended for use by personnel familiar with Medium Voltage and
solid-state power equipment. The manual contains material which will allow the
user to operate, maintain and troubleshoot the MV Dialog PlusTM controller.

Documentation

The following Rockwell Automation publications provide pertinent


information for the MV Dialog Plus:
1500-5.5
1500-5.10
1502-5.0
1502-5.1
1560D-2.2

Description

Installation Manual Centerline Medium Voltage Controllers


Routine General Maintenance Procedures
Maintenance Instruction Manual Centerline Medium
Voltage Contactors (400 A size)
Maintenance Instruction Manual Centerline Medium
Voltage Contactors (800 A size)
General Specifications

The MV Dialog Plus is a solid-state, three-phase, AC line controller. It is


designed to provide microprocessor-controlled starting and stopping of
standard three-phase, squirrel-cage induction motors, using the same control
module (in most cases) as the Allen-Bradley Bulletin 150 SMC Dialog Plus.
1503D Chassis Mount Retrofit Controller
A chassis-mount medium voltage solid-state controller designed to mount in
an OEM or customer supplied structure, and designed to work in conjunction
with an existing or OEM/customer supplied starter. It is comprised of
several modular components, including:

Frame-mounted or loose power stacks including gate driver boards


Loose interface and voltage divider/feedback boards
Fiber optic cables for SCR firing
Microprocessor based control module
Vacuum bypass contactor

1560D Retrofit Controller


A medium voltage solid-state controller designed to work in conjunction
with an existing customer-supplied starter. It includes:

Tin-plated, copper, horizontal power bus (optional)


A continuous, bare copper ground bus
Power electronics
A bypass vacuum contactor
A low voltage control panel complete with microprocessor-based control module
Top and bottom plates to accommodate entry cable connectors

Note: See Interlocking, page 2-8.

1560D-5.1 February 2000

1-2

Product Overview

Description (cont.)

1562D Combination Controller


A medium voltage solid-state controller that provides isolation and
protection on new installations. It includes:

Tin-plated, copper, horizontal power bus (optional)


A continuous, bare copper ground bus
Power electronics
A main non-load-break isolating switch and operating handle
An isolation vacuum contactor
A bypass vacuum contactor
Three (3) current limiting power fuses for NEMA Class E2 operation
Three (3) current transformers
A control power transformer (optional)
A low voltage control panel complete with microprocessor-based control
module
Space for necessary auxiliary control and metering devices
Top and bottom plates to accommodate entry cable connectors
Motor overload protection
The MV Dialog Plus controller offers a full range of starting modes as
standard:
Soft Start with Selectable Kickstart
Current Limit Start with Selectable Kickstart
Dual Ramp Start
Full Voltage Start
Other features that offer further user benefit include:
Expanded protective features
Metering
Communication capability
Innovative starting and stopping options provide enhanced performance:
Soft Stop
Pump Control !
Preset Slow Speed "
SMB Smart Motor Braking "
Slow Speed with Braking "
These modes, features and options are further described in this chapter.
NOTE: The Accu-Stop option is not available in the MV Dialog Plus.

1560D-5.1 February 2000

The MV Dialog Plus product uses a modified version of the Bulletin 150 Pump Control Module. Do not use
a pump module for the low voltage product line in the medium voltage product. There is no difference for
the standard or soft stop modules.

"

These options utilize gating patterns which result in motor and line currents that produce noise and vibration
in the motor and/or distribution transformer. The factory should be consulted before applying these options.

Product Overview

Starting Modes

1-3

Soft Start
This mode has the most general application. The motor is given an initial
torque setting, which is user-adjustable from 0 to 90% of locked-rotor
torque. From the initial torque level, the output voltage to the motor is
steplessly increased during the acceleration ramp time. The acceleration
ramp time is user-adjustable from 0 to 30 seconds. Once the MV Dialog
Plus controller senses that the motor has reached the up-to-speed condition
during the voltage ramp operation, the output voltage automatically
switches to full voltage, and the bypass contactor is closed.
Figure 1.1
Soft Start

Percent
Voltage

100%

Initial
Torque

Start

Run
Time (seconds)

1560D-5.1 February 2000

1-4

Product Overview

Starting Modes (cont.)

Selectable Kickstart !
Selectable kickstart provides a power boost at start-up that is 550% of
full-load current. The additional power helps motors generate higher
torque to overcome the resistive mechanical forces of some applications
when they are started. The selectable kickstart is user-adjustable from 0.0
to 2.0 seconds.
Figure 1.2
Selectable Kickstart
Percent
Voltage
Kickstart
100%

Initial
Torque

Start

Run
Time (seconds)

Current Limit Start#"


This starting mode provides a fixed, reduced-voltage start that is used when
limiting the maximum starting current is necessary. The Current Limit level
is user-adjustable from 50% to 600% of the motor's full-load ampere rating,
and the current limit time is user-adjustable from 0 to 30 seconds. Once the
MV Dialog Plus controller senses that the motor has reached the up-tospeed condition during the current limit starting mode, the output voltage
automatically switches to full voltage and the bypass contactor is closed.
Figure 1.3
Current Limit Start
Percent
Full Load
Current

600%

50%

Start
Time (seconds)
!
"

1560D-5.1 February 2000

Kickstart is also available with Current Limit Start.


The Current Limit Start mode design is based on a motor with a locked-rotor current rating that is 600% of
the full-load current rating.

Product Overview

Starting Modes (cont.)

1-5

Dual Ramp Start !


This starting mode is useful for applications that have varying loads (and
therefore varying starting torque requirements). Dual Ramp Start allows
the user to select between two separate Soft Start profiles with separately
adjustable ramp times and initial torque settings.
Figure 1.4
Dual Ramp Start
Percent
Voltage
Ramp #2
100%

Initial
Torque #2
Initial
Torque #1
Ramp #1
Start #1
Start #2

Run #1
Run #2
Time (seconds)

Dual Ramp Start is available only with the standard controller.

Full Voltage Start


This starting mode is used for applications requiring across-the-line starting.
The output voltage to the motor will reach full voltage within second.
Figure 1.5
Full Voltage Start

100%

Percent
Voltage

Time (seconds)

1560D-5.1 February 2000

1-6

Product Overview

Protection and Diagnostics

The MV Dialog Plus controller is capable of providing the following


protective and diagnostic features:

Overload
The MV Dialog Plus controller meets applicable requirements as a motor
overload protective device. Thermal memory provides added protection
and is maintained even when control power is removed. The built-in
overload algorithm controls the value stored in Parameter 11, Motor
Thermal Usage (see Chapter 4, Programming). An Overload Fault will
occur when this value reaches 100%. The programming parameters below
provide application flexibility and easy setup. See Note 3.
Parameter
Overload Class
Overload Reset
Motor FLC
Service Factor

Range
Off, 10, 15, 20, 30
Manual Auto
1.0 - 999.9 Amps
0.01 - 1.99

Important:During slow speed and/or braking operations, current


waveforms exhibit non-sinusoidal characteristics. These non-sinusoidal
characteristics inhibit the controller's current-measurement capability.
To compensate for additional motor heating that may result, the controller
uses motor thermal modeling, which increments motor thermal usage.
This compensation takes place when these options are in use: Preset
Slow Speed, Smart Motor Braking, and Slow Speed with Braking.
Notes:
1. The factory default setting for Overload Class, which is "OFF", disables
overload protection. An overload trip class and the motor's full-load
current rating must be programmed to enable overload protection.
2. A Bulletin 825 converter module (Cat. No. 825MCM20) is required to
provide current feedback during bypass operation.
3. If the motor is started with the bypass contactor closed, the overload
function in the MV Dialog Plus is automatically disabled. In this case,
a separate overload relay is required.
4. Automatic reset of an overload fault requires the start input to be
cycled in a two-wire control scheme. This applies to the following
firmware releases: 1.07 (standard), 1A07L (Soft Stop), and 1B05L
(Pump Control) or earlier.
5. If the MV Dialog Plus is used to control a multi-speed motor, or more
than one motor, the Overload Class parameter must be programmed to
"OFF" and separate overload relays must be supplied for each speed/
motor.

1560D-5.1 February 2000

1-7

Product Overview

Figure 1.6
Overload Trip Curves
Class 10

Class 15

Class 20

Class 30

100.0

1000.0

1000.0

1000.0

10.0

1.0

0.1
1

5 6 7 8 9 10

Multiples of FLC

100.0

10.0

1.0

5 6 7 8 9 10

Multiples of FLC

Approximate trip time for 3-phase balanced


condition from cold start.

Approximate Trip Time (seconds)

10000.0

Approximate Trip Time (seconds)

10000.0

Approximate Trip Time (seconds)

10000.0

Approximate Trip Time (seconds)

1000.0

100.0

10.0

1.0

100.0

10.0

1.0
1

5 6 7 8 9 10

Multiples of FLC

5 6 7 8 9 10

Multiples of FLC

Approximate trip time for 3-phase balanced


condition from cold
hotstart.

Figure 1.7
Restart Trip Curves after Auto Reset
100000

1000

Seconds

100

Class 10
Class 15
Class 20
Class 30

10

Auto Reset Times:


Class 10 = 90 s
Class 15 = 135 s
Class 20 = 180 s
Class 30 = 270 s

Note:
Figures 1.6 and 1.7 provide
the overload trip curves for
the available trip classes.

0.1
0
100%

1000%

Load
Current
Setting
PerPercent
cent FullFull
Load
Current
Setting

1560D-5.1 February 2000

1-8

Product Overview

Protection and Diagnostics


(cont.)

Stall Protection and Jam Detection


The MV Dialog Plus controller provides both stall protection and jam
detection for enhanced motor and system protection.
Stall protection is user-adjustable from 0.0 to 10.0 seconds (enabled
only after start time expires).
Jam detection allows the user to determine the jam level (up to 999% of
the motor's full-load current rating) and the delay time (up to 10.0
seconds) for application flexibility.
Figure 1.8
Stall Protection

Figure 1.9
Jam Detection !

Percent
Full
Load
Current

User Programmed Trip Level

100%

Running

Jam
Time (seconds)

1560D-5.1 February 2000

Jam detection is disabled during slow speed and braking operation.

Product Overview

Protection and Diagnostics


(cont.)

1-9

Open Gate
An open-gate fault indicates that improper SCR firing, typically caused by
an open SCR gate or driver system, has been detected on one of the power
poles. Before the controller shuts down, it will attempt to start the motor a
total of three times (or as programmed in Parameter 64).

Line Faults
The MV Dialog Plus controller continually monitors line conditions for
abnormal factors. Pre-start protection includes:

Power Loss (with phase indication)


Line Fault (with phase indication)
Power loss
Missing load connection
Shorted SCR

Starting and Stopping protection includes:


Line Fault (no phase indication)
Power loss
Missing load connection
Shorted SCR
Additional programmable parameters are provided for the following
protective features:

Undervoltage ! can be adjusted from 0 to 99% of the programmed line


voltage and has a programmable delay time of 0 to 99 seconds.
Overvoltage ! can be adjusted from 0 to 199% of the programmed
line voltage and has a programmable delay time of 0 to 99 seconds.
Phase reversal " protection can be toggled either ON or OFF.
Voltage unbalance ! protection can be programmed for trip levels of 0
to 25% with a programmable delay time of 0 to 99 seconds.

Underload $
If a sudden drop in current is detected, motor operation can be halted by
utilizing the underload protection of the MV Dialog Plus controller.
The MV Dialog Plus controller provides an adjustable underload trip
setting from 0 to 99% of the programmed motor full-load current rating.
Trip delay time can be adjusted from 0 to 99 seconds. The Bulletin 825
current converter module must be connected for this feature to be available.
!
"
$

Undervoltage, overvoltage, and voltage unbalance protection are disabled during braking operation.
Phase reversal protection is functional only at pre-start.
Underload protection is disabled during slow speed and braking operations.

1560D-5.1 February 2000

1-10

Product Overview

Protection and Diagnostics


(cont.)

Excessive Starts/Hour
The MV Dialog Plus module allows the user to program the desired
number of starts per hour (up to 99). This helps eliminate motor stress
caused by repeated starting over a short time period.
Note: The base rating of the MV Dialog Plus is two starts (thirty seconds
each max.) per hour. Applications requiring more frequent starts, or longer
duration starts, should be reviewed with the factory to avoid equipment damage.

Overtemperature
The power module temperature is monitored during starting and stopping
maneuvers by thermistors. The thermistor is connected to the gate driver
board where it is processed, and the status is transmitted by fibre-optic cable
through the interface board to the control module. When an overtemperature
condition exists, the control module trips and indicates a temperature fault.
An overtemperature condition could indicate high ambient temperature,
overloading or excessive cycling. After the power module temperature is
reduced to allowable levels, the fault can be cleared (see page 9-1 for
instructions).

Metering

Power monitoring parameters include:

Three-phase current
Three-phase voltage
Power in kW (see note 5 below)
Power usage in kWh (see note 5 below)
Power factor (see note 5 below)
Motor thermal capacity usage
Elapsed time

Notes:
1. The current sensing capability of the MV Dialog Plus controller requires
a Bulletin 825 converter module to maintain the three-phase current,
and motor thermal capacity measurements.
2. Current measurement is not available during the slow speed and/or
braking operations of the Preset Slow Speed, SMB Smart Motor Braking, and Slow Speed with Braking control options.
3. Voltage measurement is not available during the braking operation of
the SMB Smart Motor Braking, and Slow Speed with Braking control
options.
4. The elapsed time values are automatically saved to memory every 12
hours.
5. The current Series A SMC Dialog Plus module does not provide power
metering functions when used in the MV Dialog Plus Controller.

1560D-5.1 February 2000

Product Overview

Communication

1-11

A serial interface port (called SCANport) is provided as standard, which


allows connection to a Bulletin 1201 human interface module or a variety
of Bulletin 1203 communication modules.
Figure 1.10
SCANport Location

ESC.

SCANport

SEL.

Important: Only one peripheral device can be connected to the SCANport.


The maximum output current through the SCANport is 100 mA.

Programming

Setup is easy with the built-in keypad and two-line, 16-character, backlit
LCD. Parameters are organized in a four-level menu structure, using a text
format for straightforward programming.
Figure 1.11
Built-in Keypad and LCD

ESC.

SEL.

1560D-5.1 February 2000

1-12

Product Overview

Status Indication

Three programmable hard contact outputs are provided as standard. The first
two contacts are Form C and programmable for Normal or Up-to-speed. They
must be set for "Up-to-speed" to control the bypass contactor, and for operating
logic on the interface board. The third contact is programmable as Normal or
Fault. For Bulletin 1560D applications, it is set for "Fault" to signal the line
contactor to open in the user's starter feeding the MV Dialog controller. For
Bulletin 1562D applications, it is set for "Normal" to control the closing and
opening of the line contactor. The contact will open if there is a fault condition.

Control Options

The MV Dialog Plus controller offers the control options described below.
Important: The options listed in this section are mutually exclusive and
must be specified when ordering. An existing controller may be upgraded
to another control option by replacing the control module and possibly other
components. Consult your nearest Rockwell Automation sales office.
Option maneuvers count as a start when determining thermal capacity of the MV
Dialog Plus. i.e., a soft start followed by a soft stop counts as two starts, and the
unit must have the required rest period before another start. (See Note below).

Soft Stop Option


This option can be used in applications that require an extended coast-torest time. The voltage ramp-down time is user-adjustable from 0 to 60
seconds and is adjusted independently from the starting time. The load
will stop when the output voltage drops to a point where the load torque is
greater than the developed motor torque.
Note: Consult factory if settings over 30 seconds are required. The base
rating of the MV Dialog Plus is two starts (or one start/stop combination)
per hour, thirty seconds maximum for each operation. A stopping operation
counts as a start for purposes of thermal capacity calculations.
Figure 1.12
Soft Stop Option
Percent
Voltage

100%

Kickstart

Coast-to-rest
Soft
Stop

Initial
Torque

Start

Run
Time (seconds)

Soft Stop

ATTENTION: Soft Stop is not intended to be used as


an emergency stop. Such usage may result in severe injury
or death. Refer to the applicable standards for emergency
stop requirements.
1560D-5.1 February 2000

Product Overview

Control Options (cont.)

1-13

Pump Control Option


This option reduces surges during the starting and stopping of a centrifugal
pump by smoothly accelerating and decelerating the motor. The microprocessor analyzes the motor variables and generates commands that control
the motor and reduce the possibility of surges occurring in the system.
The motor current will vary during the acceleration period, and may be
near the motor rated starting current. The pump algorithm does not limit
starting current since full voltage is needed to reach full speed with a
loaded motor.
The starting time is programmable from 0-30 seconds, and the stopping
time is programmable from 0-120 seconds.
Application Considerations
1. Consult factory if settings over 30 seconds are required. The base rating
of the MV Dialog Plus is two starts (or one start/stop combination) per
hour, thirty seconds maximum for each operation. A stopping operation
counts as a start for purposes of thermal capacity calculations.
2. The Pump Control option functions only for centrifugal pumps. It is
not suited for positive displacement, piston, or other types of pumps.
3. The Pump Stop option functions only for a centrifugal pump running at
greater than approximately 2/3 of the motor rated horsepower.
4. Pump applications with input and/or output valves that are closed during
starting and/or stopping may not benefit from the Pump Control option.
Consult the factory for applications with valves.
5. For starting or stopping times longer than 15 seconds, power fuse
selection should be reviewed to ensure no element damage occurs.
The fuse minimum melting time-current characteristic curve should
be consulted to ensure that at 1.1 times the full voltage locked rotor
current of the motor, the actual starting or stopping time does not
exceed 75% of the fuse melting time.
6. Motor overload and/or upstream breaker settings may have to be
adjusted to allow the starting or stopping current to flow for extended
periods.

1560D-5.1 February 2000

1-14

Product Overview

Control Options (cont.)

Pump Control Option (cont.)


Figure 1.13
Pump Control Option
100%
Motor
Speed

Pump Start

Run
Time (seconds)

Pump Stop

ATTENTION: Pump stopping is not intended to be used


as an emergency stop. Refer to the applicable standard for
emergency stop requirements.

ATTENTION: Pump stopping may cause motor heating


depending on the mechanical dynamics of the pumping
system. Therefore, select the lowest stopping time setting
that will satisfactorily stop the pump.

1560D-5.1 February 2000

Product Overview

Control Options (cont.)

1-15

Preset Slow Speed Option


This option can be used in applications that require a slow-speed jog for
general purpose positioning. Preset Slow Speed provides either 7% of
base speed (low) or 15% of base speed (high) settings in the forward
direction. Reverse can also be programmed and offers 10% of base speed
(low) and 20% of base speed (high) settings.
Figure 1.14
Preset Slow Speed Option

Forward

15% High
7% Low
Time (seconds)

Start

Run

10% Low
20% High
Reverse

Important: Slow speed running is not intended for continuous operation due
to reduced motor cooling. The two starts per hour limitation also applies to
slow speed operation. This option employs a cycle-skipping scheme which
produces limited torque. Applications should be checked with the factory.

SMB Smart Motor Braking Option


This option can be used in applications that require reduced stopping times.
The MV Dialog Plus controller incorporates a microprocessor-based
system that applies braking current to a standard squirrel-cage induction
motor without any additional equipment. This option offers a user-adjustable braking current setting from 0 to 400% of the motor's full load current
rating. Furthermore, it provides automatic shut-off at zero speed detection.
Figure 1.15
SMB Smart Motor Braking Option

100%
Smart Motor Braking
Motor
Speed

Coast-to-rest

Start

Run

Brake

Time (seconds)
Automatic Zero Speed
Shut-off
1560D-5.1 February 2000

1-16

Product Overview

Control Options (cont.)

SMB Smart Motor Braking Option (cont.)


Note: All braking current settings in the range of 1-100% will provide
100% braking current to the motor.

ATTENTION: SMB Smart Motor Braking is not intended


to be used as an emergency stop. Such usage may result in
severe injury or death. Refer to the applicable standards for
emergency stop requirements. High brake current settings
can produce high torque transients. Use the lowest setting
that suits the application.

Slow Speed with Braking Option


The Slow Speed with Braking option provides a jog speed for process
setup and braking-to-stop at the end of the cycle.
Figure 1.16
Slow Speed with Braking Option

100%
Coast-to-rest
Motor
Speed

7% or 15%
Braking

Slow
Speed

Start

Run

Stop

Time (seconds)

ATTENTION: Slow Speed with Braking option is not


intended to be used as an emergency stop. Such usage may
result in severe injury or death. Refer to the applicable
standards for emergency stop requirements.

1560D-5.1 February 2000

Product Overview

Hardware Description

1-17

The following sections contain descriptions of system components and


system operation. Each section will be described to give the user an
understanding of the MV Dialog PlusTM to facilitate operation and maintenance of the system. Refer to Figure 1.17, System Diagram.

Power Module
The controller consists of three power modules, one for each phase. Each
power module consists of incoming and outgoing terminals for cables, SCRs,
heatsink and clamp assembly. The SCRs are connected in inverse parallel
(and in series for 12- or 18-SCR assemblies) to form a three-phase, AC
line controller configuration.
Each power module includes a snubber circuit to limit the rate of rise in
voltage across each SCR pair. The module also includes gate driver
circuits which derive their power from the snubber circuit. A patent
application has been submitted for this process.
Voltage sharing resistors are connected across each SCR pair to provide
static voltage balance for series-connected SCRs. These resistors are
tapped to provide a reference for overvoltage protection circuitry on the
gate driver board.
A resistive voltage divider is used to reduce the line- and load-side voltages
to lower levels that can be handled by the SMC Dialog Plus control
module. The resistors for the top portion of the divider are located on the
Voltage Divider Resistor circuit board, and the bottom portion of the
divider is on the Voltage Feedback circuit board. The latter board provides
the resistor connection to ground, and power Zener diodes (with their own
ground connection) as a protection circuit to prevent high voltages from
entering the control module if a resistor or resistor ground were to open
circuit. The voltage feedback board provides the voltage reference signals
to the interface board for connection to the control module.

Self-Powered Silicon-Controlled Rectifier Gate Driver Board


This board provides the turn-on capability for SCR devices. The board
also provides optical fibre isolation between itself and the gating source
logic. It is powered by recovering energy from the snubber circuit, so it is
fully isolated from the control and logic circuits; it is self-economizing
when the unit is not running, or is in bypass mode.

1560D-5.1 February 2000

1-18

Product Overview

Hardware Description (cont.)

Self-Powered Silicon-Controlled Rectifier Gate Driver Board (cont.)


The MV Dialog Plus has three heatsinks fitted with a thermistor to
monitor SCR temperature rise. The circuitry on the gate driver board
accepts the thermistor, and drives a fibre-optic cable if the temperature is
below the setpoint. If the temperature rises above the setpoint, the driver
is turned off, and the MV Dialog Plus is signalled to stop gating and
initiate a temperature fault.
Due to the self-powered nature of the circuits, this function is active only
while the SMC is active. While the starter is off, or in bypass, no power is
dissipated in the SCRs and the temperature of the SCRs can only decrease.

Interface Board
This circuit board takes line- and load-side voltage feedback signals from
the voltage feedback board and passes them via pins to the MV Dialog
Plus for processing. The control module produces gating signals for the
SCRs, which are received via pins on the interface board, and used to drive
fibre-optic transmitters. The gating signals are sent to the gate-driver
circuit board via fibre-optic cables. The interface board also receives
temperature feedback from the gate-driver board via fibre-optic cable(s).
If the heatsink temperature rises above a set value, a signal is sent to the
Dialog Plus to stop gating the SCRs and initiate a temperature fault.
For a detailed description of this circuit board, refer to Figure 3.1 on
page 3-5.

1560D-5.1 February 2000

Product Overview

1-19

CONTROL COMMON

50/60 Hz

Figure 1.17
System Diagram

UTS N/O

1560D-5.1 February 2000

1-20

Product Overview

Functional Description

Bulletin 1562D Basic Control Standard Module


When wired as shown in Figure 1.18a, the controller operates as follows:
Pressing the "Start" button initiates the start sequence. Relay "CR" closes
and applies control power to terminal 16 of the Dialog module. The auxiliary
contact #3 (set for "normal") closes, picking up "MC" and "MCX", which
completes the hold-in circuit on the start button, and closes the main contactor.
The Dialog module examines the line voltage, looks for fault conditions,
checks phase rotation, calculates zero crossing information, and begins
gating the SCRs to start the motor.
When the motor approaches rated speed, the Dialog module closes the
"UTS" (up-to-speed) auxiliary contacts, closing relay "BC", which closes
the bypass contactor. The motor then runs at full line voltage. The UTS
signal is also passed to the Interface board.
The "ART" (anti-restart timer) relay is energized when the motor is started,
and de-energized when the bypass contactor closes. The off-delay time
period then begins, to prevent another start until the SCRs and other
components have some time to cool down.
When the "Stop" button is pressed, the "CR" relay opens terminal 16 on
the Dialog module. The "Normal" contact opens, dropping out the main
contactor, allowing the motor to stop. The "UTS" contact also opens, but
"BC" is held closed for a short time by the "MCX" off-delay contact and
"B" auxiliary. This holds the bypass contactor closed for about 10 seconds
to protect the power electronics from any voltage transients due to opening
the motor circuits.
The Standard Control Module includes the "Dual Ramp" feature. To select
Ramp #1 or Ramp #2, a contact is used to change the input state of terminal 15
on the Dialog Plus module. See page 4-10 for information on programming.

Bulletin 1562D Basic Control Soft Stop or Pump Control


When wired as shown in Figure 1.18b, the controller operates in much the
same manner as in Figure 1.18a.
Terminal 15 on the Dialog module now controls the optional start and stop
maneuvers. Terminal 16 must remain energized for the module to run.
When the Stop button is pressed, and CR opens, the Dialog will
initiate the option stop (Soft Stop or Pump Stop, depending on the module
specified). An uncontrolled, or coast stop, is achieved by opening the
connection to terminal 16. This contact should remain open to ensure all
hold-in contacts clear, to prevent a re-start.

1560D-5.1 February 2000

Product Overview

Functional Description (cont.)

1-21

Bulletin 1562D Basic Control Soft Stop or Pump Control (cont.)


If the motor has started, the unit is in the bypass mode, and a trip occurs
within the Dialog module or from an external protection relay. MC and
MCX will drop out immediately. This will complete the hold-in rung
ahead of the BC relay, to keep the Bypass contactor closed for a short
time to protect the power electronics from any voltage or current transients
due to the abnormal conditions which caused the trip. A trip due to an
overload or fault condition will result in a coast stop.

Bulletin 1562D SCANport Control Standard Module


When wired as shown in Figure 1.18c, the controller operates as follows:
When a Start command is initiated via the SCANport, the Dialog module
closes an internal hold-in contact between terminals 16 and 17. If there is
voltage present on terminal 17, it will appear at terminal 16, which has
voltage sensing capability. If voltage is sensed at terminal 16, the module
will close the Normal contacts at terminals 29 and 30 to initiate the start
sequence. The motor can be stopped by removing power to terminal 17
(and therefore terminal 16), or via SCANport, which will cause the internal
contact between 16 and 17 to open, thus removing power from terminal 16.
The ART contact prevents a restart within its time period by withholding
the input to terminal 17. The Bypass hold-in rung works the same as in the
previous descriptions.
Refer to Chapter 8, Serial Communications, for more information on using
SCANport to control the MV-DialogTM controller.

Bulletin 1562D SCANport Control Soft Stop or Pump Control


When wired as shown in Figure 1.18d, the controller works the same as
described above for the Standard module. A connection must be added to
supply voltage to terminal 15 on the Dialog module, to activate the option
input. The SCANport allows for both an option stop (Soft Stop or Pump
stop) and a coast stop. A stop may also be forced by opening the
connection to terminal 15 (option stop) or terminal 17 (coast stop).

1560D-5.1 February 2000

1-22

Product Overview

Functional Description (cont.)

Bulletin 1560D Basic Control Standard Module


The Bulletin 1560D is intended for addition to an existing motor controller,
which provides circuit isolation, motor switching, and overload and
overcurrent protection. When wired as shown in Figure 1.19a, the
controller operates as follows:
When a start is initiated in the existing motor controller and the contactor
(or breaker) closes, a contact must be supplied to tell the 1560D to start
also. As long as sufficient time has passed since the last start, the ART
contact will be closed, and allow CR to pick up and seal itself in. A
CR contact will apply voltage to terminal 16 of the Dialog module.
When stopping the motor, the contactor in the existing controller will open,
removing power from the motor, and then the CR relay. The bypass
hold-in rung will keep the bypass contactor closed for a short time.
A separate contact may be used to select between two possible start
settings when using the Dual Ramp feature.
The Aux 3 contacts on the Dialog module should be programmed for
Fault, and wired into the existing controller to trip the main contactor (or
breaker) in the event of a fault condition sensed by the Dialog module.
If possible, it is better to have the Dialog module control the main contactor
directly. In this case, the control circuit would look like, and function like,
the descriptions above for the Bulletin 1562D.

Bulletin 1560D Basic control Soft Stop or Pump Control


When wired as shown in Figure 1.19b, the controller operates much the
same as described above for the Standard module. The control signal uses
terminal 15 instead of 16, and a coast stop can be achieved by opening
the connection to terminal 16.
It is more important in this configuration to integrate the control circuit of
the 1560D with the existing controller, for better control of the Soft Stop
(or Pump Stop). The start signal for this scheme cannot be a slave of the
main contactor, since it must remain closed to accomplish the option stop
maneuver. The Dialog module can be used to control the main contactor
such that it will close when a start is initiated, and remain closed until it
has sensed the motor has stopped following an option stop maneuver.

1560D-5.1 February 2000

Product Overview

1-23

Figure 1.18a
Bulletin 1562D Basic Control Circuit Standard Module

NO RMAL

*
* If supplied

1560D-5.1 February 2000

1-24

Product Overview

Figure 1.18b
Bulletin 1562D Basic Control Circuit Soft Stop or Pump Control

NO RMAL

*
* If supplie

1560D-5.1 February 2000

Product Overview

1-25

Figure 1.18c
Bulletin 1562D with SCANport Control Standard Module

NO RMAL

*
* If supplied

1560D-5.1 February 2000

1-26

Product Overview

Figure 1.18d
Bulletin 1562D with SCANport Control Soft Stop or Pump Control

NORMAL

*
* If supplied

1560D-5.1 February 2000

Product Overview

1-27

Figure 1.19a
Bulletin 1560D Basic Control Circuit Standard Module

FAULT

*
* If supplied

1560D-5.1 February 2000

1-28

Product Overview

Figure 1.19b
Bulletin 1560D Basic Control Circuit Soft Stop or Pump Control

FAULT

*
* If supplied

1560D-5.1 February 2000

Chapter

Installation
ATTENTION: Perform the installation duties correctly.
Errors may cause commissioning delays, equipment damage
or personal injury.
Important: For the 1503D, refer to applicable documentation from OEM
installation, grounding, interlocking and wiring. This manual should be
utilized in conjunction with the OEM supplied documentation, and is
suitable for commissioning, programming, calibration, metering, serial
communications, diagnostics, troubleshooting, and maintenance of a
standard solid-state controller.

Receiving

Safety and Codes

Unpacking and Inspection

It is the responsibility of the user to thoroughly inspect the equipment


before accepting the shipment from the freight company. Check the item(s)
received against the purchase order. If any items are damaged, it is the
responsibility of the user not to accept delivery until the freight agent has
noted the damage on the freight bill. Should any concealed damage be
found during unpacking, it is again the responsibility of the user to notify
the freight agent. The shipping container must be left intact and the freight
agent should be requested to make a visual inspection of the equipment.
ATTENTION: The Canadian Electrical Code (CEC),
National Electrical Code (NEC), or other local codes
outline provisions for safely installing electrical equipment.
Installation MUST comply with specifications regarding
wire type, conductor sizes, branch circuit protection,
interlocking and disconnect devices. Failure to do so may
result in personal injury and/or equipment damage.

After unpacking the material, check the item(s) received against the bill of
lading to ensure that the nameplate description of each item agrees with
the material ordered. Inspect the equipment for physical damage, as stated
in the Rockwell Automation Conditions of Sale.
Remove all packing material, wedges, or braces from within the controller.
Operate the contactors and relays manually to ensure that they operate freely.
Store the equipment in a clean, dry place if it will not be installed immediately
after unpacking. The storage temperature must be between -20C and 75C
(-4F and 167F) with a maximum humidity of 95%, non-condensing, to
guard against damage to temperature sensitive components in the controller.

1560D-5.1 February 2000

2-2

Installation

General Precautions

In addition to the precautions listed throughout this manual, the following


statements, which are general to the system, must be read and understood.
ATTENTION: The controller contains ESD (electrostatic
discharge) sensitive parts and assemblies. Static control
precautions are required when installing testing, servicing, or
repairing the assembly. Component damage may result if
ESD control procedures are not followed. If you are not
familiar with static control procedures, refer to applicable
ESD protection handbooks.

ATTENTION: An incorrectly applied or installed controller


can damage components or reduce product life. Wiring or
application errors, such as undersizing the motor, incorrect or
inadequate AC supply, or excessive ambient temperatures,
may result in malfunction of the system.

ATTENTION: Only personnel familiar with the controller


and associated machinery should plan or implement the
installation, start-up, and subsequent maintenance of the
system. Failure to do this may result in personal injury and/or
equipment damage.

Transportation and Handling

The controller must be transported on a pallet or via use of the lifting


angles supplied as part of all 90-inch high cabinets or frame units.
ATTENTION: Ensure that the load rating of the lifting
device is sufficient to safely raise the controller sections.
Failure to do so may result in severe injury and/or equipment
damage. Refer to the packing slip enclosed with shipment
for shipping weights.
Round rollers can be used to assist in moving the controller to the installation site. Once at the final site, the pipe rolling technique can be used to
place the cabinet in the desired position.
ATTENTION: Care must be exercised when using either a
forklift, or the pipe rolling technique, for positioning purposes to
ensure that the equipment is not scratched, dented or damaged in
any manner. Always exercise care to stabilize the controller
during handling to guard against tipping and injury to personnel.

1560D-5.1 February 2000

Installation

Installation Site

2-3

Consider the following when selecting the installation site:


A. The operating ambient temperature must be between 0C and 40C
(32F and 104F) for NEMA Type 1 or 12 enclosures.
B. The relative humidity must not exceed 95%, non-condensing. Excessive
humidity can cause electrical problems from corrosion or excessive
dirt build-up.
C. The equipment must be kept clean. Dust build-up inside the enclosure
inhibits proper cooling and decreases the system reliability. The
equipment should not be located where liquid or solid contaminants can
drop onto it. Controllers with ventilated enclosures (in particular those
with fans) must be in a room free of airborne contaminants.
D. Only persons familiar with the function of the controller should have
access to it.
E. The losses in the controller produce a definite heat dissipation,
depending on the unit size, that tends to warm the air in the room.
Attention must be given to the room ventilation and cooling requirements to ensure that the proper environmental conditions are met.
F. Operational altitude is 3,300 feet (1 km) maximum without derating.
Higher altitudes may require optional components.
G. The area of the controller should be free of radio frequency interference
such as encountered with some welding units. This may cause erroneous
fault conditions and shut down the system.
ATTENTION: An incorrectly applied or installed controller
can result in component damage or a reduction in product
life. Wiring or application errors, such as, undersizing the
motor, incorrect or inadequate AC supply, or ambient
temperatures above or below the specified temperature range
may result in malfunction of the controller.

Mounting
The 1503D, 1560D and 1562D are designed to be mounted in the vertical
position. Standard cabinet drawings with certified dimension drawings can
be obtained by contacting your local Rockwell Automation Sales office for
the 1560D/1562D. Please refer to OEM documentation for the 1503D.
Refer to drawings for mounting requirements.

1560D-5.1 February 2000

2-4

Installation

Installation Site (cont.)

Grounding Practices
The purpose of grounding is to:
A. Provide safety for Personnel.
B. Limit dangerous voltages to ground on exposed parts.
C. Facilitate proper overcurrent device operation under ground fault
conditions.
D. Provide for electrical interference suppression.
Important: Generally, grounding should be in accordance with the
Canadian Electrical Code (CEC) or National Electrical Code (NEC) and
other local codes.
Each power feeder from the substation transformer to the controller must
be equipped with properly sized ground cables. Simply utilizing the
conduit or cable armour as a ground is not adequate. The conduit or cable
armour and ground wires should be bonded to ground at both ends. Each
enclosure and/or frame must be bonded to ground at a minimum of two
locations.
Each AC motor frame must be bonded to grounded building steel within 20
feet (6.1 m) of its location and tied to the controllers ground bus by ground
wires within the power cables and/or conduit. The conduit or cable armour
should be bonded to ground at both ends.
ATTENTION: Any instruments used for test or troubleshooting should have their case connected to ground for
safety. Failure to do so may result in damage to equipment
or personal injury.

1560D-5.1 February 2000

Installation

Power Connections

2-5

The controller requires a three-phase supply and an equipment grounding


conductor to earth ground. A neutral conductor of the three-phase supply
is not necessary and is usually not routed to the controller. Three-phase
wiring will connect the controller to the motor.
Figure 2.1
Power Connections 1560D 400 A, 2400 V to 4160 V

Line Connections

Line Connections

Load Connections

Load Connections

Front View

RH Side View

Note: Bottom cable exit shown. Lugs may be oriented upwards for
cables exiting through the top of the cabinet.
Important: For 1503D, refer to applicable documentation from OEM for
installation, grounding, interlocking and wiring. This manual should be
utilized in conjunction with the OEM supplied documentation, and is
suitable for commissioning, programming, calibration, metering, serial
communications, diagnostics, troubleshooting, and maintenance of a
standard solid-state controller.

1560D-5.1 February 2000

2-6

Installation

Power Connections (cont.)

Figure 2.2
Power Connections 1560D 400 A, 6900 V (6.9 kV)

Phase 1 Module
Phase 1 Line Connection
Phase 1 Load Connection

Phase 2 Module
Phase 2 Line Connection

Phase 2 Load Connection


Phase 3 Line Connection

Phase 3 Module

Phase 3 Load Connection

Bypass Contactor

1560D-5.1 February 2000

Installation

Power Connections (cont.)

Phase 1 Module

2-7

Figure 2.3
Power Connections 1560D 800 A, 2400 V to 6900 V (6.9 kV)

Phase 1 Line Terminal


Phase 1 Load Terminal

Phase 2 Line Terminal


Phase 2 Module
Phase 2 Load Terminal

Phase 3 Line Terminal


Phase 3 Module

Phase 3 Load Terminal


(Not visible this view)

Bypass Contactor

Important: Refer to 1500-5.5 for power/ground bus location and cable


routing for a Bulletin 1562D. For retrofit units (Bulletin 1560D), refer to
Figures 2.1, 2.2 or 2.3.
Important: For retrofit units (Bul. 1560D), the CEC and NEC require that
branch-circuit protection of the AC line input to the controller be provided
by a circuit breaker or motor starter. This function is included with a
Bulletin 1562D.
Important: The control and signal wires should be positioned at least
six (6) inches (150 mm) from power cables. Additional noise suppression
practices (including separate steel conduits for signal leads, etc.) are
recommended.

1560D-5.1 February 2000

2-8

Installation

Power Wiring

The wire sizes must be selected individually, observing all applicable


safety and CEC or NEC regulations. The minimum permissible wire size
does not necessarily result in the best operating economy. The minimum
recommended size for the wires between the controller and the motor is the
same as that used if a main voltage source connection to the motor was used.
The distance between the controller and motor may affect the size of the
conductors used.
Consult the wiring diagrams and appropriate CEC or NEC regulations to
determine correct power wiring. If assistance is needed, contact your area
Rockwell Automation Sales Office.

Interlocking

Hinged doors and panels, which provide access to medium voltage


components, must be mechanically interlocked to ensure circuit isolation.
If a combination MV Dialog Plus (1562D) is purchased from Rockwell
Automation, all medium voltage compartments will be mechanically
interlocked such that they cannot be opened unless the isolating switch for
the unit is open. Each medium voltage door is interlocked to the isolating
switch handle. To open the doors, move the isolating switch to the OFF
position and loosen the two retaining bolts on the main power cell door.
Once this door is open, the other doors may be opened in sequence,
depending on the specific interlock scheme provided. If a retrofit-type
MV Dialog Plus is purchased (1560D), it is intended to be added to an
existing motor controller, and has no isolating means included.
ATTENTION: For 1503D and 1560D, it is the responsibility
of the installer/user to ensure the equipment interlocking
scheme is in place and functional before energizing the
equipment. Inadequate interlocking could expose personnel
to energized parts which could result in severe burns, injury
or death.
NOTE: Rockwell Automation can assist with the selection of an appropriate interlocking method, which may include mechanical modifications
to the cabinet(s) or key-type lock systems.
NOTE: An auxiliary cabinet may be attached to the main structure. It will
be ram-interlocked with the main power cell door, which will not allow it
to be opened until the main power cell door is opened.
Important: For 1503D, refer to applicable documentation from OEM for
installation, grounding, interlocking and wiring. This manual should be
utilized in conjunction with the OEM supplied documentation, and is
suitable for commissioning, programming, calibration, metering, serial
communications, diagnostics, troubleshooting, and maintenance of a
standard solid-state controller.

1560D-5.1 February 2000

Installation

Installation

2-9

Physical Location
The controller is designed for limited front access (components may have to
be removed) and should be installed with adequate and safe clearance to
allow for total door opening. The back of the unit may be placed against a
wall and several units may be set end to end. In special cases where floor
space is limited and the unit is not against a wall, certain cabinet sections
may be placed back to back. This requirement must be stated in the
specifications in order to mechanically alter the controller.

Fan
The controller may include a cooling fan which is used to cool the component.
It should be checked for free operation and no obstruction of the airflow.

Ground Bus Bar


Controllers which are delivered in two (or more) sections, or retrofit controllers, will require that the ground bus bar (6 mm 51 mm [ in. 2 in.]),
which runs the entire length of the equipment in the center back side, be
reconnected. A mechanical lug for #8-#10 AWG or #6-250 MCM cable is
supplied at the incoming end of the line-up. When the sections are brought
together, bus links are used to connect the bus bars.
Important: Refer to 2-high, Series B drawings in Publication 1500-5.5
for power/ground bus connection.

Power and Control Wiring


Controllers consisting of two or more sections will require that the power
and control wiring be connected per the schematic drawings provided.

Control Cables
Control cable entry/exit should be located near the terminal blocks; customers
connections are to be routed along the empty side of the terminals. Nylon
cable tie loops are provided at the left, front corner of the cabinet to route
control cables safely behind the low voltage panel hinges. Cables should
be routed so they do not interfere with the swing of the low-voltage panels.

Fibre-Optic Cables
The small, gray, fibre-optic cables are fragile and must be protected during
installation from sharp bends and impact.

1560D-5.1 February 2000

2-10

Installation

Installation (cont.)

Power Factor Correction Capacitors


The controller can be installed on a system with power factor correction
capacitors. The capacitors must be located on the line side of the controller.
This is required to prevent damage to the SCRs in the MV Dialog Plus
controller. A separate switching contactor is recommended to apply the
capacitors only after the bypass contactor has closed, and to remove them
when the bypass contactor opens. See Figure 2.4 for two different
acceptable connection methods.
NOTE: Consult the factory if there are any capacitors on the same
branch circuit as the MV Dialog Plus.
When discharged, a capacitor has essentially zero impedance. For
switching, sufficient impedance should be connected in series with the
capacitor bank to limit the inrush current. A method of limiting the surge
current is to add inductance in the capacitor conductors. This can be
accomplished by putting turns or coils in the power connections to the
capacitors (6 in. diameter coil, six loops). For more information, refer to
NEMA standard ICS 2, Part 2, Capacitor Applications.
Care should be used in mounting the coils so that they are not stacked
directly on top of each other or they will have a cancelling effect. Also,
the coils should be mounted on insulated supports away from metal parts
so they will not act like induction heaters.
ATTENTION: Any covers or barriers removed during
installation must be replaced and securely fastened before
energizing equipment. Failure to do so may result in severe
burns, injury or death.

1560D-5.1 February 2000

Installation

2-11

Figure 2.4
Typical One-Line Diagram Showing 2 Different Styles
of Power Factor Capacitor Connections

Power Bus
Isolation Switch

Isolation Switch

Fuse

Fuse

Contactor
Isolation Contactor
di/dt Inductor

di/dt Inductor
Capacitor
Contactor

PFCC

PFCC
(Power Factor
Correction Capacitor)

Bypass
Contactor

Motor

1560D-5.1 February 2000

2-12

Installation

Surge Arrestor Protection


Devices

1560D-5.1 February 2000

Rockwell Automation highly recommends that motor surge capacitors and/or


motor surge arresters not be located on the load side of the SMC. The
issues that warrant this are:

Motor and system inductance limits the rate at which the current can
change through the SMC. If capacitance is added at the motor, the
inductance is negated. The surge capacitors downstream of the SMC
represent a near zero impedance when presented with a step voltage
from the turn on of the SCRs near the line voltage peak. This causes a
high level of di/dt to occur, due to the fact that the motor cables are
generally short in length. There is very little impedance between the
capacitor and SCR to limit the di/dt of this capacitor charging current.
This can result in damage to the power semiconductors (SCRs) in the
SMC.

It is essential to understand the clamping voltage of the arresters and


type of grounding used in the distribution system. The switching of the
SCRs generates slightly higher than nominal peak line to ground
voltages. The typical peaks are 1.5 times the nominal line to ground
peak voltages. These may cause the arresters to conduct, which could
affect the operation of the SMC and result in faults. Depending upon
the instance at which the arresters conduct, this could also result in
SCR damage.

The capacitance in combination with the line and motor impedance


could also be excited by the voltage steps from SCR switching to
create resonant voltage swings which could exceed the device voltage
withstanding ratings or surge arrester rating, or cause distorted voltage
signals which may be misinterpreted by the MV Dialog Plus control
system.

Installation

Motor Overload Protection

2-13

Thermal motor overload protection is provided as standard (though it must


be programmed) with the MV Dialog Plus controller. If the overload
trip class is less than the acceleration time of the motor, nuisance tripping
may occur.

ATTENTION: Overload protection should be properly


coordinated with the motor to avoid damage to equipment.

Three special applications require consideration: Emergency Bypass,


Two-speed Motors, and Multi-motor Protection.

Emergency Bypass
In standard bypass configuration, the MV Dialog Plus controller relies on a
Bulletin 825 converter module to provide current feedback to the Dialog Plus
module in order to maintain thermal memory and power monitoring
capability. It is possible, however, to use traditional electromechanical or
solid-state overload relays for emergency bypass configurations in situations
where the Dialog Plus module does not initiate the start sequence, and the
MV Dialog Plus controller operates as a full-voltage starter.

Two-speed Motors
The MV Dialog Plus controller has overload protection available for single
speed motors. When the MV Dialog plus controller is applied to a two-speed
motor, the Overload Class parameter must be programmed to OFF, and
separate overload relays must be provided for each speed.

Multi-motor Protection
The MV Dialog Plus controller provides overload protection for only one
motor. When the MV Dialog Plus is controlling more than one motor, the
Overload Class Parameter must be programmed to OFF, and individual
overload protection is required for each motor.

1560D-5.1 February 2000

2-14

Installation

Human Interface Module

The Bulletin 1201 human interface modules may be used to program and
control the SMC Dialog Plus controller. The human interface modules
have two sections: a display panel and a control panel. The display panel
duplicates the two-line, 16-character, backlit LCD display and programming
keypad on the front of the SMC Dialog Plus controller. Refer to Chapter 4
for a description of programming keys; refer to Appendix D for a listing
of human interface module catalog numbers that are compatible with the
controller.
The control panel provides the operator interface to the controller. The
keys that provide start and stop control are described below.
Start
The green start button begins motor operation.
Stop
The red stop button halts motor operation.
Jog
The jog button is active only when a control option is present.
Pressing the jog button will initiate the option maneuver
(for example: Pump Stop)
ATTENTION: The Bulletin 1201 human interface module's
stop push button is not intended to be used as an emergency
stop. Such usage may result in severe injury or death. Refer
to the applicable standards for emergency stop requirements.
All other controls available with the various human interface modules
are non-functional with the MV Dialog Plus controller.

1560D-5.1 February 2000

Installation

2-15

Human Interface Module (cont.) Connecting the Human Interface Module to the Controller
Figure 2.5 shows the connection of the SMC Dialog Plus controller to a
human interface module. See Figure 1.18(c) on page 1-24 for the control
wiring diagram that enables start-stop control from a human interface
module.
Figure 2.5
SMC Dialog Plus Controller with Human Interface Module

11

12

21

L1

L2

L3

13 14

22

ESC.

15 16

17

23 24 25 26

18

27

19 20

28

Latching
Mechanism
Pull back moving part (connector body) to disconnect
cable from the SCANport connection.

Bulletin 1202
Cable

29 30

SEL.

SMC Dialog Plus Controller

Human Interface Module

1560D-5.1 February 2000

2-16

Installation

Human Interface Module (cont.) Control Enable


To enable motor control from a connected human interface module, follow
the procedure below with the connected human interface module's
programming keys.
Note:

Series A and Series B human interface modules require different


procedures. Be sure to use the correct table.

Series A Human Interface Modules


Description

Action

Display
STOPPED
0.0 AMPS

1. Press any key to access the Choose


Mode function.

CHOOSE MODE
_____

2. Scroll with the Up/Down keys until the


Program option appears.

CHOOSE MODE
PROGRAM

3. Press the Enter key to access the


Program option.

PROGRAM
_____

4. Scroll with the Up/Down keys to the


Linear List option.

PROGRAM
LINEAR LIST

5. Press the Enter key to access the


Linear List programming group.

VOLTS PHASE A-B


0 VOLTS

6. Scroll with the Up/Down keys to


parameter number 85 Logic Mask.

LOGIC MASK
0

7. Press the Select key to move the


cursor to the second line to modify the
parameter. !

LOGIC MASK
0

8. Press the Up key until the value 4


appears.

LOGIC MASK
4

9. Press the Enter key to accept the new


setting.

LOGIC MASK
4

! Zero and 4 are the only valid settings.

Note:

1560D-5.1 February 2000

If a human interface module is disconnected from the MV


Dialog Plus controller while the Logic Mask is set to 4,
a "Comm Fault" will occur.

Installation

2-17

Human Interface Module (cont.) Control Enable (cont.)


Series B Human Interface Modules
Description

Action

Display
STOPPED
0.0 AMPS

1. Press any key to access the Choose


Mode function.

CHOOSE MODE
_____

2. Scroll with the Up/Down keys until the


Control Logic option is presented.

CHOOSE MODE
CONTROL STATUS

3. Press the Enter key to access the


Control Logic options.

CONTROL LOGIC
DISABLE

4. Press the Select key to access the


settings available.

CONTROL LOGIC
DISABLE

5. Use the Up/Down keys to obtain the


Enable option.

CONTROL LOGIC
ENABLE

6. Press the Enter key to accept.

CONTROL LOGIC
ENABLE

Note: If a human interface module is disconnected from the MV


Dialog Plus controller while Control Logic is enabled,
a "Comm Fault" will occur.

1560D-5.1 February 2000

2-18

Installation

Communication Modules

The Bulletin 1203 communication module allows the user to connect the
SMC Dialog Plus controller to various networks and communication
protocols. The figure below shows how the controller and the communication module connect.
Figure 2.6
SMC Dialog Plus Controller with Communication Module

L2
3

L1
1

12

11

21

13

22

14

23

15

24

16

25

17

26

L3
5

19

18

27

28

20

29

Latching
Mechanism

Bulletin 1202 Cable

Pull back moving part (connector body) to disconnect


cable from the SCANport connection.
30

2
SH
1
Re m I/O

Re m I/O STS

Re m I/O A ct
He a tl h
V+
VG

SCA Nb u sSTS

FA ULT

ES C . S EL.

SMC Dialog Plus Controller

1560D-5.1 February 2000

Communication Module

Installation

Converter Modules

2-19

The Bulletin 825 converter module provides three-phase current feedback


to the SMC Dialog Plus controller for metering and overload protection
during bypass operation. Cat. No. 825-MCM20 is to be used with current
transformers.
The current transformer ratio must be programmed in the calibration group
for proper current measurement scaling. See page 5-2 for instructions on
programming this parameter.
Figure 2.7 shows the connection between the controller and the module.
Figure 2.7
Converter Module Connection Interface

L1

L2

L3
Converter
Module !

T1

T2

T3

Cable (provided as
standard with the
converter module) "

150-NFS
Fanning Strip

21

!
"

22

23

24 25

26 27

28 29

30

The converter module rating must be programmed in the calibration group for proper current measurement
scaling.
Cable length is three meters. Only the cable provided with the converter module is compatible with the
SMC Dialog Plus controller. Use of any other cable may result in faulty controller operation.

1560D-5.1 February 2000

2-20

Installation

Converter Modules (cont.)

The figure below illustrates the connection of the current transformers to


the converter module.
Figure 2.8
Current Transformer Connection to Converter Module
Current Transformer !"

L1

L2

L3
Converter Module #

T1

!
"
#

1560D-5.1 February 2000

T2

T3

The current transformer (CT) ratio must be programmed in the calibration group for proper current
measurement scaling. See page 5-2 for instructions on programming this parameter.
Another current transformer connects L2 and T2, and another connects L3 and T3.
The converter module, Cat. No. 825-MCM20, must be used in these applications.

Installation

Control Terminal Designations

2-21

As shown in Figure 2.9, the SMC Dialog Plus controller is equipped


with 20 control terminals on the front of the controller.
Figure 2.9
SMC Dialog Plus Controller Control Terminals

21

22

23

24

25

26

Terminal Number

19

18

17

16

15

14

13

12

11

27

28

20

29

30

Description

11

Control Power Input

12

Control Power Common

13

Controller Enable Input !

14

Logic Ground

15

Dual Ramp/Option Input !

16

Start Input !

17

Stop Input !

18

Auxiliary Relay Common

19

N.O. Auxiliary Contact #1 (Normal/Up-to-speed)

20

N.C. Auxiliary Contact #2 (Normal/Up-to-speed)

21

Not Used

22

Not Used

23

Not Used

24

Not Used

25

Converter Module Fanning Strip Connection !

26

Converter Module Fanning Strip Connection !

27

Converter Module Fanning Strip Connection !

28

Converter Module Fanning Strip Connection !

29

N.O./N.C. Auxiliary Contact #3 (Normal/Fault)

30

N.O./N.C. Auxiliary Contact #3 (Normal/Fault)

"

Do not connect any additional loads to these terminals. These parasitic loads may
cause problems with operation, which may result in false starting and stopping.

"

When control power is absent from terminals 11 and 12, this contact will be normally
open. Upon application of control power, the contact will take the state, normally open or
normally closed, as programmed. Refer to Fault Auxiliary Contact on page 9-3.

1560D-5.1 February 2000

2-22

Installation

1560D-5.1 February 2000

Chapter

Commissioning Procedure

Preliminary Set-Up

A. Ensure the work area is clean and tidy. Pathways to main disconnect
and emergency stop push-button must be clear and unobstructed.
B. The following test equipment is to be prepared for use:
Test power supply, supplied with each controller
Multimeters
Hi-Pot Tester (recommended) or Megger
Oscilloscope with memory (optional)
C. Complete drawing package and parts list.
D. Specification of project.

1560D-5.1 February 2000

3-2

Commissioning Procedures

System Characteristics
Job Name: ______________________________

Job Number: _________________________________

Rated Voltage: __________________________

Rated Current: _____________

Actual Motor Load


Load Type:

Fan ___Pump___Conveyor___Compressor___Mixer___
Other_________________________________________
Constant Torque_______ or Variable Torque _______

Actual Motor Data: __________________________________________


Motor HP: _________________________________________________
Motor Rated Speed: _________________________________________
Motor F.L.A.: ______________________________________________
Motor S.F.: ________________________________________________
Motor L.R.A.: ______________________________________________
Frequency: ________________________________________________
Phases: ___________________________________________________

1560D-5.1 February 2000

S.F.: _________

Commissioning Procedures

Preliminary Check

3-3

ATTENTION: Ensure that all sources of power are isolated and locked out before working on installed equipment.
Verify that all circuits are voltage free using a hot stick or
appropriate voltage measuring device. Failure to do so may
result in severe burns, injury or death.

A. Verify correct power cable phase sequencing, and that connections are
tight.
B. Verify power fuse ratings and condition.
C. Verify control fuse ratings and condition.
D. Check that power cable installation has not damaged components, and
that electrical spacings have not been reduced.
E. Check that fibre-optic cables are fully seated in their connectors.
F. Check that circuit board plug connectors are installed and fully
inserted in their sockets.
G. Check that the cooling fan (if supplied) is secured and the rotor is not
obstructed.
H. Verify integrity and operation of all interlocks.
I. In the case of the 1503D, verify wiring and perform all tests in
conjunction with OEM documentation.

Programming

MV Dialog Plus Module


Refer to Chapter 4 for programming procedures.
The standard factory settings are as shown in Appendix B.
Settings may be different on engineered orders, or when option modules or
customer requirements dictate different settings.
Important: The module should be programmed with an understanding of
how the SMC functions, and the characteristics of the motor and driven
load. Inappropriate settings may elicit unexpected results such as lack of
acceleration torque or full-voltage starting. For Pump Control applications,
refer to Application Considerations on page 1-13.
If the factory settings are not suitable for the application, program the
module to meet the application requirements. Contact your local Rockwell
Automation representative or the factory if assistance is required.

1560D-5.1 February 2000

3-4

Commissioning Procedures

Hi-Pot and Megger Test

It is recommended that insulation levels be checked before energizing


power equipment. This may be done with a High Voltage AC insulation
tester (HI-POT) or a Megger. See Publication 1502-5.0 for suggested HI-POT
testers, and for test procedures for vacuum contactors. If using a Megger,
a 5000 volt type is recommended.
ATTENTION: Solid-state devices can be destroyed by
high voltage. Use jumper wires between heatsinks to
short out the SCRs before applying high-test voltages to
the power circuit. Disconnect the white wires (1L1, 1T1,
1L2, 1T2, 1L3, 1T3) from the voltage feedback board and
remove the plug connector. On the 1562D, 400A, the voltage
feedback board is located on the back of the low voltage
panel; on the 1560D, 400A/800A, the voltage feedback
board is located on the left side of the structure. If voltage
transformers are present, remove one primary fuse from each
device. On the 1503D, consult OEM documentation for
location of voltage feedback board
ATTENTION: Use caution when performing the HI-POT or
Megger Test. High voltage testing is potentially hazardous and
may cause severe burns, injury or death. Where appropriate,
the case of the test equipment should be connected to ground.
Insulation may be tested from phase to phase and phase to ground. The
recommended level for AC HI-POT testing is (2 X VLL) Volts, where VLL
is the rated line-to-line voltage of the power system. The leakage current
may be recorded for future comparison testing, and must be less than 20 mA.
If a Megger is used, it should indicate 50 k megohms or greater if it is
isolated as explained in the next paragraph. If the motor is connected, the
Megger should indicate 5 k megohms or greater.
If a 1560D is being tested, it is recommended that the input and output
cables be disconnected for each phase. If a 1562D is being tested, it is
recommended that the main contactor be in the open position, and that the
output cables be disconnected for each phase. (See points marked with an
asterisk * in Figure 1.17, page 1-18.) This will ensure the unit is isolated from
the line and the motor. The line and the motor may be tested separately to
locate problem areas. If a 1503D is being tested, consult OEM documentation.
After completing the test, remove all semiconductor jumpers and test the
devices with a multimeter to ensure no damage has occurred from the
insulation test. Reconnect the system as it existed prior to this section.
Perform the power supply and resistance checks in the following sections.
ATTENTION: Failure to reconnect all wires and cables
correctly may result in equipment damage, personal injury or
death.

1560D-5.1 February 2000

Commissioning Procedures

3-5

Figure 3.1
Connection and Test Information for Interface Board

DIP1: Pulse Turn ON (slide up) to


apply test pulses to gate drive circuits.
NOTE: Must be OFF for normal operation.

Test Point 2: +12V


LED 1 (Green): Power ON
when control power applied.

LED 2 (Red): Pulse ON


when test pulses on.

CONTROL FUSE (F1): Replace with


indicated size and type, depending on
rated control voltage. Part Numbers:
1/10A 80174-028-02
1/16A 80174-028-01

L
POWER

N
G

LINE
NEUTRAL

CONTROL POWER:
100-120 or 220-240 VAC
50 or 60 Hz

GROUND

Test Point 1
LED 3 (Yellow): Phase A.
ON when gate signal present.

VOLTAGE SELECTION PLUG


(TB2): Apply jumpers per rated
control voltage range.

Phase A Fibre Optic Transmitters.


Send gate signals to gate driver
board via fibre optic cables. All
transmitters within a phase are in
series and are driven simultaneously.
(See note 2)

Motor voltage inputs from


voltage feedback board

Test Point 10:


Phase A Gate Signal

UTS: Dialog Term. 19


Control Common

Test Point 1

LED 7 (Red): VF inhibit.


ON when voltage feedback
signals are inhibited.

Phase B Fibre Optic Transmitters


(See note 2)
Test Point 11:
Phase B Gate Signal

LED 6 (Red): UTS status.


ON when Dialog UTS signal
is true.

Test Point 1
LED 4 (Yellow) ON
when Phase B gate signal present

Test Point 1

LED 5 (Yellow) ON
when Phase C gate signal present

LED 8, LED9, LED10 (Green)


ON when signal present at
temperature feedback fibre
optic receiver(s).

Test Point 12:


Phase C Gate Signal

Phase C fibre optic


Transmitters
(See note 2)

Temperature
feedback fibre
optic receivers.
One cable from a
gate driver board
in each phase.

Test Point 3: +5 V

Test Point 1

DIP 2: Use to defeat individual or all temperature feedback channels.


Switch 4 must be OFF for normal operation. If there are fibre optic
cables present in the blue receivers to the left, the corresponding
switch(es) must be OFF (press in at bottom to turn off). If a blue
receiver does not have a cable plugged in, the corresponding switch
must be ON.

NOTES:
1. All test point voltages or signals are relative to TP1 (COM) except TP6 TEMP MODULE which is relative to TP19 TEMP COM only.
TP19 must not be connected to ground or TP1 COM. There are several TP1 locations on the board for convenience.
2. There are two versions of the circuit board: -51 and -53 have four fibre optic transmitters per phase (for <2700 volt operation, only two
per phase will be utilized); -52 and -54 have six fibre optic transmitters per phase for >5000 volt operation.
3. Part numbers 80187-131-51 and -52 are factory set for 100-120 VAC control power. 80187-131-53 and -54 are factory set for 220-240 VAC
control power. They can be changed in the field by moving the jumpers on the voltage selection plug (TB2) and changing the fuse (F1).

1560D-5.1 February 2000

3-6

Commissioning Procedures

Power Supply Tests

ATTENTION: Servicing energized industrial control


equipment can be hazardous. Severe injury or death can
result from electrical shock, burn, or unintended actuation of
controlled equipment. Before proceeding, ensure that all
sources of power are isolated and locked out. Verify that all
circuits are voltage free using a hot stick or appropriate
voltage measuring device. Any covers or barriers removed
during this procedure must be replaced and securely fastened
before energizing equipment. Where appropriate, the case of
test equipment should be connected to ground.
1. Isolate incoming power
2. Open the door(s) providing access to the SCR/heatsink assemblies.
You will be touching components which are connected to the high
voltage power circuit, so be sure to isolate power as stated above.
3. Apply rated control voltage to the control circuits from a separate
control source, or by plugging into the test source connector, and
selecting the TEST position of the control switch.
4. Locate the MV Dialog Interface board in the control section (See
Figure 3.2). This circuit board has the black control module mounted on
it. Locate the switch labeled DIP1 at the upper left corner of the board.
Close the switch by sliding the toggle up. This starts a pulse generator
to supply simulated gate-pulse signals via fibre optic cables to the gate
driver boards. LED 2 (red) above the switch, and the three yellow
LEDs (LED 3, 4, 5) on the left side of the Interface board should be lit.
(Note: They may appear dim, depending on ambient light conditions).
Figure 3.2
Interface PCB

Close switch to activate test pulses.


LED2 indicates pulses are activated.

LED2
DIP1

1560D-5.1 February 2000

Commissioning Procedures

Power Supply Tests (cont.)

3-7

5. Since the gate driver circuits normally receive power from the snubber
circuits when the SMC is operating, an alternate source must be used
for testing. Locate the Portable Test Power Supply that was included
with the equipment, and verify that the rating corresponds to the
available power system (i.e. 110/120 VAC or 220/240 VAC). Plug the
unit into the power source, and plug the green connector into TB1 on
each of the gate driver sections (See Figure 3.3).
Figure 3.3
Test Power Application
Yellow LED

Plug in test
power supply
(TB1)

TP7 (Gate)
TP1 (Com)
TP2 (+)

Yellow LED
Plug in test
power supply
(TB1)

TP7 (Gate)
TP1 (Com)
TP2 (+)

6. The yellow LED on the upper right-hand side of the energized gate
driver circuit should be lit (it may appear dim, depending on ambient
light conditions). This is normally sufficient to verify that the gate drive
system is functioning, however, a more detailed check can be made
utilizing steps 7 and 8.

1560D-5.1 February 2000

3-8

Commissioning Procedures

Power Supply Tests (cont.)

7. The gate-driver board voltage may be checked by connecting a DC


voltmeter to TP2 (+) and TP1 (-) (See Figure 3.3). With the specified
power supply connected, the voltage should be 12 2 VDC.
8. The actual gate pulse may be checked by connecting an oscilloscope
between TP7 and TP1 (See Figure 3.3). The pulse should appear as
shown in Figure 3.4a and 3.4b.
Figure 3.4b
Gate Pulse Detail ABB SCR

14

14

12

12

10

10

Volts

Volts

Figure 3.4a
Gate Pulse Detail GEC (GPS) SCR

6
4

6
4

-2

-2

-2

-2

Microseconds

Microseconds

Figure 3.5
Gate Pulse Test Waveform

-2.0 -1.5 -1.0 -0.5

0.0

0.5

1.0

1.5

2.0

2.5

3.0

Milliseconds

9. If no pulse is observed, and the yellow LED is lit, check for a shorted
gate on the SCR by removing the green plug and connecting an
ohmmeter to the gate leads. If the LED is not lit, and the circuit
voltage is as specified in step 7 (above), pinch the tab on the fibre-optic
connector and carefully pull it straight out of the receiver. The end of
the connector should glow red to indicate the presence of a gate signal.

1560D-5.1 February 2000

Commissioning Procedures

Power Supply Tests (cont.)

3-9

If it does not, remove the other end of the cable from the interface
board and check that the grey transmitter is emitting red light. If it is,
the fibre-optic cable must be replaced. If it isnt, the interface board
should be replaced.
10. When each gate driver circuit has been checked, disconnect the power
supply and remove it from the cabinet.
ATTENTION: The gate-drive circuits operate at high
voltage when the SMC is energized. Failure to remove the
portable test power supply will result in equipment damage
and may cause severe injury or death.
11. Open the switch DIP1 on the interface board (see Figure 3.2) before
returning the unit to service.
ATTENTION: If the DIP1 switch is not in the open
position when the SMC is energized, the motor will start in
an uncontrolled manner and may cause severe damage.
12. Check that all plugs and connectors are secure. Retrieve all hardware
and tools from the equipment. Replace and secure any barriers
removed during servicing and close all doors before applying power.

Control Function Tests


ATTENTION: Servicing energized industrial control
equipment can be hazardous. Severe injury or death can
result from electrical shock, burn, or unintended actuation
of controlled equipment. Recommended practice is to
disconnect and lock out control equipment from power
sources, and allow any stored energy in capacitors to dissipate.
The safety related work practices of NFPA 70E, Electrical
Safety Requirements for Employee Workplaces, must be
followed if it is necessary to work in the vicinity of energized
equipment.
1. Apply rated control voltage to the control circuit.
2. Using the control schematic, apply control signals to cause relays and
contactors to energize, to verify operation.
3. Remove any jumpers used in the test and restore all circuits to normal
when finished.

1560D-5.1 February 2000

3-10

Commissioning Procedures

Resistance Checks

To ensure that resistors and connections have not been damaged during
shipment and installation, the following resistance tests should be performed
before energizing the starter.
1.

Remove all power from the equipment.


ATTENTION: Verify that all circuits are voltage free
using a hot stick or appropriate voltage measuring device.
Severe injury or death can result from electrical shock, burn,
or unintended actuation of controlled equipment.

2. Measure DC resistance per the following chart:


Location of Probes

1000 V

1300 V

1500 V

2300 V

3300 V

4160 V

6900 V

Cathode to Cathode !

22K-30K

23K-31K

24K-32K

Cathode to Cathode "

17K-23K

19K-25K

20K-27K

21K-29K

40K-53K

43K-57K

64K-84K #

Cathode to Gate

10-40 ohm

10-40 ohm

10-40 ohm

10-40 ohm

10-40 ohm

10-40 ohm

10-40 ohm

!
"
#

Measured between terminals Cathode on SPGD Boards, upper two or bottom two within a phase.
Measured between terminals Cathode on SPGD Boards, top to bottom within a phase.
Measured between line and load terminals within a phase.

3. If abnormal readings are obtained, refer to Power Circuit Troubleshooting on page 10-9.

Start-Up

1. Remove any temporary jumpers or grounding devices used during


commissioning.
2. Check that all tools are removed from the equipment. Any tools or
hardware used or dropped during installation and commissioning must
be retrieved and accounted for.
3. Check that all barriers or covers removed during installation or commissioning have been securely mounted.
4. Close and secure all doors, and verify function of all interlocks that
prevent access to medium voltage compartments when the unit is
energized.
5. The controller is ready to power the motor.

1560D-5.1 February 2000

Chapter

Programming

Overview

This chapter provides a basic understanding of the programming keypad


built into both the SMC Dialog Plus controller and the optional Bulletin
1201 human interface modules. This chapter also describes programming
the controller by modifying the parameters.

Keypad Description

The keys found on the front of the SMC Dialog Plus controller are
described below.
Escape

Pressing the Escape key causes the programming system to move


up one level in the menu structure.

Select

The Select key has two functions:


Pressing the Select key alternately causes the top or bottom line
of the display to become active (indicated by flashing first
character).
In parameter modification with series A FRN 3.00 or greater and
series B human interface modules, Select moves the cursor from
the least significant digit to the most significant.

Programming Menu

Up/Down
Arrows

These keys are used to increment and decrement a parameter value


or to scroll through the different modes, groups and parameters.

Enter

When pressed, a mode or group will be selected, or a parameter


value will be entered into memory. After a parameter value has
been entered into memory, the top line of display will automatically
become active, allowing the user to scroll to the next parameter.

Parameters are organized in a four-level menu structure for straightforward


programming. Figure 4.1 details the programming menu structure and the
four-level hierarchy.

1560D-5.1 February 2000

4-2

Programming

Programming Menu (cont.)

Figure 4.1
Menu Structure Hierarchy

"
#$

"

The SMC Dialog Plus controller does not support EEPROM, Link, Process or Start-up modes.

"

Steps back one level.

Control Status and Search are only available when using a Series B Bulletin 1201 human interface module.

Password protected.

English is currently the only available language.

1560D-5.1 February 2000

Programming

Programming Menu (cont.)

Linear
List
See page 4-4

Figure 4.1 (cont.)


Menu Structure Hierarchy

Metering
See
Chapter 6

4-3

Basic Setup

Advanced Setup

Faults

Calibrate
See
Chapter 5

Language
"

! Steps back one level.


" English is currently the only language available.
# For further information on parameters, see Appendix B.
$ For further information on parameter management, see pages 4-6 and 4-7.

1560D-5.1 February 2000

4-4

Programming

Programming Menu (cont.)

Table 4.A
Parameter Linear List
Parameter No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
!

1560D-5.1 February 2000

Description
Volts Phase AB
Volts Phase BC
Volts Phase CA
Current Phase A
Current Phase B
Current Phase C
Wattmeter !
Kilowatt Hours !
Elapsed Time
Power Factor !
Mtr. Therm Usage
Factory Use
Factory Use
SMC Option
ETM Reset
Factory Use
Parameter Mgmt.
Clear Fault
Fault Buffer #1
Fault Buffer #2
Fault Buffer #3
Fault Buffer #4
Fault Buffer #5
Factory Use
Factory Use
Factory Use
Factory Use
Starting Mode
Dual Ramp
Ramp Time #1
Initial Torque #1
Ramp Time #2
Initial Torque #2
Current Limit Level
Kickstart Time
Overload Class
Stall Delay
Energy Saver !
Aux. Contacts #1 & 2
Aux. Contact #3
Contact 3 Config.
Stop Time
Factory Use
Slow Speed Sel.

Not used with MV Dialog Plus Controller.

Parameter No.
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88

Description
Slow Speed Dir.
Slow Accel Current
Slow Running Current
Braking Current
Factory Use
Factory Use
Stopping Current
Undervolt. Level
Undervolt. Delay
Overvolt. Level
Overvolt. Delay
Jam Level
Jam Delay
Unbalance Level
Rebalance !
Underload Level
Underload Delay
Phase Reversal
Starts per Hour
Restart Attempts
Restart Delay
Factory Use
Factory Use
Factory Use
Line Voltage
Motor FLC
Factory Use
Mtr. Code Letter
Factory Use
Converter Rating
CT Ratio
Calibration
Enter Calib. Amps
Language Select
Motor HP Rating
Motor kW Rating
LRC Ratio
Factory Use
Factory Use
Service Factor
Logic Mask
Unbalance Delay
S/W Version
Overload Reset

Programming

Password

4-5

Password protection lets the user limit access to the programming system
of the SMC Dialog Plus. This feature is disabled with a setting of 0
(factory set default). To modify the password or login after a password is
programmed, complete the procedure below.
Description

Action

Display
STOPPED
0.0 AMPS

1. Press any key to go from the status


display to the Choose Mode menu.

CHOOSE MODE
DISPLAY

2. Scroll with the Up/Down keys until the


Password option appears.

CHOOSE MODE
PASSWORD

3. Press the Enter key to access the


Password menu.

PASSWORD
MODIFY
Options: Login, Modify,
Logout

4. Press the Enter key.

ENTER PASSWORD
_____

5. Press the Up/Down keys to enter the


desired number. If you are modifying
the password, make a note of it as
displayed.

ENTER PASSWORD
#####

6. Press the Enter key after you have


completed modifying the password.!

CHOOSE MODE
PASSWORD

! After you have completed the programming process, re-enter the Password mode to logout. This will eliminate
unauthorized access to the programming system.

Note: If you lose or forget the password, contact your nearest Rockwell
Automation sales office. You can also call Rockwell Automation
Medium Voltage Headquarters at 1-519-623-1810 for assistance.

Search

The Search mode allows the user to view only those parameters that have
settings other than the factory default values. This mode is only available
when using Bulletin 1201 human interface module.

1560D-5.1 February 2000

4-6

Programming

Parameter Management

Before you begin programming, it is important to understand how the


controller memory is:
structured within the SMC Dialog Plus controller
used on power-up and during normal operation
Refer to Figure 4.2 and explanations below.
Figure 4.2
Memory Block Diagram

EEPROM

RAM

ROM

Random Access Memory (RAM)


This is the work area of the controller after it is powered up. When you
modify parameters in the Program mode, the new values are stored in RAM.
When power is applied to the controller, parameter values stored in the
EEPROM are copied to RAM. RAM is volatile and the values stored in
this area are lost when the controller is powered down.

Read-only Memory (ROM)


The SMC Dialog Plus controller comes with factory default parameter
values. These settings are stored in nonvolatile ROM and are displayed
the first time you enter the Program mode.

Electrically Erasable Programmable Read-only Memory (EEPROM)


The SMC Dialog Plus controller provides a nonvolatile area for storing
user-modified parameter values in the EEPROM.

1560D-5.1 February 2000

Programming

Parameter Management
(cont.)

4-7

Using Parameter Management


Description
Saving to EEPROM
To ensure that the newly modified
parameters are not lost if control
power is removed from the controller,
store the values into EEPROM.

Action

Display
PARAMETER MGMT
STORE IN EE

Recalling from EEPROM


Parameters stored in EEPROM can
be manually brought to RAM by
directing the controller to recall the
values stored in its EEPROM.

PARAMETER MGMT
RECLL FRM EE

Recalling Defaults
After parameter values have been
modified and saved to EEPROM,
factory default settings can still be
re-initialized.

PARAMETER MGMT
DEFAULT INIT

1560D-5.1 February 2000

4-8

Programming

Parameter Modification

All parameters are modified using the same method. The basic steps to
performing parameter modification are described below.
Note:

Parameter values modified while the motor is operating are not


valid until the next start sequence begins.
Description

Action

Display
STOPPED
0.0 AMPS

1. Press any key to go from the status


display to the Choose Mode menu.

CHOOSE MODE
DISPLAY

2. Scroll with the Up/Down keys until the


Password option appears.

CHOOSE MODE
PROGRAM

3. Press the Enter key to access the


Program menu.

PROGRAM
METERING

4. Scroll with the Up/Down keys until the


option you want to use (Basic Setup,
Advanced Setup, etc.) appears. For
this example, Basic Setup will be used.

PROGRAM
BASIC SETUP

5. Press Enter to select the Basic Setup


group.

SMC OPTION
STANDARD

6. Scroll to the next parameter by using


the Up key.

"

STARTING MODE
SOFT START
Options: Soft Start,
Current Limit

7. To modify the parameter, press the


Select button to move the cursor to
the second line.

STARTING MODE
SOFT START

8. Scroll to the option of your choice by


using the Up/Down keys. For this
example, we will choose Current Limi

STARTING MODE
CURRENT LIMIT

9. Press the Enter key to accept the new


setting.

STARTING MODE
CURRENT LIMIT $

10. Scroll to the next parameter by using


the Up key. Continue the process
until all desired settings are entered.

RAMP TIME #1
10 SEC

11. Press the Enter key to save the new


settings to EEPROM.

PARAMETER MGMT
STORE IN EE

! If the Choose Mode menu does not provide the Program option, then you must enter your password.
" The first parameter displayed advises the user if any control option (i.e. Pump Control) is resident. This
parameter is factory set and cannot be modified by the user.
# The display will indicate that the second line is now active by flashing the first character. If the LCD display
does not provide a flashing cursor, then the controller is in the Display mode.
$ You will notice that the cursor has returned to flashing the first character of the first line.

1560D-5.1 February 2000

Programming

Soft Start

4-9

The following parameters are specifically used to adjust the voltage ramp
supplied to the motor.
Parameter

Option

Starting Mode
This must be programmed for Soft Start.

Soft Start, Current Limit

Ramp Time #1 !
This programs the time period that the controller will ramp
the output voltage up to full voltage from the Initial Torque
level programmed.

0 to 30 seconds

Initial Torque #1
The initial reduced output voltage level for the voltage ramp
to the motor is established and adjusted with this parameter.

0 to 90% locked rotor torque

Kickstart Time
A boost of 550% full load current is provided to the motor for
the programmed time period.

0.0 to 2.0 seconds

! If the controller senses that the motor has reached full speed before completing the voltage ramp, it will
automatically switch to providing full voltage to the motor.

Current Limit Start

To apply a fixed, reduced-output voltage to the motor, the following


parameters are provided for user adjustment:

Parameter

Option

Starting Mode
This must be programmed for Current Limit.

Soft Start, Current Limit

Ramp Time #1 !
This programs the time period that the controller will hold
the fixed, reduced output voltage before switching to full
voltage.

0 to 30 seconds

Current Limit Level


This parameter provides adjustability for the reduced output
voltage level provided to the motor.

50 to 600% full load current

Kickstart Time
A boost of 550% full load current is provided to the motor for
the programmed time period.

0.0 to 2.0 seconds

! If the controller senses that the motor has reached full speed before completing the current limit start, it
will automatically switch to providing full voltage to the motor.

1560D-5.1 February 2000

4-10

Programming

Dual Ramp Start

The SMC Dialog Plus controller provides the user with the ability to
select between two Soft Start settings. The parameters below are available
in the Advanced Setup programming mode to obtain Dual Ramp control:
Parameter
Advanced Setup
The user must select the Advanced Setup programming
mode to obtain access to the Dual Ramp parameters.
Starting Mode
This must be programmed for Soft Start.
Dual Ramp !
This allows the user the option to choose between two Soft
Start profiles defined by:
1) Ramp Time #1/Initial Torque #1 and
2) Ramp Time #2/Initial Torque #2.
When this feature is turned on, the ramp time/initial torque
combination is determined by a hard contact input to
terminal 15. When this input signal is low, ramp time/initial
torque #1 are selected. When this input is high, ramp
time/initial torque #2 are selected.
Ramp Time #1
This programs the time period during which the controller
will ramp the output voltage up to full voltage for the first
Soft Start setup.
Initial Torque #1
This parameter establishes and adjusts the initial reduced
output voltage level for the first Soft Start setup.
Ramp Time #2
This programs the time period during which the controller
will ramp the output voltage up to full voltage for the second
Soft Start setup.
Initial Torque #2
The initial reduced output voltage level for the second Soft
Start setup is established and adjusted with this parameter.

Option

No, Yes

0 to 30 seconds

0 to 90% locked rotor torque


0 to 30 seconds

0 to 90% locked rotor torque

! The Dual Ramp feature is available only with the standard controller.

Full Voltage Start

The SMC Dialog Plus controller may be programmed to provide a


full-voltage start (output voltage to the motor reaches full voltage
within second) with the following programming:
Parameter
Starting Mode
This must be programmed for Soft Start.
Ramp Time #1
This must be programmed for 0 seconds for a full voltage start.
Initial Torque #1
This must be programmed for 90% for a full voltage start.
Kickstart Time
This must be programmed for 0.0 seconds for a full voltage start.

1560D-5.1 February 2000

Option

Programming

Basic Setup

4-11

The Basic Setup programming group provides a limited parameter set,


allowing quick start-up with minimal adjustments. If the user is planning
to implement some of the advanced features (i.e., Dual Ramp, Unbalance
Level, etc.), then the Advanced Setup programming group should be
selected. It provides all the Basic Setup parameter set plus the advanced set.
Parameter
SMC Option
Displays the type of controller. This is factory set and not
adjustable.
Starting Mode
Allows the user to program the SMC Dialog Plus controller
for the type of starting that best fits the application.
Ramp Time #1
This sets the time period during which the controller will
ramp the output voltage.
Initial Torque #1 !
The initial reduced voltage output level for the voltage ramp
is established and adjusted with this parameter.
Current Limit Level "
This parameter provides adjustability for the reduced output
voltage level provided to the motor.
Kickstart Time
A boost of 550% of full load current is provided to the motor
for the programmed time period.
Stall Delay
Allows the user to program the stall protection delay time.
The delay time begins after the start time has timed out.
Energy Saver
Aux. Contacts 1 & 2
Form C contacts are provided as standard with the SMC
Dialog Plus controller. These contacts are located at
terminals 18, 19 and 20. Aux. Contacts 1 & 2 allow the user
to configure the operation of the contacts.
Aux. Contact 3
A third auxiliary contact is provided between terminals 29
and 30. Aux. Contact 3 allows the user to program the
operation of the contact.
Contact 3 Config
This parameter provides the user with the ability to program
the powered up state of the third auxiliary contact.
Parameter Mgmt #
The newly programmed parameter values can be saved to
memory, or the factory default parameter values can be
recalled.

Option
Standard
Soft Start, Current Limit
0 to 30 seconds
0 to 90% locked rotor torque
50 to 600% full load current
0.0 to 2.0 seconds
0.0 to 10.0 seconds
Off (not used in MV Dialog
Plus)
Normal, Up-to-Speed

Normal, Fault

N.O., N.C.
Ready, Default Init., Recll
Frm EE, Store in EE

! Starting Mode must be programmed to Soft Start to obtain access to the Initial Torque parameter.
" Starting Mode must be programmed to Current Limit to obtain access to the Current Limit Level parameter.
# The new programmed parameter values will not be stored to the EEPROM without the users direction
in Parameter Management. Store in EE.

1560D-5.1 February 2000

4-12

Programming

Advanced Setup

While the Basic Setup group allows the user to get started with a minimum
number of parameters to modify, the Advanced Setup group allows full
access to the SMC Dialog Plus controller's powerful parameter set.
Following is a listing of the additional setup parameters provided.
Note:

All of the Basic Setup parameters are available in the Advanced


Setup group. The parameters shown below are in addition to the
parameters in Basic Setup.
Parameter

Dual Ramp !
Allows the user the option to choose between two Soft Start
profiles.
Ramp Time #2
Determines the soft start time for the second ramp of the
Dual Ramp feature.
Initial Torque #2
Provides the initial torque setting for the second ramp of the
Dual Ramp feature.
Undervoltage Level $
Determines the trip level as a percentage of line voltage.
Undervoltage Delay $
Provides a delay period prior to a trip occurrence.
Overvoltage Level
Determines the trip level as a percentage of line voltage.
Overvoltage Delay "
Provides a delay period prior to a trip occurrence.
Jam Level #
Determines the trip level as a percentage of the motors full
load current.
Jam Delay
Provides a delay period prior to a trip occurrence.
Unbalance Level
Allows the user to set the voltage unbalance trip level.
Unbalance Delay "
Provides a delay period prior to a trip occurrence
Rebalance
Underload Level "
Determines the trip level as a percentage of the motors full
load current.
Underload Delay
Provides a delay period prior to a trip occurrence.

Option
Off, On
0 to 30 seconds
0 to 90% locked rotor torque
0 to 99% (0 is the Off setting)
0 to 99 seconds
0 to 199% (0 is the Off setting)
0 to 999% (0 is the Off setting)
0 to 999% (0 is the Off setting)
0.0 to 10.0 seconds
0 to 25% (0 is the Off setting)
0 to 99 seconds
Off (not used in MV Dialog Plus)
0 to 99% (0 is the Off setting)
0 to 99 seconds

! The Dual Ramp feature is available only with the standard controller.
" The delay time must be set to a value greater than zero when Overvoltage or Unbalance are enabled.
# For Jam and Underload detection to function, the Motor FLC must be programmed in the Calibration
group. See Chapter 5 for instructions.
$ For Medium Voltage applications, the Undervoltage Level should be set to 80%, and the Undervoltage
Delay should be zero.

1560D-5.1 February 2000

Programming

Advanced Setup (cont.)

Parameter
Phase Reversal
Allows the user to enable phase reversal protection.
Starts Per Hour #
Allows the user to limit the number of starts during a one
hour period.
Restart Attempts !
Determines the number of attempts the controller will make
to automatically restart the motor after a fault.
Restart Delay !
Provides a delay period prior to a restart attempt.
ETM Reset
Allows the user to reset the accumulated value of the
elapsed time meter.
Parameter Management "
The newly programmed parameter values can be saved to
memory, or the factory defaults parameter values can be
recalled.

4-13

Option
Off, On
0-99 (0 is the Off setting)
0 to 5
0 to 60 seconds
Off, On
Ready, Default Init.,
Recll Frm EE, Store in EE

! The Auto Restart feature is not available.


" The new programmed parameter values will not be stored to the EEPROM without the users direction
in parameter management: Store in EE
# The base rating of the MV Dialog Plus is two starts (or one start/stop combination) per hour, thirty
seconds maximum for each operation.

Example Settings

Undervoltage !
With Line Voltage programmed for 4160 V and the Undervoltage level
programmed for 80%, the trip value is 3328 V.

Overvoltage !
With Line Voltage programmed for 2400 V and the Overvoltage level
programmed for 115%, the trip value is 2760 V.

Jam "
With Motor FLC programmed for 150 Amps and the Jam level
programmed for 400%, the trip value is 600 Amps.

Underload "
With Motor FLC programmed for 90 Amps and the Underload level
programmed for 60%, the trip value is 54 Amps.

!
"

The average value of the three phase-to-phase voltages is utilized.


The largest value of the three phase currents is utilized.

1560D-5.1 February 2000

4-14

Programming

1560D-5.1 February 2000

Chapter

Calibration
Overview

The Calibrate programming group allows the user to set parameters to


calibrate the controller to the connected motor. It is important to correctly
input the data to achieve the best performance from your controller.

ATTENTION: For overload protection, it is critical that


the data be entered as it appears on the motor nameplate.
Failure to do so may result in equipment damage.

Motor Data Entry

In the Program mode, enter the correct values into the Calibrate group:
Parameter

Option

Display

Overload Class
The factory default setting disables
overload protection. To enable it, enter
the desired trip class in this parameter.
See pages 1 -5 and 1 -6 for further
details and trip curves.

Off, 10, 15,


20, 30

OVERLOAD CLASS

Overload Reset
Allows the user to select either a manual
or auto reset after an overload fault.

Manual, Auto

OVERLOAD RESET
MANUAL

Motor HP Rating !"


Enter the value from the motors
nameplate.

0.0 6,533.5 hp

MOTOR HP RATING
#### HP

Motor kW Rating !"


Enter the value from the motors
nameplate.

0.0 6,553.5 kW

MOTOR KW RATING
#### KW

1 9,999 V

LINE VOLTAGE
#### VOLTS

Motor FLC !
Enter the value from the motors
nameplate.

1.0 999.9 A

MOTOR FLC
###.# AMPS

Service Factor
Enter the value from the motors
nameplate

0.01 1.99

SERVICE FACTOR
#.##

Line Voltage !
Enter the system voltage in this
parameter. This must be done to
ensure optimum motor performance and
correct operation of undervoltage and
overvoltage protection.

Refer to the SMC Dialog Plus Controller nameplate for maximum ratings. Exceeding these
could result in damage to the controller.

"

The controllers programming system will not allow both HP and kW values to be programmed.

1560D-5.1 February 2000

5-2

Calibration

Motor Data Entry (cont.)

Parameter

Option

Display

Motor Code Letter !


Enter the value from the motors
nameplate. If the motor nameplate
does not provide this, consult the motor
manufacturer. See Table 5.A for code
letter definitions.

A V

MOTOR CODE LETTER


#

LRC Ratio !
IEC motors do not provide a motor code
letter. Consult the motor manufacturer
for the motors locked rotor current/full
load current ratio.

0.0 19.9

LRC RATIO
##.#

Converter Rating
If a Bulletin 825 converter module will
provide current feedback to the
controller, enter the converters rating to
ensure proper current measurement
scaling.

None, 20

CONVERTER RATING
###

CT Ratio "
For controllers using external current
transformers with the 20A converter
module for current feedback, current
transformers with 5A secondaries are
required. Enter the current transformer
ratio in this parameter.

5 through 1200:5

CT RATIO
#### : 5

The controllers programming system will not allow both Motor Code Letter and LRC Ratio to
be programmed.

"

The Dialog module allows selection of most standard current transformer ratios. The only valid
ratio below 50:5 is 5:5. Motors with full load currents less than 30 amperes would normally use
a current transformer with a lower ratio (e.g. 30:5). This ratio cannot be selected on the dialog
module, so it is recommended that a valid ratio be used whenever possible. If an unlisted ratio
is used, the current can be read from the Dialog module by programming a different ratio, and
using an external correction factor. For example: If the motor FLC is 22 amperes, and a 30:5
current transformer is used, the Dialog module can be programmed for a 300:5 current
transformer. When the motor is drawing 22 amperes, the Dialog display will read 220 amperes.
The display value needs to be multiplied by 0.1 to obtain the actual motor current.

Table 5.A
Motor Codes
Letter Designation

kVA/hp #

Letter Designation

kVA/hp #

0 3.15

9.0 10.0

3.15 3.55

10.0 11.2

3.55 4.0

11.2 12.5

4.0 4.5

12.5 14.0

4.5 5.0

14.0 16.0

1560D-5.1 February 2000

5.0 5.6

16.0 18.0

5.6 6.3

18.0 20.0

6.3 7.1

20.0 22.4

7.1 8.0

22.4 and up

8.0 9.0

Locked kVA per horsepower range includes the lower figure up to, but not including, the higher
figure. For example, 3.14 is designated by letter A, and 3.15 by letter B.

Chapter

Metering
Overview

While the SMC Dialog Plus controller operates your motor, it also
monitors several different parameters, providing a full function metering !
package.

Viewing Metering Data

To access the metering information, follow the procedure below:


Description

Action

Display
AT SPEED
###.# AMPS

1. Press any button to access the


Choose Mode menu.

CHOOSE MODE
______

2. Scroll with the Up/Down keys until


the Display option is shown.

CHOOSE MODE
DISPLAY

3. Press the Enter key to select the


Display option.

CHOOSE GROUP
______

4. Scroll with the Up/Down keys until


the Metering option is displayed.

CHOOSE GROUP
METERING

5. Press the Enter key to access the


Metering group.
! Refer to page 1-10 for details on the metering functions.

1560D-5.1 February 2000

6-2

Metering

Viewing Metering Data (cont.)


Description
6. Scroll through the Metering
parameters with the Up/Down keys
to access the desired information.

Action

Display
VOLTS PHASE A-B
### VOLTS
VOLTS PHASE B-C
### VOLTS
VOLTS PHASE C-A
### VOLTS
CURRENT PHASE A
###.# AMPS
CURRENT PHASE B
###.# AMPS
CURRENT PHASE C
###.# AMPS
WATTMETER
##### kW

KILOWATT HOURS !
##### kWH
ELAPSED TIME
##### HOURS
POWER FACTOR
.##
MTR. THERM USAGE
## %
! Refer to page 1-10 for details on the metering functions.

1560D-5.1 February 2000

Chapter

Options
Overview

The SMC Dialog Plus controller offers a variety of unique control options
that provide enhanced motor starting and stopping capabilities. (See
pages 1-12 to 1-15 for brief descriptions of each option.)
Note:

Human Interface Module

Only one option module can reside in a controller. Contact


factory before substituting one option module for another.

The control buttons available with the Bulletin 1201 human interface
modules are compatible with the SMC Dialog Plus controller's control
options. The following table details the function of each button with
respect to each option.
Notes:

1. Control logic must be enabled prior to initiating control


commands to the SMC Dialog Plus controller. Refer to
pages 2-10 and 2-11 for instructions.
2. The control terminals must be wired according to Figure
1.18(c) on page 1-24.

Option

Action

Operation
The green start button, when pressed,
will commence motor acceleration to full
speed.

Soft Stop

The red stop button, when pressed, will


provide a coast stop.
The jog button, when pressed, will
initiate a soft stop maneuver.
The green start button, when pressed,
will commence motor acceleration to full
speed.

Pump Control

The red stop button, when pressed, will


provide a coast stop.
The jog button, when pressed, will
initiate a pump stop maneuver.

1560D-5.1 February 2000

7-2

Options

Human Interface Module


(cont.)
Option

Action

Operation
The green start button, when pressed,
will commence motor acceleration to full
speed.

Preset Slow
Speed

The red stop button, when pressed, will


provide a coast stop.
The jog button, when pressed, will
initiate slow speed motor operation from
a stopped status.
The green start button, when pressed,
will commence motor acceleration to full
speed.

Smart Motor
Braking

The red stop button, when pressed, will


provide a coast stop.
The jog button, when pressed, will
initiate a brake stop.
The green start button, when pressed,
will commence motor acceleration to full
speed.

Slow Speed with


Braking

The red stop button, when pressed, will


provide a coast stop.
With a stopped status, the jog button,
when pressed, will initiate slow speed
motor operation. From an at speed
condition, the jog button, when pressed,
will initiate a brake stop

ATTENTION: The Bulletin 1201 human interface


module's stop push button is not intended to be used as
an emergency stop. Such usage may result in personal
injury or death. Refer to applicable standards for
emergency stop requirements.

1560D-5.1 February 2000

Options

Programming Parameters

7-3

The following table outlines the option-specific parameters that are


provided with each control option. These parameters are in addition to
those already discussed in the Basic Setup, Advanced Setup, Metering, and
Calibration groups. Diagrams supporting the options described below are
shown later in this chapter.
Option

Soft Stop

Pump
Control
!

Parameter
SMC Option
This parameter identifies the type of
control present and is not user
programmable.

Soft Stop

Soft Stop Time


Allows the user to set the time period
for the soft stopping function.

0-60 seconds !

SMC Option
This parameter identifies the type of
control present and is not user
programmable.

Pump Control

Pump Stop Time


Allows the user to set the time period
for the pump stopping function.

0120 seconds !

Starting Mode
Allows the user to program the SMC
Dialog Plus controller for the type of
starting that best fits the application.

Pump Start, Soft Start,


Current Limit Start

SMC Option
This parameter identifies the type of
control present and is not user
programmable.

Preset Slow

Slow Speed Select


Allows the user to program the slow
speed that best fits the application.
Preset Slow
Speed
!"

Range

Low: 7% forward; 10% reverse


High: 15% forward; 20% reverse

Slow Speed Direction


This parameter programs the slow
speed motor rotational direction.

Forward, Reverse

Slow Accel Current


Allows the user to program the
required current to accelerate the
motor to slow speed operation.

0450% of full load current

Slow Running Current


Allows the user to program the
required current to operate the motor
at the slow speed setting.

0450% of full load current

Thermal capacity limits must not be exceeded. The base rating for MV Dialog units is 30 seconds
maximum. Consult factory if settings over thirty seconds are required. The base rating of the MV
Dialog Plus is two starts (or one start/stop combination per hour), thirty seconds maximum for each
operation. A stopping operation counts as a start for purposes of thermal capacity calculations.

"

Slow speed running is not intended for continuous operation due to reduced motor cooling. The two
starts per hour limitation also applies to slow speed operation.

Refer to Application Considerations on page 1-13.

1560D-5.1 February 2000

7-4

Options

Programming Parameters
(cont.)

Option

SMB Smart
Motor Braking

Parameter
SMC Option
This parameter identifies the type of control
present and is not user programmable.
Braking Current #
Allows the user to program the intensity of
the braking current applied to the motor.
SMC Option
This parameter identifies the type of control
present and is not user programmable.
Slow Speed Select
Allows the user to set the slow speed that
best fits the application.

Slow Speed
with Braking
"

Slow Accel Current


Allows the user to program the required
current to accelerate the motor to slow
speed operation.

Range

SMB Braking

0400% of full load current

Slow Speed Brake


Low: 7%
High: 15%

0450% of full load current

Slow Running Current


Allows the user to program the required
current to operate the motor at the slow
speed setting.

0450% of full load current

Braking Current !
Allows the user to program the intensity of
the braking current applied to the motor.

0400% of full load current

! All braking/stopping current settings in the range of 1100% will provide 100 % braking current to the
motor.
" Slow speed running is not intended for continuous operation due to reduced motor cooling. The two
starts per hour limitation also applies to slow speed operation.

Control Wiring for


SCANport Control

1560D-5.1 February 2000

Refer to Figure 1-18(c) or 1-18(d) on pages 1-24 and 1-25 respectively


for the applicable wiring diagram to achieve start-stop control via the
SCANport.

Options

Soft Stop Option

7-5

Figure 7.1
Soft Stop Option Sequence of Operation

100%
Coast-to-rest

Motor
Speed

Start
Push Buttons
Start
Stop
Soft Stop

Run

Soft Stop
Time (seconds)

Closed
Open
Closed
Open
Closed
Open

Auxiliary
Contacts
Soft Stop Operation
Normal
Coast-to-rest Operation
Up-to-speed

ATTENTION: The user is responsible for determining


which stopping mode is best suited to the application
and will meet applicable standards for operator safety on
a particular machine. Failure to do so may result in
severe injury and/or equipment damage.

1560D-5.1 February 2000

7-6

Options

Pump Control Option

Figure 7.2
Pump Control Option Sequence of Operation

Coast-to-rest

100%

Motor
Speed

Start

Run

Soft Stop
Time (seconds)

Push Buttons
Start

Closed
Open

Stop

Closed
Open
Pump Stop
Closed
Open
Auxiliary
Contacts
Pump Stop Operation
Normal
Coast-to-rest Operation
Up-to-speed

ATTENTION: The user is responsible for determining


which stopping mode is best suited to the application
and will meet applicable standards for operator safety on
a particular machine. Failure to do so may result in
severe injury and/or equipment damage.

Refer to Application Considerations on page 1-13.

1560D-5.1 February 2000

Options

SMB Smart Motor Braking


Option

7-7

Figure 7.3
SMB Smart Motor Braking Sequence of Operation

100%

Smart Motor Braking


Coast-to-rest

Motor
Speed

Start
Push Buttons
Start
Stop
Soft Stop

Run

Brake
Time (seconds)

Automatic Zero Speed


Shut-off

Closed
Open
Closed
Open
Closed
Open

Auxiliary
Contacts
Smart Motor Braking Operation
Normal
Coast-to-rest Operation
Up-to-speed

ATTENTION: The user is responsible for determining


which stopping mode is best suited to the application and
will meet applicable standards for operator safety on a
particular machine. Failure to do so may result in severe
injury and/or equipment damage.

1560D-5.1 February 2000

7-8

Options

Preset Slow Speed Option

Figure 7.4
Preset Slow Speed Option Sequence of Operation

100%
7 or 15%
Motor
Speed

Slow
Speed

Start

Run

Coast

Time (seconds)

Push Buttons
Start
Stop

Closed
Open

Closed
Open
Slow Speed
Closed
Open
Auxiliary
Contacts

Normal

Up-to-speed

Important: Slow speed running is not intended for continuous operation


due to reduced motor cooling. The two starts per hour limitation also
applies to slow speed operation. This option employs a cycle-skipping
scheme which produces limited torque. Applications should be checked
with the factory.

1560D-5.1 February 2000

Options

Slow Speed with Braking


Option

7-9

Figure 7.5
Slow Speed with Braking Option Sequence of Operation

100%

Braking

Motor
Speed

Slow
Speed
Push Buttons

Start

Run

Brake

Time (seconds)

Start
Stop

Closed
Open

Closed
Open
Slow Speed
Closed
Open
Auxiliary
Contacts
Normal

Up-to-speed

ATTENTION: The user is responsible for determining


which stopping mode is best suited to the application
and will meet applicable standards for operator safety on
a particular machine. Failure to do so may result in
severe injury and/or equipment damage.
Important: Slow speed running is not intended for continuous operation
due to reduced motor cooling. The two starts per hour limitation also
applies to slow speed operation. This option employs a cycle-skipping
scheme which produces limited torque. Applications should be checked
with the factory.

1560D-5.1 February 2000

7-10

Options

1560D-5.1 February 2000

Chapter

Serial Communications
Overview

The SMC Dialog Plus controller can be started, stopped, and programmed
through PLCs or SLCs using an optional Bulletin 1203 communication
module. Additionally, parameter data can be read to the logic controller
through block transfer. The amount of information that can be transferred
from the SMC Dialog Plus controller is determined by the DIP switch
settings on the communication module.
Note: Parameter values modified while the motor is operating are not
valid until the next start sequence begins.

Logic Control Data

The information in Table 8.A provides the logic control information that
can be sent to the SMC Dialog Plus controller through the logic controller's
output image table.
Table 8.A
Logic Control Data
Logic Bits !

15

14

13

12

11

10

Description
6

X
X
X
X

Definition

0
Stop "
Start "
Option Command
Clear Faults #

1
0
1
0
1
0
1
0

= Stop
= Not Stopped
= Start
= Not Start
= Option Init.
= Not Option Init.
= Clear Faults
= Not Clear Faults

Bits 4 -15 are not used


!

Only one bit may be asserted at any given time.

"

The stop bit will take priority when more than one bit is asserted. Other bits will be ignored until the stop bit is reset.

A 0 to 1 transition is required for a valid command.

Control Wiring

Refer to Figure 1.18(c) or 1.18(d) on pages 1-24 and 1-25 respectively for
the applicable wiring diagram to achieve start-stop control via the
SCANport.

1560D-5.1 February 2000

8-2

Serial Communications

Control Enable

In accordance with factory programming, "STOP" is the only control


command active on the SMC Dialog Plus controller when the SCANport
is utilized. To enable motor control from a PLC or SLC through a Bulletin
1203 communication module, follow the programming procedure below.

Description

Action

Display
STOPPED
0.0 AMPS

1. Press any key to access the Choose


Mode function.

CHOOSE MODE
_____

2. Scroll with the Up/Down keys until


the Program option appears.

CHOOSE MODE
PROGRAM

3. Press the Enter key to access the


Program option.

PROGRAM
_____

4. Scroll with the Up/Down keys to the


Linear List option.

PROGRAM
LINEAR LIST

5. Press the Enter key to access the


Linear List programming group.

VOLTS PHASE A-B


0 VOLTS
1

6. Scroll with the Up/Down keys to


parameter number 85 Logic Mask.

LOGIC MASK
0

85

7. Press the Select key to move the


cursor to the second line to modify
the parameter.

LOGIC MASK
0

85

8. Press the Up key until the value 4


appears. !

LOGIC MASK
4

85

9. Press the Enter key to accept the


new setting.

LOGIC MASK
4

85

! Zero and 4 are the only valid settings.

Note:

1560D-5.1 February 2000

If a communication module is disconnected from the SMC


Dialog Plus controller while control is enabled (Logic Mask = 4),
a Comm Fault will occur.

Serial Communications

SMC Status Data

8-3

The Information in Table 8.B provides the SMC Dialog Plus controller
status information that can be sent to the logic controller's input image table.
Table 8.B
SMC Status Data
Logic Bits

15

14

13

12

11

10

Description
6

X
X

Enabled !
Running
Not Used
Not Used

X
X
X
X

Definition

Starting
Stopping
Fault
At Speed

1 = Enabled
0 = Not Enabled
1 = Running
0 = Not Running

1 = Starting
0 = Not Starting
1 = Stopping
0 = Not Stopping
1 = Faulted
0 = Not Faulted
1 = At Speed
0 = Not At Speed

Bits 9-15 are not used


! When control power is applied, this bit is always set to 1.

Reference/Feedback

The SMC Dialog Plus controller does not support the analog reference
feature of SCANport. However, the SCANport analog feedback feature is
supported. The feedback word will always be equal to Parameter
number 4, Current Phase A.

Parameter Listing

Refer to Appendix B, Table B.1 for a complete listing of the SMC Dialog
Plus controller's parameters and groups. In addition to the range of
adjustments, the parameters' units are provided.

Scale Factor Conversion

The parameter values of the SMC Dialog Plus controller are stored as
unscaled numbers. When reading parameter data in the PLC/SLC's input
image table, divide this number by the scale factor shown in Appendix B,
Table B.1 to arrive at the proper value.
When writing from the PLC/SLC's output image table to the SMC Dialog
Plus controller, the scale factor must be taken into consideration to ensure
that the proper value is sent.

1560D-5.1 February 2000

8-4

Serial Communications

Display Unit Equivalents

Some parameter setting options use a text description when viewed from
the built-in LCD display or a human interface module. For example, the
parameter Starting Mode has the available settings of Soft Start and Current
Limit Start. Table B.2, found in Appendix B, provides the required display
unit decimal equivalent for use when sending a command from a logic
controller to the SMC Dialog Plus controller.

Datalinks/SLC Block
Transfers

The SMC Dialog Plus controller does not offer Datalinks. To communicate
with an SLC logic controller, use the 1747-SN (Series B) scanner. Refer to
the scanner user manual for instructions on block transferring data between
the SMC Dialog Plus controller and an SLC processor.

Interfacing

Refer to the appropriate communication module manual for detailed


information regarding communication module installation, DIP switch
settings, block transfer instructions, and communication module troubleshooting.

Processing Time

The typical time for the SMC Dialog Plus controller to process a single
parameter data request (i.e., block transfer) via the SCANport is approximately 100 milliseconds. Keep this value in mind when determining the
message length of multiple parameter value read or write operations.

1560D-5.1 February 2000

Serial Communications

Remote I/O Examples

8-5

Example #1 SLC 500 Controller without Block Transfer


This example demonstrates discreet control of an SMC Dialog Plus
controller from an SLC 500 logic controller. Additionally, the SLC controller
reads the Current Phase A from the SMC Dialog Plus controller via the
analog feedback word. Many of the selections shown are example-specific.
Some changes by the user may be necessary to apply the concepts of this
example to a specific application.
System Configuration
SLC 5/02 or higher

12

11

21

13

22

24

25

26

19

18

17

16

15

14

23

L3
5

L2
3

L1
1

27

1747-SN Scanner

28

Remote I/O Link

20

29

30

2
SH
1
Rem I/O
Rem I/O STS
Rem I/O ACT
Health
V+
V- SCANbus STS
G

SMC Dialog Plus


Controller

Note:

FAULT

1203-GD1
Communication Module

Bulletin 1202 SCANport Cable

It is critical that during the system design phase that each device
on the Remote I/O link is allocated a unique segment of the
SLC's I/O image table. This is accomplished by coordination of
the device's rack address, rack size and starting group address.

1560D-5.1 February 2000

8-6

Serial Communications

Remote I/O Examples (cont.)

1203-GD1 Communication Module Switch Settings


The following information is provided to explain the required 1203-GD1
communication module switch settings for this example. Refer to the
1203-GD1 manuals for further details related to the switch settings.
Example Information
Description

Switch Setting

SMC Rack Address

02

SW1: Switches 1 & 2 (Not used);


Switches 3-6 & 8 (On); Switch 7 (Off)

Starting Group Address

SW2: Switches 1 & 2 (On)

Last Rack

No

SW2: Switch 3 (Off)

Hold Last State

Yes

Sw2: Switch 4 (On)

Fault on Comm Loss

Yes

SW2: Switch 5 (On)

Fault Controller

No

SW2: Switch 6 (Off)

R I/O Baud Rate

115 k

SW2: Switch 7 (On); Switch 8 (Off)

Block Transfer

No !

SW3: Switch 1 (Off)

Logic Cmd/Status

Yes !

SW3: Switch 2 (On)

Reference/Feedback

Yes !

SW3: Switch 3 (On)

Datalinks

No !"

SW3: Switch 4-8 (Off)

! The configuration requires a 1/4 rack size allocation.


" The SMC Dialog Plus controller does not support Datalinks.

1560D-5.1 February 2000

8 7 6 5 4 3 2 1

Starting Module Group (0)


Starting Module Group (0)
Last Rack Setting (Off)
Hold Last State (On)
Fault on Comm Loss (On)
Fault Controller (Off)
R I/O Baud Rate (115k)
R I/O Baud Rate (115k)

SW3

8 7 6 5 4 3 2 1

Not Used
Not Used
On
On
On
On
Off
On

SW2

8 7 6 5 4 3 2 1

SW1

Switch Settings

Block Transfer On
Logic Cmd/Sts On
Reference/Fdbk Off
Datalink A Off
Datalink B Off
Datalink C Off
Datalink D Off
Truncate Last Datalink Off

Serial Communications

Remote I/O Examples (cont.)

8-7

G-File Configuration
The SLC system uses G-files to configure the R I/O link. G-files are
configured through the SLC programming software. The configuration is
based on the devices connected to the R I/O link. For this example, the
following G-file configuration map for the scanner's I/O image file of the
SMC Dialog Plus controller applies.
Address !
G1:0
G1:1
G1:2

15
xxxx
0000
0000

Data
xxxx
xxxx
0001 0000
0001 0000

0
xxxx
0000
0000

Description
Word 0 cannot be edited.
Logical device address (rack 2, start group 0)
Logical Image size (1/4 rack)

! Words 3 and 4 do not require configuration since the communication module does not support
Complimentary I/O.

I/O Addressing
The 1203-GD1 communication module uses
one-slot addressing.
Based on the module switch settings as described above, the discrete I/O
can be mapped to the PLC I/O Image as shown below.
SLC I/O Image Table Map
SLC I/O Group Number

Output Image

Input Image

Logic Command

Logic Status

Reference "

Feedback

" The output image word that maps to the Reference word (O: 1.17, in this example) must have the value 0
to ensure proper SMC Dialog Plus controller operation.

Addressing format
I : 1 0 / 12
I for input or O for output
Slot number
Word number
Input or output number
(bit identifier: 015)

1560D-5.1 February 2000

8-8

Serial Communications

Remote I/O Examples (cont.)

I/O Addressing (cont.)


SMC Dialog Plus Controller Logic Control Addresses !
I or O

Slot "

Word #

Bit $

Address

Stop

16

00

O:1.16/00

Start

16

01

O:1.16/01

Option Command

16

02

O:1.16/02

Clear Fault

16

03

O:1.16/03

Bit Description

SMC Dialog Plus Controller Status Addresses !


I or O

Slot "

Word #

Bit %

Address

Enabled

16

00

I:1.16/00

Running

16

01

I:1.16/01

Bit Description

Starting

16

04

I:1.16/04

Stopping

16

05

I:1.16/05

Fault

16

07

I:1.16/07

At Speed

16

08

I:1.16/08

SMC Dialog Plus Controller Feedback Address !

1560D-5.1 February 2000

I or O

Slot "

Word #

Address

17

I:1.17

The addresses shown are example-specific. Addresses for any given installation can be
determined, based upon the 1203-GD1 communication module switch settings for: rack
address, starting group number, block transfer, logic commands/status, and
reference/feedback by applying the I/O addressing format for SLC 500 controllers.

"

The 1747-SN scanner resides in slot 1.

Based on the 1203-GD1 communication module switch settings (rack 2, starting group 0).
Refer to the 1747-SN User Manual, Publication 1747-6.6.

$
%

Refer to Table 8.A.


Refer to Table 8.B.

Serial Communications

8-9

Remote I/O Examples (cont.)

Example # 1 Ladder Logic Program


First Rung: When the Machine START push button is pressed, the SLC sends a START command to the SMC Dialog Plus controller. The SMC Dialog
Plus controller will start if no STOP command is being issued by the SLC or any other control device. (The start button is a normally open contact in this
example.)
Machine
START
Push Button
: 1.8

SMC
START
Command
: 1.16

Second Rung: When the Machine STOP push button is pressed, the SLC sends a STOP command to the SMC Dialog Plus controller. (The stop
button is a normally closed contact in this example.) The branch provides a logic "latched" circuit which exerts the STOP command until the feedback
from the SMC Dialog Plus controller indicates that it has received the command and has responded appropriately.
SMC
STOP
Command
: 1.16

Machine
STOP
Push Button
: 1.8
1

SMC
STOP
Command
: 1.16

SMC
Running
Bit
: 1.16

0
1
Third Rung: The SMC Dialog Plus controller's Current Phase A value returned by the analog feedback word (I:1.17 in this example) is moved every
scan to integer file 7, element 2.

MOV
MOVE
Source:

I:1.17

Dest:

N7:2

1560D-5.1 February 2000

8-10

Serial Communications

Remote I/O Examples (cont.)

Example #2 SLC 500 Controller with Block Transfer


This example demonstrates a block transfer of the SMC Dialog Plus
controller's metering group (parameters 1-11) to an SLC 500. Many of the
selections shown are example-specific. Some changes by the user may be
necessary to apply the concepts of this example to a specific application.
System Configuration
SLC 5/02 or higher

12

11

21

13

22

24

17

16

15

14

23

L3
5

L2
3

L1
1

25

26

19

18

27

1747-SN
B Scanner
1747-SNSeries
Scanner

28

Remote I/O Link

20

29

30

2
SH
1
Rem I/O
Rem I/O STS
Rem I/O ACT
Health
V+
V- SCANbus STS
G

SMC Dialog Plus


Controller

1560D-5.1 February 2000

FAULT

1203-GD1
Communication Module

Bulletin 1202 SCANport Cable

Serial Communications

Remote I/O Examples (cont.)

8-11

1203-GD1 Communication Module Switch Settings


The following information is provided to explain the required 1203-GD1
communication module switch settings for this example. Refer to the 1203GD1 manuals for further details related to the switch settings.
Example Information
Description

Switch Setting

SMC Rack Address

SW1: Switches 1 & 2 (Not used);


Switches 3-8 (On)

Starting Group Address

SW2: Switches 1 & 2 (On)

Last Rack

Yes

SW2: Switch 3 (On)

Hold Last State

Yes

Sw2: Switch 4 (On)

Fault on Comm Loss

Yes

SW2: Switch 5 (On)

Fault Controller

Yes

SW2: Switch 6 (On)

R I/O Baud Rate

57 k

SW2: Switches 7 & 8 (Off)

Block Transfer

Yes

SW3: Switch 1 (On)

Logic Cmd/Status

Yes

SW3: Switch 2 (On)

Reference/Feedback

No

SW3: Switch 3 (Off)

No !

Datalinks

SW3: Switches 4-8 (Off)

! The SMC Dialog Plus controller does not support Datalinks.

SLC Image Table Map


SLC Word

Output Image

Input Image

Rack Size

Start at Group

Block Transfer

Block Transfer

1/4

0!

Logic Command

Logic Status

! Set SW2, Switches 1 and 2 to "On".

8 7 6 5 4 3 2 1

Starting Module Group (0)


Starting Module Group (0)
Last Rack Setting (On)
Hold Last State (On)
Fault on Comm Loss (On)
Fault Controller (On)
RIO Baud Rate (57 K)
RIO Baud Rate (57 K)

SW3

8 7 6 5 4 3 2 1

Not Used
Not Used
On
On
On
On
On
On

SW2

8 7 6 5 4 3 2 1

SW1

Switch Settings
Block Transfer On
Logic Cmd/Sts On
Reference/Fdbk Off
Datalink A Off
Datalink B Off
Datalink C Off
Datalink D Off
Truncate Last Datalink Off

1560D-5.1 February 2000

8-12

Serial Communications

Remote I/O Examples (cont.)

Software Configuration Settings


RIO Configuration Using G-Files The block transfer operation requires
that the G-File of the 1747-SN scanner module be configured. The scanner's
G-File settings are based on the devices that you have on the RIO link. It
consists of setting logical device starting addresses and the logical device
image size of each physical device/adapter with which the scanner
communicates.
The G-File is configured as part of the I/O configuration procedure for the
processor file. You edit the data off-line under the I/O configuration menu
only. After the 1747-SN specialty I/O module is assigned to a slot, access
the SPIO CONFIG [F9] menu instruction in the Advanced Programming
Software (APS). The configuration settings are set as follows:
1. [F5], ADVNCD SETUP to specify input size, output size, scanned
input, scanned output, M0 and M1 file sizes.
This SMC Dialog application example utilizes the following settings:
Maximum Input Words: 32 (fixed, cannot modify)
Maximum Output Words: 32 (fixed, cannot modify)
Scanned Input Words: 32 (default value !)
Scanned Output Words: 32 (default value !)
M0 Length: 3300 (size is set for block transfer operation)
M1 Length: 3300 (size is set for block transfer operation)
!

Setting the scanned input and scanned output words to less than 32 can reduce the
processor scan time by transferring only part of the input and output image that your
application requires. It is important that you do not set either of these values to 0.

2. [F7], G-FILE SIZE to specify the number of words required for the I/O
module, 3 for standard operation, 5 if using complementary I/O. (In
this application example, G-File size = 3.)
3. [F6], MODIFY G-FILE
Word 0 of the G-File is configured automatically by the processor
according to the particular specialty I/O module. Word 0 cannot be
edited.
Word 1, Primary/Normal Logical Device Address Specifies the
logical starting address of each primary/normal RIO link device. The
logical address consists of the logical rack number (0, 1, 2 or 3) and
starting logical group (0, 2, 4 or 6). Each bit in this word represents a
logical address. To specify an address (in binary mode), you enter a 1
at the bit corresponding to the starting logical address of each logical
device. (For this SMC Dialog example application, Word G1/16 = 1,
indicating logical rack 0, starting group 0.)

1560D-5.1 February 2000

Serial Communications

Remote I/O Examples (cont.)

8-13

Software Configuration Settings (cont.)


3. [F6], MODIFY G-FILE (cont.)
Word 2, Primary/Normal Device Logical Image Size Specifies the
logical image size (amount of scanner I/O image) of the devices set in
Word 1. As with Word 1, these bits correspond to RIO logical rack
and logical group numbers. To specify image size (in binary mode), you
enter a 1 at each group a device occupies. (This SMC Dialog example
is using 1/4 rack size, Word G1/33 = 1.)
Word 3 and Word 4 refer to Complementary I/O Configuration (if
G-File size is set to 5), which is not used in this sample application.
Please reference the RIO Scanner User Manual (Publication 1747-6.6)
and the Advanced Programming Software (APS) User Manual
(Publication 1746-6.4) for further information on any of the above
settings or operations.

SLC 500 Ladder Logic Program


Terms used:

BT
BTR
BTW

Block Transfer
Block Transfer Read
Block Transfer Write

The sample ladder logic program that follows performs a consecutive


parameter value read of the SMC Dialog Plus controller's metering
group (parameters 1-11) by using a BTW/BTR pair. The BTW operation
defines to the Bulletin 1203 communication module the type of parameter
read/write operation ("Continuous Parameter Value Read" for this example)
and identifies the parameter to be polled. Execution of the BTR operation
allows the communication module to respond, providing the requested data.
Notes:

1. The ladder-logic program does not contain error checking


and handling. Refer to the SLC 500 and 1747-SN scanner
manuals for this documentation.
2. For this example, Allen-Bradley's APS programming software
is used.

1560D-5.1 February 2000

8-14

Serial Communications

Remote I/O Examples (cont.)

BT Control Buffer Layout The following table maps integer files starting at
N10:0 with the associated M0 file location as defined in the sample ladder
logic program that follows.
BT Control Datafile
Control Flags
BT Length
BT Logical Address !
Address

N10:0

"

64

Bulletin 1203 communication modules use full slot addressing. Refer to the 1747-SN scanner manual
for complete details to determine a BT logical address.

"

This word is set by the ladder logic program. Refer to the 1747-SN scanner manual for Control Flag
Definitions.

BTW Datafile Format A four-word data file is required to accomplish a


"Continuous Parameter Value Read". For the example that follows, the
BTW Datafile will begin at address N10:10.
BTW Datafile
Message Length
PLC Decimal Value
Number of Parameter Values to Read
Starting Parameter Number
Address

N10:10

1!

11

! This is a fixed value, associated with the "Continuous Parameter Value Read" function.

1560D-5.1 February 2000

Serial Communications

Remote I/O Examples (cont.)

8-15

Data Path for the BTW Rung 2:6 of the sample ladder-logic program that
follows executes a COP instruction to the M0 file to load the necessary
data for the BTW.

Address

0123456789

Address

N10:0

M0:1.100

N10:10

M0:1.110

N10:20

M0:1.120

N10:30

M0:1.130

N10:40

M0:1.140

N10:50

M0:1.150

N10:60

M0:1.160

N10:70

M0:1.170

0123456789

BTR Datafile Format A BTR Datafile must also be defined to accept the
data read during the BTR operation. For this example, the BTR Datafile
will begin at address N10:110.
BTR Datafile
Header Word
PLC Decimal Value
Number of Parameter Values to Read
Starting Parameter Number
Address

N10:110

15

11

#1

#2

#3

#4

#5

#6

N10:120

#7

#8

#9

#10

#11

Message OK:
Message Error:

Note:

1
-32767

The values of parameters 1-11 read from the SMC Dialog Plus
controller are loaded into addresses N10:114 through N10:124.

1560D-5.1 February 2000

8-16

Serial Communications

Remote I/O Examples (cont.)

Data Path for the BTR Rung 2:5 of the sample ladder logic program that
follows executes a COP instruction to copy the data obtained from the
BTR to program-defined integer file.

Address

1560D-5.1 February 2000

0123456789

Address

M1:1.100

N10:100

M1:1.110

N10:110

M1:1.120

N10:120

M1:1.130

N10:130

M1:1.140

N10:140

M1:1.150

N10:150

M1:1.160

N10:160

M1:1.170

N10:170

0123456789

Serial Communications

8-17

Remote I/O Examples (cont.)


Example #2 Ladder Logic Program
Rung2:0
2:0
Rung
This
word
onon
thethe
firstfirst
scan.
Thisrung
rungclears
clearsthe
theVirtual
VirtualBTBTCommand
Command
word
scan.

First Scan
S:1
15

MOV
MOVEMOVE
Source
Source
0

Dest Dest
N10:0
128

N10:0
128

Rung 2:1
2:1
Rung
Copy the
the BT
BTStatus
StatusBits
Bitsfrom
fromthe
the1747-SN
1747-SNinto
into
Virtual
Status
Buffer.
Copy
thethe
Virtual
BTBT
Status
Buffer.

MOV
MOVE
MOVE
Source
M1:1.100
Source M1:1.100
*
Dest N10:100N10:100
Dest
0
0
Rung2:2
2:2
Rung
Thisrung
rungsets
setsupupthe
theBTBTbuffer
bufferforfor
a BTW.
This
a BTW.
User
Logic

BTR_Avail

BTW_Avail

Virtual
BT_Enable
Bit

Virtual
BTW = 0
BTR = 1

N10:0
B3:0

I:1.0

I:1.0

N10:0

10

13

15

7
Virtual
Virtual
BT_Enable
BT_Enable
Bit
Bit
N10:0
L

Rung2:3
2:3
Rung
This
rung
turnsoffoffthe
theVirtual
VirtualBT_Enable
BT_Enable
when
a BTW
completed.
This rung turns
when
a BTW
hashas
completed.
Virtual
BTW = 0
BTR = 1

Virtual
BT Done
Bit
N10:0

Virtual
BT_Enable
Bit

N10:100
U

15

13

15

1560D-5.1 February 2000

8-18

Serial Communications

Remote I/O Examples (cont.)


Example #2 Ladder Logic Program (cont.)
Rung 2:4
This rung sets up the BT buffer for a BTR and sets the Virtual BT_Enable.
User
Logic

BTR_Avail

B3:0

Virtual
BTW = 0
BTR = 1
N10:0

I:1.0

L
7
Virtual
BT_Enable
Bit
N10:0

10

L
15

Rung 2:5
This rung copies the BTR data from the 1747-SN, clears the Virtual BT_Enable, and clears the User Logic Bit.
BTR_Avail
Virtual
Virtual
BTW = 0
BT Done
BTR = 1
Bit
I:1.0

N10:0
10

N10:100
7

COP
COPY FILE
Source #M1:1.100
Dest #N10:100
Length 74

13

Virtual
BT_Enable
Bit
N10:0
U
15
User
Logic
B3:0
U
1
Rung 2:6
This rung copies the BT information to the 1747-SN for execution.
COP
COPY FILE
Source #N10:0
Dest #M0:1.100
Length 74

Rung 2:7
2:7
Rung
END
END

1560D-5.1 February 2000

Serial Communications

Remote I/O Examples (cont.)

8-19

The information in the data table listed below was obtained from a 150 hp
motor, 1800 RPM rated at 480 volts. The motor was operating continuously
for a period of 72 hours.
Parameter
Description

Parameter
Number

Display
Value

Voltage Phase A-B

470

Wattmeter

Voltage Phase A-B

474

Voltage Phase A-B

Current Phase A
Current Phase B
Current Phase C
!

Parameter
Description

Parameter
Number

Display
Value

7!

90.0

Kilowatt Hours

82

469

Elapsed Time

72

4!

120.0

Power Factor

10!

.92

5!

120.0

11

80

6!

120.0

Motor Thermal
Usage

Refer to Appendix B and apply the scale factor to above parameters in the data table below.

Address

Data

B3:0

Address

(Radix = BINARY)
0000

Data

0000

0000

0000

(Radix = DECIMAL)

N10:0
N10:10
N10:20
N10:30
N10:40
N10:50
N10:60
N10:70
N10:80
N10:90
N10:100

128
4
0
0
0
0
0
0
0
0
0

64
1
0
0
0
0
0
0
0
0
64

0
11
0
0
0
0
0
0
0
0
0

0
1
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0
0
0

N10:110
N10:120
N10:130
N10:140
N10:150
N10:160
N10:170
N10:180
N10:190
N10:200

15
900
0
0
0
0
0
0
0
0

1
82
0
0
0
0
0
0
0

11
72
0
0
0
0
0
0
0

1
92
0
0
0
0
0
0
0

470
80
0
0
0
0
0
0
0

474
0
0
0
0
0
0
0
0

469
0
0
0
0
0
0
0
0

M0:1
M0:2
M0:3
M0:4

File Length:
File Length:
File Length:
File Length:

3300
0
0
0

M1:1
M1:2
M1:3
M1:4

File Length:
File Length:
File Length:
File Length:

3300
0
0
0

Address
G1:0

Data

0
0
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0
0
0

1200 1200 1200


0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

(Radix = HEX)
2020

0001

000F

1560D-5.1 February 2000

8-20

Serial Communications

Remote I/O Examples (cont.)

Example #3 PLC 5/20, 5/40, 5/60 and 5/80


This example demonstrates PLC control of an SMC Dialog Plus
Controller with the Pump Control option. Use of the Option Command
bit to initiate the pump stop maneuver is also shown. Finally, the SMC
fault bit is monitored as a conditional logic input for the block transfer of
the associated fault code stored in the SMC Dialog Plus controller's
Parameter 19, Fault Buffer #1. Many of the selections shown are examplespecific. Some changes by the user may be necessary to apply the
concepts of this example to a specific application.
System Configuration
PLC 5/20, 5/40. 5/60, or 5/80

12

11

21

13

22

24

25

26

19

18

17

16

15

14

23

L3
5

L2
3

L1
1

27

28

Remote I/O Link

20

29

30

2
SH
1
Rem I/O
Rem I/O STS
Rem I/O ACT

V+

Health

V- SCANbus STS
G

SMC Dialog Plus


Controller

FAULT

1203-GD1
Communication Module

Bulletin 1202 SCANport Cable

Note: It is critical that, during the system design phase, each device on
the Remote I/O link is allocated a unique segment of the PLC's I/O
image table. This is accomplished by coordination of the device's
rack address, rack size and starting group address.

1560D-5.1 February 2000

Serial Communications

Remote I/O Examples (cont.)

8-21

1203-GD1 Communication Module Switch Settings


The following information is provided to explain the required 1203-GD1
communication module switch settings for this example. Refer to the
1203-GD1 manuals for further details related to the switch settings.
Example Information
Description

Switch Setting

SMC Rack Address

02

SW1: Switches 1 & 2 (Not Used),


Switches 3-6 & 8 (On), Switch 7 (Off)

Starting Group Address

SW2: Switches 1 & 2 (On)

Last Rack

No

SW2: Switch 3 (Off)

Hold Last State

Yes

SW2: Switch 4 (On)

Fault on Comm Loss

Yes

SW2: Switch 5 (On)

Fault Controller

No

SW2: Switch 6 (Off)

R I/O Baud Rate

115 k

SW2: Switch 7 (On), Switch 8 (Off)

Block Transfer

Yes !

SW3: Switch 1 (On)

Logic Cmd/Status

Yes!

SW3: Switch 2 (On)

Reference/Feedback

No !

SW3: Switch 3 (Off)

No !"

Datalinks

SW3: Switch 4-8 (Off)

! This configuration requires a 1/4 rack size allocation.


" The SMC Dialog Plus controller does not support Datalinks.

8 7 6 5 4 3 2 1

Starting Module Group (0)


Starting Module Group (0)
Last Rack Setting (Off)
Hold Last State (On)
Fault on Comm Loss (On)
Fault Controller (Off)
R I/O Baud Rate (115k)
R I/O Baud Rate (115k)

SW3

8 7 6 5 4 3 2 1

Not Used
Not Used
On
On
On
On
Off
On

SW2

8 7 6 5 4 3 2 1

SW1

Switch Settings

Block Transfer On
Logic Cmd/Sts On
Reference/Fdbk Off
Datalink A Off
Datalink B Off
Datalink C Off
Datalink D Off
Truncate Last Datalink Of

1560D-5.1 February 2000

8-22

Serial Communications

Remote I/O Examples (cont.)

I/O Addressing
The 1203-GD1 communcation module uses one-slot addressing. Based on
the module switch settings as described above, the discrete I/O can be
mapped to the PLC I/O Image as shown below.
PLC I/O Group Number

Output Image

Input Image

Block Transfer

Block Transfer

Logic command

Logic Status

Addressing Format

I : 02
I for input or O for output
2-digit I/O rack number
I/O group number (0-7)
Input or output number
(octal bit address; 0-7, 10-17)

1560D-5.1 February 2000

0 / 12

Serial Communications

8-23

Remote I/O Examples (cont.)


Communication Module Block Transfer Status Word Addresses !
I or O

Rack

Group

Bit "

Address

Block Transfer Ready


(BT_READY)

02

10

I:020/10

Block Transfer Write in Progress


(BTW_IN_PROG)

02

11

I:020/11

Block Transfer Read Available


(BTR_AVAIL)

02

12

I:020/12

Block Transfer Wait


(BT_WAIT)

02

13

I:020/13

Block Transfer Error


(BT_ERROR)

02

14

I:020/14

Block Transfer Write Available


(BTW_AVAIL)

02

15

I:020/15

Bit Description

SMC Dialog Plus Controller Logic Control Addresses !


I or O

Rack

Group

Bit #

Address

Stop

02

00

O:021:00

Start

02

01

O:021/01

Option Command

02

02

O:021/02

Clear Fault

02

03

O:021:03

I or O

Rack

Group

Bit $

Address

Enabled

02

00

I:021/00

Running

02

01

I:021/01

Starting

02

04

I:021/04

Stopping

02

05

I:021/05

Fault

02

07

I:021/07

At Speed

02

10 %

I:021/10

Bit Description

SMC Dialog Plus Controller Status Addresses !


Bit Description

! The addresses shown are example-specific. Addresses for any given installation can be determined,
based upon the 1203-GD1 communication module switch settings for: rack address, starting group
number, block transfer, logic command/status, and reference/feedback by applying the I/O addressing
format for PLC-5 controllers.
" Refer to Figure 3.1 of the Bulletin 1203 Remote I/O Communication Module.
# Refer to Table 8.A.
$ Refer to Table 8.B.
% This is the octal address representation for this bit.

1560D-5.1 February 2000

8-24

Serial Communications

Remote I/O Examples (cont.)

Block Transfer Instructions


Block transfer operations with the 1203-GD1 communication module
require coordinated block transfer write (BTW) and block transfer read
(BTR) instructions to achieve successful data transmissions.
BTW
BLOCK TRNSFR WRITE
Rack:
02
Group:
0
Module:
0
Control Block:
BT11:0
Data File:
N10:10
Length:
64
Continuous:
N

BTR
(EN)
(DN)
(ER)

BLOCK TRNSFR READ


(EN)
Rack:
02
Group:
0
(DN)
Module:
0
Control Block:
BT11:1 (ER)
Data File:
N10:90
Length:
64
Continuous:
N

Rack The number reported here should correspond to the communication


module's rack assignment as selected via DIP switch group one (SW1).
Group The number reported here should correspond to the communication module's starting group address via DIP switch group two (SW2),
switches 1 and 2.
Module In all cases (with regards to the 1203-GD1 communication
module) the number 0 should be reported here.
Control Block ! For this example a block transfer file type (BT) of one
element is used for the control block. An integer file (type N) of five
contiguous words could also be used.
Data File ! The first word of the data file (integer, Type N) selected for
the BTW or BTR block is reported here.
Length The block transfer message length (number of words) is reported
here.
!

1560D-5.1 February 2000

It is critical that care is given to all file assignments to ensure that no overlapping or overwriting occurs.

Serial Communications

Remote I/O Examples (cont.)

8-25

Block Transfer Datafiles


The tables below provide the necessary data file configuration for a
parameter value read of the SMC Dialog Plus controller's Fault Buffer #1.
BTW Datafile:
Message Length
PLC Decimal Value
Parameter Number
Address

N10:10

769!

19

! This is a fixed value, associated with the Parameter Value Read function.

BTR Datafile:
Header Word 1
PLC Decimal Value
Parameter Number
Parameter Value

Address
N10:90

6!

"

19

There is no significance to the number returned to Header Word 1.

"

Message OK:
Message Error:

If a message error occurs, the error code will be presented here. See Table 5.A of the Bulletin 1203
Remote I/O Communications Module Reference Manual, Publication 1203-5.0, for a listing of the error
codes and descriptions.

769
-31999

1560D-5.1 February 2000

8-26

Serial Communications

Remote I/O Examples (cont.)

Example #3 Ladder Logic Program

First Rung: When the Machine START push button is pressed, the PLC sends a START command to the SMC Dialog Plus controller. The SMC Dialog
Plus controller will start if no STOP command is being issued by the PLC or any other control device. (The start button is a normally open contact in this
example.)
Machine
SMC
START
START
Push Button
Command
: 016
: 021

01

11
11

01

Second Rung: When the Machine STOP push button is pressed, the PLC sends an OPTION command ("pump stop" in this example) to the SMC
Dialog Plus controller. (The stop button is a normally closed contact in this example.) The branch provides a logic "latched" circuit which exerts the
OPTION command until the feedback from the SMC Dialog Plus controller indicates that it has returned to a "stopped" status (not running).
SMC
Machine
OPTION
STOP
Command
Push Button
: 021
: 016
12

SMC
OPTION
Command
: 021

02

SMC
Running
Bit
: 021

02
01
Third Rung: The SMC Fault Bit initiates a PLC block transfer write to the communication module, requesting a parameter value read (SMC
Dialog Plus controller Parameter 19, Fault Buffer #1, in this example).
BT
Read
Available
BTR_AVAIL

SMC
Fault
Bit
: 021
07

: 020
12
BT
Error
BT_ERROR

BT
Write
Available
BTW_AVAIL
: 020
15

BTW
BLOCK TRNSFR WRITE
Rack:
Group:
Module:
Control Block:
Data File:
Length:
Continuous:

(EN)
02
0
0
BT11:0
N10:10
3
N

(DN)
(ER)

: 020
14

Fourth Rung: A block transfer read occurs whenever the communication module's BT Read Available status bit is true, in this example, the
communication module responds to the PLC request (BTW in the third rung) by supplying the value stored in Parameter 19.
BT
Read
Available
BTR_AVAIL
: 020
12

1560D-5.1 February 2000

BTR
BLOCK TRNSFR READ
Rack:
Group:
Module:
Control Block:
Data File:
Length:
Continuous:

(EN)
02
0
0
BT11:1
N10:90
4
N

(DN)
(ER)

Serial Communications

DeviceNet Examples

8-27

Example #1 SLC 500 Controller with Explicit Messaging


This example demonstrates discreet control of the SMC Dialog Plus
controller in addition to use of the explicit messaging function for
transferring parameter data to an SLC500. The DeviceNet Manager
(revision 3.001) software is used in this example for network and node
configuration. RSView is used as the man-machine interface in this
example. Many of the selections shown are example specific. Some changes
by the user may be necessary to apply the concepts of this example to a
specific application.
System Configuration

SLC 5/04

1747-SDN Scanner

DeviceNet Trunk

1203-GK5
Communication Module
SMC DialogPlus
Controller

Bulletin 1202 SCANport Cable

Notes:
1) 1747-SDN scanner firmware revision 3.01 or later required.
2) 1203-GK5 module firmware revision 1.9 or later required.

1560D-5.1 February 2000

8-28

Serial Communications

DeviceNet Examples (cont.)

1203-GK5 Communication Module Switch Settings


The following information is provided to explain the required 1203-GK5
communication module switch settings for this example. Refer to the
1203-GK5 manual for further details related to the switch settings.
Example Information
Description
Node Address:
Data Rate:
Datalinks:
Zero data to logic
command on fault:
Fault on comm loss:
Fault on PLC/SLC
program/idle modes:
!

125k
No !
Yes

SW1, Switch 6 (Off)

Yes

SW1, Switch 7 (Off)

Yes

SW1, Switch 8 (Off)

The SMC Dialog Plus controller does not support Datalinks.

Switch Settings

1560D-5.1 February 2000

13

Switch Settings
SW2, Switches 1, 3 & 4 (On)
Switches 2, 5 & 6 (Off)
SW2, Switches 7 & 8 (Off)
SW1, Switches 1 4 (Off)

Serial Communications

DeviceNet Examples (cont.)

8-29

1203-GK5 Communication Module Switch Settings (cont.)


I/O Mapping
The SMC Dialog Plus controller's first two words of data are pre-configured
in the 1203-GK5 Communication module as follows:
Word

Output Data

Input Data

1
2

Logic Command
Reference !

Logic Status
Feedback "

! The SMC Dialog Plus Controller does not utilize this feature; a value of
zero should be given.
" The feedback word is the value of parameter 4, Current Phase A.

After you have your network "project" configured in the DeviceNet Manager
software, and perform a Network Who, the following screen will appear:

Notice that the SMC Dialog Plus controller is identified as node 13,
which was configured by setting the DIP switches on the 1203-GK5
communication module.

1560D-5.1 February 2000

8-30

Serial Communications

DeviceNet Examples (cont.)

I/O Mapping (cont.)


Double-click the Master (node 0) on the DeviceNet network; the following
screen will appear:

Select the Edit Scan List option by clicking on the button; the following
screen will appear:

Notice that the SMC Dialog Plus controller (node 13) has an active
status. This means that it is active in the scan list and will communicate
with the 1747-SDN scanner on the network.

1560D-5.1 February 2000

Serial Communications

DeviceNet Examples (cont.)

8-31

I/O Mapping (cont.)

You will also notice that Yes is listed twice under the Mapped column.
The left-side Yes indicates that input data is mapped from the SMC Dialog
Plus controller to the SLC-500. The right-side Yes indicates that output
data from the SLC-500 is mapped to the SMC Dialog Plus controller.
Configure the 1747-SDN if No is displayed.
To view the actual areas inside the SLC-500 processor where the device
data will be transferred to and from, select the Datatable Map by clicking
on the button; the following screen will appear:

This indicates that the SMC Dialog Plus controller's input data is mapped
to words 7 and 8.
By clicking the ratio button next to Output, the output data mapping can
be seen; the following screen will appear:

1560D-5.1 February 2000

8-32

Serial Communications

DeviceNet Examples (cont.)

I/O Mapping (cont.)

This indicates that the SLC-500's output data associated with the SMC
Dialog Plus controller is mapped to words 7 and 8.
Given this data table mapping, following are the individual logic command
and status bit addresses for the SMC Dialog Plus controller:
SMC Dialog Plus Controller Logic Command Addresses !
Bit Description

Address

Stop
Start
Option Command
Clear Fault

O:1.7/00
O:1.7/01
O:1.7/02
O:1.7/03

! Refer to Table 8.A

SMC Dialog Plus Controller Status Addresses "


Bit Description

Address

Enabled
Running
Starting
Stopping
Fault
At Speed

O:1.7/00
O:1.7/01
O:1.7/04
O:1.7/05
O:1.7/07
O:1.7/08

" Refer to Table 8.B

1560D-5.1 February 2000

Serial Communications

DeviceNet Examples (cont.)

8-33

Explicit Messaging
The 1747-SDN scanner module uses the M0 and M1 file areas for data
transfer. Words 224 through 256 must be used to execute the Explicit
Message Request and Response functions. The minimum data size for an
Explicit Message Request is 6 words and the maximum is 32 words.
Following is the data format to follow for a scattered parameter value read
(Get Attribute Multiple) as used in this example:
Explicit Message Request (Get Attribute Multiple)
15

0
TXID
PORT
SERVICE

Word 0

COMMAND
SIZE
MAC ID

CLASS
INSTANCE
ATTRIBUTE
PARAMETER
PATA PLACE HOLDER
Word 31

Explicit Message Response (Get Attribute Multiple)


15

0
TXID
PORT
SERVICE

Word 0

STATUS
SIZE
MAC ID
PARAMETER
DATA
Word 31

Transmission ID (TXID): The scanner uses this value to track the


transaction to completion, and returns the value with the response that
matches the request downloaded by the SLC-500 processor. The TXID
data size is one byte.
Command: This code instructs the scanner how to administer the request.
A listing of these codes can be found in the 1747-SDN User Manual,
Publication 1747-5.8. The Command data size is one byte.
Status: The Status code provides the communication modules status and
its response.
Port: The physical channel of the scanner where the transaction is to be
routed. The port setting can be zero (channel A) or one (channel B). The
Port data size is one byte.

1560D-5.1 February 2000

8-34

Serial Communications

DeviceNet Examples (cont.)

Explicit Messaging (cont.)


Size: This identifies the size of the transaction body in bytes. The
transaction body begins at word 3. The maximum size is 58 bytes. The
Size data size is one byte.
Service: This code specifies the type of request being delivered. The
Service data size is one byte.
Mac ID: The DeviceNet network node address of the device for which the
transaction is intended is identified here. The slave device must be listed in
the scanner modules scan list and be on-line for the Explicit Message
transaction to be completed.
Class: The desired DeviceNet class is specified here. The Class data size
is one word.
Instance: This code identifies the specific instance within the object class
towards which the transaction is directed. The value zero is reserved to
denote that the transaction is directed towards the class itself versus a
specific instance within the class.
Attribute: This code identifies the specific characteristic of the object
towards which the transaction is directed. The Attribute data size is one
word.
Examples
The following table lists the most common codes for each given transaction
type:
Transaction Type

Service !

Class !

Instance !

Single Parameter Read

0E

0F

Par.# "

Single Parameter Write

10

0F

Par.# "

Scattered Parameter Read

32

93

Scattered Parameter Write

34

93

! The numerical values are in a hexidecimal format.


" This is the actual parameter number as listed in Appendix B of this manual.

1560D-5.1 February 2000

Attribute !

Serial Communications

DeviceNet Examples (cont.)

8-35

Sequence of Events
Use the following sequence of events as a guide for establishing explicit
messages in your SLC ladder logic:
1. Put the Explicit Message Request data into an integer (N) file of the
SLC-500 processor.
2. Use the file copy instruction (COP) to copy the Explicit Message
Request data entered in step one to the M0 file, words 224 through 256.
3. Use the examine-if-closed instruction (XIC) to monitor bit 15 of the
scanners Module Status Register for an indication that it has received
a response from the 1203-GK5 communication module.
4. Copy the data from the M1 file, words 224 through 256, into a file in
the SLC-500 processor using the file copy instruction (COP).
5. Use the move instruction (MOV) to copy a one-word file from the
SLC-500 processor into word 224 of the M0 file. The upper byte of the
word should contain the TXID value for this transaction and the lower
byte should contain the value 4 which is the command for the scanner
to clear its response buffer. After the move is completed, bit 15 of the
scanners Module Status Register should go to a value of zero,
allowing the next explicit message to be executed.

Setting Up the Data File


In this example, the data file for the Explicit Message Request begins at
N11:0. Following is the structure for a Get Attribute Multiple of the SMC
Dialog Plus controllers Metering group parameters (1 - 11). Please note
that the data shown is in a hexadecimal format. The first three words are
shown segmented into two bytes, corresponding to the upper and lower
bytes shown in the Explicit Message Request table.

1560D-5.1 February 2000

8-36

Serial Communications

Setting Up the Data File (cont.)

"" "" ""

"

"

"

TXID
Command
Port
Size
Service
MAC ID
Class
Instance
Attribute

File

N11:0

0l 01

00 2E

32 0D

0093

0000

0000

0001

0001

0002

0001

Parameter Number
Data Place Holder
Parameter Number
Data Place Holder
Parameter Number
Data Place Holder
Parameter Number
Data Place Holder
Parameter Number
Data Place Holder

"

"

"

"

"

"

File

N11:10

0003

0001

0004

0001

0005

0001

0006

0001

0007

0001

Parameter Number
Data Place Holder
Parameter Number
Data Place Holder
Parameter Number
Data Place Holder
Parameter Number
Data Place Holder
Parameter Number
Data Place Holder

"

"

"

"

"

"

File

N11:20

0008

0001

0009

000A

000B

0001

Note:

There is no required value for the words identified as "Data Place Holder".

1560D-5.1 February 2000

Serial Communications

8-37

Example Ladder Logic Program

1560D-5.1 February 2000

8-38

Serial Communications

Example Ladder Logic Program (cont.)

1560D-5.1 February 2000

+D=FJAH

'

Diagnostics
Overview

This chapter describes the fault diagnostics of the MV Dialog Plus


controller. Further, this section describes the conditions that cause
various faults to occur.

Protection Programming
Many of the protective features available with the SMC Dialog Plus
controller can be enabled and adjusted through the programming parameters
provided. For further details on programming, refer to the Advanced Setup
section in Chapter 4, Programming.

Fault Display

The SMC Dialog Plus controller comes equipped with a built-in, two-line,
16-character LCD. The LCD displays the fault message on the first line
and the fault code on the second line.
Figure 9.1
Fault Display

OVERLOAD
F7
Note:

Clear Fault

The fault display will remain active as long as control power is


applied. If control power is cycled, the fault will be cleared, the
controller will re-initialize, and the display will show a status of
"Stopped".

Important: Resetting a fault will not correct the cause of the fault condition.
Corrective action must be taken before resetting the fault.
You can clear a fault using any of several methods:

Program the SMC Dialog Plus controller for a Clear Fault, which can
be found in the Faults and Linear List groups.

If a human interface module is connected to the controller, press the


Stop button.
Note: The stop signal will not clear a fault if Control Logic is disabled
(Logic Mask, parameter #85, equals ).

Cycle control power to the SMC Dialog Plus controller.


Note: Communications faults cannot be cleared via this method.

Important: An overload fault cannot be reset until the Motor Thermal


Usage (parameter 11) value is below 75%. See page 1-6 for further details.
1560D-5.1 February 2000

9-2

Diagnostics

Fault Buffer

The SMC Dialog Plus controller stores the five most recent faults in
memory. Display the fault buffer by selecting the Faults group and
scrolling through the fault buffer parameters. The information is stored
as fault codes. To determine what faults have occurred, use the fault
code cross-reference below.

Fault Codes
Table 9.A provides a complete cross-reference of the available fault codes
and corresponding fault descriptions.
Table 9.A
Fault Code Cross-Reference
Fault Description
Power loss A fault
Power loss B fault
Power loss C fault
Undervoltage fault
Overvoltage fault
Stall
Overload fault
Controller temp fault
Underload fault
Imbalance fault
Line A fault
Line B fault
Line C fault
Line fault
Phase reversal fault
Jam fault
Cur. Feedback loss
Comm fault
Start A firing fault
Start B firing fault
Start C firing fault
Line A fault
Line B fault
Line C fault
Line fault
Power loss A fault
Power loss B fault
Power loss C fault
Excess starts/Hr
System fault
COMM fault
MPU COMM fault

Fault Number
1
2
3
4
5
6
7
8
9
10
11
12
13
15
16
19
20
21
23
24
25
26
27
28
29#
30
31
32
64
128 140

Fault Type
Line
Line
Line
Line
Line
Line
Current
Hardware
Current
Current
Line
Line
Line
Line
Line
Current
Current
Hardware
Current
Current
Current
Current
Current
Current
Current
Current
Current
Current

Unexpected condition
SCANport disconnected
Internal COMM fault

These faults occur before gating is applied (pre-start).


These faults may be either before gating or during start or stop manoeuvres.
These faults can occur during starting or running and indicate a line fault. The manner in
which they occurred does not give a phase indication.

Note: Refer to Table 10.A for fault display explanation.

1560D-5.1 February 2000

Parameter Number
1/2/3
1/2/3
1/2/3
51 52
54 / 55
37
36 / 70 / 72 / 84 / 88

60 / 61
58
1/2/3
1/2/3
1/2/3
1/2/3
62
56 / 57
70

70
70
70
70
70
70
70
70
70
70
63

Diagnostics

9-3

Fault Auxiliary Contact

The auxiliary contact is located at terminals 29 and 30. This contact can
be programmed as either Normal or Fault. Note that the state this contact
takes upon power-up (normally open or normally closed) can be programmed.
These parameters can be found in either Basic Setup, Advanced Setup, or
the Linear List groups when modifying parameters in the Program mode.

Fault Definitions

Power Loss K
Power loss indicates than an input power phase is not present. The controller's
LCD display will identify the missing phase.
Note: If all three phases are absent when a start command is issued, the
LCD will display "Starting" without motor rotation.

Line Fault L
Line fault, with the affected phase displayed, identifies three possible
pre-start conditions:

Phase loss (Power lost to one of the phases)

Load loss (Load connection open or has a low impedance to ground)

Shorted SCR (SCR shorted, low impedance or premature breakover)

Line fault, with no phase indication, is displayed when one of the following
conditions occurs while the SMC Dialog Plus controller is in the run mode:

Phase loss

Load loss

Shorted SCR

Phase Reversal K
Phase reversal is indicated when the incoming power to the SMC Dialog
Plus controller is in any sequence other than ABC. This pre-start protective
feature can be disabled.

Overvoltage and Undervoltage Protection L


Overvoltage and undervoltage protection are user-defined as a percentage
of the programmed line voltage. The SMC Dialog Plus controller continuously monitors the three supply phases. The calculated average is then
compared to the programmed trip level.
K
L

Fault occurs before gating is applied (pre-start).


Phase loss, overvoltage, and undervoltage protection are disabled during braking operation.

1560D-5.1 February 2000

9-4

Diagnostics

Fault Definitions (cont.)

Voltage Unbalance M
Voltage unbalance is detected by monitoring the three-phase supply voltages.
The formula used to calculate the percentage voltage unbalance is as follows:
Vu = 100 (Vd / Va)
Vu: Percent voltage unbalance
Vd: Maximum voltage deviation from the average voltage
Va: Average voltage
The controller will shut down when the calculated voltage unbalance
reaches the user-programmed trip percentages.

Stall Protection
Stall protection is enabled at the end of the programmed ramp time after a
motor has been started. If the controller senses that the motor is not up to
speed at the end of ramp, it will shut down after the user-selected delay
time has elapsed.

Jam Detection N
Jam detection operates when the SMC Dialog Plus controller status is "at
speed". The controller will shut down when the motor current reaches the
user-defined trip level, which is based on a percentage of the programmed
motor full-load current rating.

Overload Protection
Overload protection is enabled in the Calibration group by programming the:

Overload class

Overload reset

Motor FLC

Service factor

Refer to Chapter 5 for more information on calibration.

Underload MN
Underload protection is available for undercurrent monitoring. The controller will shut down when the motor current drops below the trip level.
This trip level, a percentage of the motor's full-load current rating, can be
programmed.
M
N

1560D-5.1 February 2000

Voltage unbalance protection is disabled during braking operation.


Jam detection and underload protection are disabled during slow speed and braking operation.

Diagnostics

Fault Definitions (cont.)

9-5

Open Gate (Start A,B,C firing fault)


Open gate indicates that an abnormal condition that causes faulty firing (i.e.,
open SCR gate or driver system) has been sensed during the start sequence.
The SMC Dialog Plus controller will attempt to start the motor a total of
three times before the controller shuts down.

Excess Starts/Hour

Excess starts/hour is displayed when the number of starts in a one-hour


period exceeds the value programmed.

Controller Temp
Controller temp is an indication that a power pole's maximum rated
temperature has been reached. The controller's microprocessor monitors
the temperature of the SCRs by using internal thermistors. When the
controller detects an over-temperature condition, the microprocessor
turns off the SCRs and displays the appropriate fault code.
An overtemperature condition could indicate the presence of inadequate
ventilation, high ambient temperature, overloading, or excessive cycling.
If an overtemperature condition exists at start-up, the SCR gate signals will
be inhibited and the controller will trip and indicate the fault. The fault
can be immediately reset. However, the motor cannot be restarted until
after the controller temperature falls below trip levels.
The temperature signal line is also used as a control signal. A "Controller
Temp" trip may also indicate a problem with other hardware in the system.
Refer to Table 10.A.

Comm Fault
The SMC Dialog Plus controller disables control through the serial
communication port as the factory default. To enable control, the Logic
Mask parameter (#85) found in the Linear List programming group must
be set to "4". With Series B human interface modules, this can also be
accomplished by enabling control logic through the Control Status
programming group.
If a Bulletin 1201 human interface module or Bulletin 1203 communication
module is disconnected from the SMC Dialog Plus controller when control
is enabled, a Comm Fault will occur.

1560D-5.1 February 2000

9-6

Diagnostics

Fault Definitions (cont.)

MPU or System Fault


These faults indicate an internal fault or that an unexpected condition was
encountered in the internal hardware or software. Reset the module by
cycling control power. If the fault persists, replace the control module.

1560D-5.1 February 2000

Chapter

10

Troubleshooting

General Notes and Warnings

For safety of maintenance personnel as well as others who might be exposed


to electrical hazards associated with maintenance activities, the safety
related work practices of NFPA 70E, Part II, should always be followed
when working on electrical equipment. Maintenance personnel must be
trained in the safety practices, procedures and requirements that pertain to
their respective job assignments.
ATTENTION: To avoid shock hazard, disconnect main
power before working on the controller, motor or control
devices such as Start/Stop push-button. Procedures which
require parts of the equipment to be energized during
troubleshooting, testing, etc., must be performed by properly
qualified personnel, using appropriate work practices and
precautionary measures as specified in NFPA 70E, Part II.

ATTENTION: Disconnect the controller from the motor


before measuring insulation resistance (IR) of the motor
windings. Voltages used for insulation resistance testing can
cause failure of SCRs. Do not make any measurements on
the controller with an IR tester (Megger), unless solid-state
devices are isolated or shorted out. Where appropriate, the
case of the test equipment should be connected to ground.

Note: The time required for the motor to come up to speed may be more or
less than the Start Time setting, and will vary depending on the
frictional load and inertial characteristics of the system.
Note: Depending on the application, the SMB Smart Motor Braking
and Slow Speed options may cause vibration and noise during the
operating cycle, and this may be minimized by lowering the current
setting. Consult the factory prior to applying these options.

For MV Dialog Plus technical support on start-up or existing installations, contact your
Rockwell Automation representative. You can also call 1-519-623-1810 for assistance
Monday through Friday from 7:30 a.m. to 5:15 p.m. (Eastern time zone).

1560D-5.1 February 2000

10-2

Troubleshooting

General Notes and Warnings


(cont.)

Important: In the case of the 1503D, refer to applicable documentation


from OEM for troubleshooting and repair. This manual should be
utilized in conjunction with the OEM supplied documentation, and is
suitable for commissioning, programming, calibration, metering, serial
communications, diagnostics, troubleshooting, and maintenance of a
standard solid-state controller.

Fault Identification

If there is a problem with the MV Dialog Plus controller, use the


following guide to assist in troubleshooting:
Is there is a fault message on the Dialog Plus control module?
YES See Table 10.A
NO Define the nature of the problem:
Motor does not start See Table 10.B
Motor rotates, but does not reach full speed See Table 10.C
Motor stops while running See Table 10.D
Miscellaneous situations See Table 10.E

1560D-5.1 February 2000

Troubleshooting

Fault Identification (cont.)


Display

Fault Code

Power Loss !
(with phase indication)

F1, F2, F3

Line Fault !
(with phase indication)

Line Fault "


(no phase indication)

F11
F12
F13

Table 10.A
Fault Display Explanation
Possible Causes

Possible Solutions

m issing supply phase (as indicated)

check for open line (eg. blown line fuse)


check voltage feedback circuits

m issing supply phase

m otor not connected properly


shorted SCR(s)

F26
F27
F28

m issing supply phase

F15

see line fault (with phase indication)


supply voltage is less than user
programmed value

Undervolt

F4
the time delay is too short for the
application

check for open line


check voltage feedback circuits
check for open load lead
check voltage feedback circuits
check for shorted SCR(s), replace if necessary
check interface board voltage feedback inputs for shorts

inspect Bulletin 825 converter module cable connections


check programming values in Calibration section
consult the factory

check power system and correct if necessary


correct the user program med value
check that the voltage divider is correct for the system
voltage
extend the time delay to match the application
requirements

supply voltage is greater than the


user-programmed value

check power system and correct if necessary


correct the user-programmed value
check that the voltage divider is correct for the system
voltage

Overvolt

F5

Stall

F6

m otor has not reached full speed by


end of the programmed ramp time

correct source of stall


adjust start parameters

Overload

F7

m otor overloaded
overload parameters are not
m atched to the motor

correct motor overload condition


check programmed values for overload class, FLC,
CT ratio, converter rating, etc.

Controller
Temperature

F8

Underload

F9

broken motor shaft


broken belts, gears, m achine
pump cavitation

repair or replace motor


check m achine, repair if necessary
check pump system
check power system and correct if necessary

F10

supply unbalance is greater than the


user-programmed value
the delay is too short for the
application
unbalanced voltage feedback

Voltage
Unbalance

10-3

controller ventilation blocked


controller duty cycle exceeded
fan failure (if supplied)
ambient temperature limit exceeded
failed therm istor
failed control module
failed gate driver board
failed fibre optic cable
failed interface board

check for proper ventilation


check application duty cycle
repair or replace fan
wait for controller to cool or provide external cooling
check connection or replace thermistor
replace control m odule
test or replace gate driver board
replace fibre optic cable
test or replace interface board

extend the time delay to match the application


requirements
check voltage feedback circuits

1560D-5.1 February 2000

10-4

Troubleshooting

Fault Identification (cont.)


Table 10.A (cont.)
Fault Display Explanation
Display

Fault code

Phase reversal

F16

Jam

F19

Current Feedback Loss

F20

Comm Fault

F21

Open Gate
(with phase indication)

F23 - F25

!
"

Excess starts
per hour

F64

System Faults

F128
And above

MPU Comm Fault

Possible Causes
incoming supply voltage is not in
the expected ABC sequence
motor current has exceeded the
user-programmed jam level
Connection between Bul. 825
current module is lost
communication disconnection at
the serial port
open gate circuitry

open resistor on voltage divider


feedback board
number of starts in a one-hour
period has exceeded the value
programmed

internal control module hardware


failure
internal control module hardware
failure

Possible Solutions
Check power wiring.
Correct the source of the jam.
Check cable. Replace cable.
Check for a communication cable disconnection to the
SMC Dialog Plus module.
Check SCR gate resistance.
Check gate lead connections to gate driver boards.
Check gate drive system; gate driver board, fibre optics,
interface board, by performing power supply tests.
Replace divider board.
Wait an appropriate amount of time to restart.
Increase the number of starts per hour setting.
NOTE: The SMC is rated for only two starts per hour.
Contact the factory if the application requires more
frequent starts.
Replace control module.
Replace control module.

Prestart fault indication.


To further define this fault, the user can clear the fault and re-initiate a start signa l. If the fault condition is still present,
the controller may display either a power loss or a line fault with the phase indicated.

1560D-5.1 February 2000

Troubleshooting

Fault Identification (cont.)

10-5

Table 10.B
Motor Will Not Start No Output Voltage to the Motor
Display
Fault displayed

Possible Cause
See fault description

See Table 10.A addressing fault


conditions

Control voltage is absent

Check control wiring and correct


if necessary
Replace control module

Display is blank
Failed control module

Stopped
0.0 Amps

Starting

Possible Solutions

Pilot devices
SMC Enable input is open at
terminal 13
Terminal 15 is open on Soft
Stop, Pum p Control and SMB
Start-Stop control has not
been enabled for the hum an
interface module
Control voltage
Failed control module

Check wiring
Check wiring

Two or three power phases


are missing

Check power system


Check voltage feedback

Check wiring
Follow the instructions on pages
2-9 to 2-11 to enable control
capability
Check control voltage
Replace control module

Table 10.C
Motor Rotates (but does not accelerate to full speed)
Display
Fault displayed

Starting

Possible Cause

Possible Solutions

See fault description

See Table 10.A addressing fault


conditions

M echanical problems

Check for binding or external


loading and correct
Check motor
Adjust the Current Limit Level to
a higher setting
Replace control m odule

Inadequate Current Limit


setting
Failed control m odule

Table 10.D
Motor Stops While Running
Display
Fault displayed

Possible Cause
See fault description

See Table 10.A addressing fault


conditions

Control voltage is absent

Check control wiring and correct


if necessary
Replace control module

Display is blank
Failed control module
Stopped
0.0 Amps

Starting

Possible Solutions

Pilot devices
Failed control module

Check control wiring and correct


if necessary
Replace control module

Two or three power phases


are missing
Failed control module

Check power system


Check voltage feedback
Replace control module

1560D-5.1 February 2000

10-6

Troubleshooting

Fault Identification (cont.)

Table 10.E
Miscellaneous Situations
Display
Motor current and
voltage fluctuates with
steady load

Possible Cause
M otor
Erratic load

Possible Solutions
Verify type of motor as a standard
squirrel cage induction motor
Check load conditions

Loose connections

Shut off all power to controller and


check for loose connections

Accelerates too fast

Starting time
Initial torque
Current limit setting
Kickstart

Increase starting tim e


Lower initial torque setting
Decrease current limit setting
Lower kickstart time or turn off

Accelerates too slow

Starting time
Initial torque
Current limit setting
Kickstart

Decrease starting time


Increase initial torque setting
Increase current limit setting
Increase kickstart time or turn off

Erratic operation

Motor stops too quickly


with Soft Stop option

Motor stops too slowly


with Soft Stop option

Time setting

Verify the programmed stopping


tim e and correct if necessary

Stopping time setting

Verify the programmed stopping


tim e and correct if necessary
The Soft Stop option is intended to
extend the stopping time for loads
that stop suddenly when power is
removed from the motor.

M isapplication

M isapplication

Soft Stop ramps voltage down over


a set period of time. In the case of
pumps, the voltage may drop too
rapidly to prevent surges. A closed
loop system such as Pump Control
would be more appropriately suited.
Refer to Publication 150-911

Duty cycle

Preset Slow Speed option:


Extended operaton at slow speeds
reduces motor cooling efficiency.
Consult manufacturer for motor
limitations.
Smart Motor Braking option:
Check duty cycle. Consult motor
m anufacturer for motor limitations.

Winding fault

Identify fault and correct


Check for shorted SCR; replace if
necessary.
Ensure power term inals are secure.

Fluid surges with


pumps still occur with
the Soft Stop option

Motor overheats

Motor short circuit

Note: For Pump Stop issues, refer to Application Considerations on page 1-13.

1560D-5.1 February 2000

Troubleshooting

Control Module Removal

10-7

The control module is not intended for field repair. The entire module
must be replaced in the event of failure. The following procedure must be
followed before unplugging the control module.
1. Remove all power from the equipment.
ATTENTION: To avoid shock hazard, ensure the main
power has been disconnected before working on the
controller, motor or control devices. Verify that all
circuits are voltage free using a hot stick or appropriate
voltage measuring device. Failure to do so may result in
burns, injury or death.
2. Make sure that the wires are properly marked and that the program
parameters are recorded.
3. Disconnect all control wires to control module.
4. Loosen the six control module screws.
5. Unplug the control module from the interface board by pulling forward.

ATTENTION: When removing the control module, make


sure the interface board pins do not bend. Also, make sure
the pins are not bent prior to installing the control module.
The gold interconnection pins on the interface board are protected with a
special contact lubricant. Do not clean or wipe these pins. This contact
lubicant is necessary for proper operation. Inspect each pin prior to
assembly of the control module. If the lubricant is missing, apply a thin
film of the recommended contact lubricant.
The Rockwell Automation approved contact lubricant is NYOGEL 759G,
manufactured by William F. Nye., Specialty Lubricants, New Bedford, MA
02742 U.S.A. To install control module, follow the reverse order for
removal.

1560D-5.1 February 2000

10-8

Troubleshooting

Voltage Feedback Circuit


Tests

The most straightforward means of checking the feedback circuits is to


perform the "snubber and resistor testing" procedure, found on page 10-22.
Another possible test involves measuring the feedback voltages at the
interface board (see Figure 1.17). This can only be done with line voltage
applied. If the motor does not start, it may be necessary to temporarily
modify the control circuit to close the line contactor without applying a
start signal to the Dialog module. In this case, the three line voltages (L1,
L2, L3) measured with respect to ground should be as follows:
System Voltage
(VLL)

Feedback Voltage
(VLG)

System Voltage
(VLL)

Feedback Voltage
(VLG)

1000

210 230

4160

177 197

1300

210 230

4800

206 226

1500

171 - 191

6600

195 215

2400

191 211

6900

204 224

3300

205 225

If any voltage is well outside this range, there may be a problem either with
the system voltage, or with the voltage divider for the affected phase. Note
that the load side voltages (T1, T2, T3) will be very low, since the SCRs
are not turned on, and only a low leakage current flows to the motor.
If the motor will start and run, the line and load voltages should be the
same when the bypass contactor is closed.

Circuit Board Replacement

The replacement of printed circuit boards is straightforward, however,


there are a number of precautions which must be considered when
handling the boards.
ATTENTION: Some circuit boards may contain CMOS
components which can be destroyed by static charges
generated by friction of materials made with synthetic fibres.
Use of damaged circuit boards may also damage related
components. A grounding wrist strap is recommended for
handling sensitive circuit boards.
1. Remove all power from the equipment.
ATTENTION: To avoid shock hazard, ensure the main
power has been disconnected before working on the controller,
motor or control devices. Verify that all circuits are voltage
free using a hot stick or appropriate voltage measuring device.
Failure to do so may result in burns, injury or death.
2. Carefully detach all wires, cables and connectors, noting their
location and orientation. For the interface board, remove the control
module (see page 10-7).

1560D-5.1 February 2000

Troubleshooting

Circuit Board Replacement


(cont.)

10-9

ATTENTION: The fibre-optic cables can be damaged if


struck or bent sharply. They have a locking feature which
requires pinching the tab on the connector and gently pulling
straight out. The component on the printed circuit board
should be held to prevent damage.
3. For boards mounted with hardware, remove the hardware, taking care
not to drop anything onto other circuits. For boards with nylon stand-off
posts, squeeze the section above the board and carefully pull the board
up and off the post.
4. Lift out the circuit board, and check that the replacement board is the
correct part number and revision before installation (refer to Appendix C).
Install the new board by replacing the hardware, or pressing down onto
nylon stand offs. Connect all wires, cables and connectors. Ensure
that all switch and/or jumper settings on the new board are identical to
those on the old board, and correct for the application.

Power Circuit
Troubleshooting

Thyristor Testing
If a power semiconductor is suspected of malfunctioning, it may be
checked as follows:
1. Remove all power from the equipment.
ATTENTION: To avoid shock hazard, ensure the main
power has been disconnected before working on the
controller, motor or control devices. Verify that all
circuits are voltage free using a hot stick or appropriate
voltage measuring device. Failure to do so may result in
burns, injury or death.

2. Measure DC resistance per the following chart:


Location of Probes

1000 V

1300 V

1500 V

2300 V

3300 V

4160 V

6900 V

Cathode to Cathode !

22K-30K

23K-31K

24K-32K

Cathode to Cathode "

17K-23K

19K-25K

20K-27K

21K-29K

40K-53K

43K-57K

64K-84K #

Cathode to Gate

10-40

10-40

10-40

10-40

10-40

10-40

10-40

!
"
#

Measured between terminals Cathode on SPGD Boards, upper two or bottom two within a phase.
Measured between terminals Cathode on SPGD Boards, top to bottom within a phase.
Measured between line and load terminals within a phase.

1560D-5.1 February 2000

10-10

Troubleshooting

Power Circuit
Troubleshooting (cont.)

Note: The actual resistance value depends on the ohmmeter used, the
particular brand/rating of thyristor, and external circuit influences.
It is impossible to accurately measure the condition of the thyristor
when it is unclamped!
3. If a short circuit is suspected, the thyristor must be isolated from all
surrounding circuitry (i.e. unplug gate and cathode leads, and remove
snubber and resistor circuit leads from the driver boards). Measure
resistance to confirm state of the thyristors. If the thyristors are not
shorted, proceed to snubber and resistor circuit testing, following this
procedure.
4. If a faulty device is found, the entire heatsink assembly must be
removed.
ATTENTION: For heatsink assemblies containing four or
more thyristors, the entire matched set shall be replaced.
Devices connected in series must have performance specifications matched for proper operation. Failure to use
matched sets may result in damage to the devices.
5. Complete heatsink assemblies with matched thyristors are available as
a renewal part (see Appendix C). In most cases, the assembly can be
dismantled to replace the SCRs.

SCR Replacement Procedure


Important: Refer to OEM documentation for SCR stack location in 1503D.
A. Remove SCR Stack from Unit
For all types of SMCs, the stack requiring new SCRs must first be removed
from the unit as follows:
1. Remove all power from the equipment.
ATTENTION: To avoid shock hazard, ensure main power
has been disconnected before working on the controller,
motor or control devices. Verify that all circuits are voltage
free using a hot stick or appropriate voltage measuring
device. Failure to do so may result in burns, injury or death.
2. Service to phase A module may require removing the medium voltage
door and swinging out the low voltage panel; see the low voltage panel,
Fig. 10.1.

1560D-5.1 February 2000

Troubleshooting

Power Circuit
Troubleshooting (cont.)

10-11

SCR Replacement Procedure (cont.)


3. Unplug all fibre-optic cables from the gate-driver board. Unplug gate
lead connectors and thermistor connectors. Remove leads from the left
side of the circuit board.
ATTENTION: The grey fibre-optic cables can be damaged
if struck or bent sharply. They have a locking feature which
requires pinching the tab on the connector and gently pulling
straight out. The component on the printed circuit board
should be held to prevent damage.
4. Remove gate-driver board by compressing the locking tabs of the
nylon circuit board supports and carefully pulling the board off the
supports.
5. Disconnect the power cables from the terminals on the left side of the
heatsink assembly. Use care not to damage components. The sharing
resistors are fragile.
6. Remove two (2) nuts at bottom front of heatsink assembly so the module
can be removed using the pull handle. (Phase C requires angling the
module to clear the front cabinet flange). Position fibre-optic cables
and wiring so they will not be damaged as the module is removed from
the cabinet.
7. Pull module out slowly, and slide onto a platform lift, or lift the module
out of the cabinet.
ATTENTION: The heatsink assembly is heavy (approx.
25 kg [55 lb] or greater). To avoid injury, always use two
people to remove and handle the assembly. Place the
heatsink on a cart to aid in its transport.
8. Place the module on a flat surface (see Fig. 10.2, 10.6 and 10.13).
When tilting the module, ensure that wires are not damaged.

1560D-5.1 February 2000

10-12

Troubleshooting

Power Circuit
Troubleshooting (cont.)

SCR Replacement Procedure (cont.)


B. Replace SCRs
Note: For 800 A units, it is mandatory that the entire stack be replaced.
The high clamping force requires the factory to tighten the clamp
hardware. See Appendix C, Spare Parts section, for part numbers.
Proceed to step C.
Note: Refer to Figures 10.2 to 10.15.
SCR positions are numbered in succession from the top down.
The SCR cathode is at the end with the wide flange.
ATTENTION: The SCRs must be oriented correctly with
the cathode end either up or down, depending on the specific
assembly. Note the orientation before removing the SCRs,
and refer to the detail in the appropriate figure in this chapter.
1. Remove the shorting bar. Measure the resistance between adjacent
heatsinks to determine which SCR(s) is (are) shorted. Assemblies with
four or six SCRs must use matched sets. See Figures 10.2, 10.6 and
10.13 for the position of the matched sets. If an SCR from each set is
shorted, all of the SCRs in the module must be replaced. A properly
functionning SCR will measure in excess of 100 kilohms from anode to
cathode, and 10-40 ohms from gate to cathode.
Important: DO NOT loosen any of the nuts on the fiber rods on either
side of the clamp bars. They must remain as they are to maintain squareness.
See Figures 10.3, 10.7 and 10.14.
2. Loosen the clamp by rotating the centre nut below the indicator washer
at the top end of the clamp. Refer to Figures 10.3, 10.7 and 10.14.
As the centre nut is rotated, the entire spring assembly is retracted
from the top heatsink. Continue to retract until there is a gap of
approximately 6 mm (0.25 in).
3. The heatsinks may now be spread apart to allow removal of the SCRs.
4. Apply a thin film of Electrical Joint Compound (supplied) to both faces
of the new SCRs.
5. Place the new SCRs in position starting from the top and pushing the
heat sinks together as you proceed down the stack. Make sure the
SCRs are positioned and oriented properly. Refer to Figures 10.4,
10.5, 10.8, 10.9 and 10.13.
6. Ensure that the SCRs are properly seated on the locating pins in the
heatsinks and rotate each SCR so that the leads are oriented toward the
front right side of the assembly.

1560D-5.1 February 2000

Troubleshooting

Power Circuit
Troubleshooting (cont.)

10-13

SCR Replacement Procedure (cont.)


B. Replace SCRs (cont.)
7. Advance the centre nut until the spring assembly engages the top
heatsink. Make sure the clamp is properly seated on the locating pins
in the top and bottom heatsinks before beginning to tighten.
8. Tighten the centre nut until the indicator washer becomes loose with
some friction. The clamp is now at the proper force and must not be
clamped any tighter. If the indicator washer becomes too loose (no
friction), back the centre nut off slowly until the washer is loose with
some friction.
9. Replace the shorting bar. Torque hardware to 30 N-m (20 lb-ft).

C. Install Refurbished Stack


1. Inspect all connections on the module. Inspect wire insulation and
components for damage.
2. Install the module in the cabinet. Watch for power cables and fibre-optic
cables as module is slid into place. Tighten locking nuts at the bottom
of the module.
3. Connect power cables and tighten hardware to 30 N-m (20 lb-ft).
4. Install gate-driver board, ensuring that the locking tabs on the nylon
circuit board supports are all engaged. Plug in thermistor and gate
connectors and reconnect wires to the left side of the board. Plug in
the fibre-optic cables.
5. Make sure all connections are secure. Perform resistance checks
according to instructions on "Thyristor testing" in Chapter 10, page
10-9, and test gate-drive circuits by performing power supply tests in
Chapter 3, page 3-6.

1560D-5.1 February 2000

10-14

Troubleshooting

Figure 10.1
Low Voltage Panel & Power Cell Detail (1562D) 400A, 2400 V to 4160 V

Voltage
Feedback
Board

Bulletin 1562D, phase A module shown extracted from cabinet.


Low voltage panel can swing out for access to Phase A module.

Important: For 1503D, refer to OEM documentation for


location of printed circuit boards and power stacks.

1560D-5.1 February 2000

Troubleshooting

10-15

Figure 10.2
1000/1300/1500/2400 Volt Heatsink Assembly, 180/360 A
Heatsink 2B
Heatsink 2A
Heatsink 1

Heatsink 3

To replace devices, place assembly on a flat


surface. Note that board assembly must
overhang the edge of the flat surface.

SCR 1

SCR 2

Figure 10.3
Heatsink Clamp

Gap

(Do not loosen)

Centre Nut
Locking Nut

Indicating Washer

(Do not loosen)

To remove clamp pressure, loosen


lower centre nut so that the gap between
the clamp surface and the heatsink is
approximately 6 mm (0.25 in.)

1560D-5.1 February 2000

10-16

Troubleshooting

Figure 10.4
Removal of SCR1
To Remove SCR1:
Remove shorting bar hardware
Pry Heatsinks 1 and 2A apart
Extract SCR
To Insert New SCR:
Apply thin film of electrical joint compound to surfaces of SCR
Install SCR so that it is seated in locating pin of heatsink (note
orientation of SCR).
Pry heatsinks to close gap, ensuring that SCR is seated properly
in both its locating pins.
Rotate SCR so that all leads have same direction.
Heatsink 1

Shorting Bar Hardware


SCR 1
Heatsink 2A

Locating Pin

Figure 10.5
Removal of SCR2
Shorting Bar Hardware
SCR 2
Heatsink 3
Heatsink 2B

Locating Pin

1560D-5.1 February 2000

Troubleshooting

10-17

Figure 10.6
3300/4160 Volt Heatsink Assembly, 180/360 A

Heatsink 4
Heatsink 5

Heatsink 3
Heatsink 2
Heatsink 1
To replace devices, place assembly on a flat
surface. Note that capacitor and board
assembly must overhang the edge of the flat
surface.
SCR1 and SCR3 are a matched pair.
SCR2 and SCR4 are a matched pair.

SCR 4

SCR 1
SCR 3

SCR 2

Figure 10.7
Heatsink Clamp

Gap

(Do not loosen)

Centre Nut
Locking Nut

Indicating Washer

(Do not loosen)

To remove clamp pressure, loosen


lower centre nut so that the gap between
the clamp surface and the heatsink is
approximately 6 mm (0.25 in.)

1560D-5.1 February 2000

10-18

Troubleshooting

Figure 10.8
Removal of SCR4
To Remove SCR4:
Remove shorting bar hardware
Pry Heatsinks 4 and 5 apart
Extract SCR
To Insert New SCR:
Apply thin film of electrical joint compound to surfaces of SCR
Install SCR so that it is seated in locating pin of heatsink (note
orientation of SCR).
Pry heatsinks to close gap, ensuring that SCR is seated properly
in both its locating pins.
Rotate SCR so that all leads have same direction.
Proceed to replace SCR's matched pair (SCR2).

Shorting Bar Hardware


Heatsink 4
SCR 4

Locating Pin

Heatsink 5

Figure 10.9
Removal of SCR2
Shorting Bar Hardware
SCR 2

Locating Pin

Note: Similar procedure used to remove and replace SCR matched pair 1 and 3.

1560D-5.1 February 2000

Troubleshooting

10-19

Figure 10.10
6900V Module, 180/360 A

Gate driver boards

Line connection

Load connection

Figure 10.11
6900V Module with Gate Driver Boards Removed, 180/360 A
Board mounting frame

Line connection

Load connection

1560D-5.1 February 2000

10-20

Troubleshooting

Figure 10.12
6900V Module with Boards and Frame Removed, 180/360 A
Module retaining hardware locations (4)

Line connection

Load connection

1560D-5.1 February 2000

Troubleshooting

10-21

Figure 10.13
6900V Heatsink Assembly, 180/360 A
Positioned on bench for SCR replacement
SCR4
SCR5
SCR6

SCR3
SCR2
SCR1

SCR1, SCR2 and SCR5 are a matched set.


SCR3, SCR4 and SCR6 are a matched set.

Heatsink 7

Heatsink 1

Heatsink 6

Heatsink 2

Heatsink 5

Heatsink 3
Heatsink 4

Spacer block (must be flat):


Minimum height = 30 mm (1.25 in.)
Maximum width = 200 mm (8.0 in.)
Minimum length = 400 mm (16.0 in.)

Figure 10.14
6900V SCR Replacement, 180/360 A

Do not loosen

To remove clamp pressure, loosen lower


centre nut so that the gap between the
clamp surface and the heatsink is
approximately 6 mm (.25 inch).
A 21 mm open end wrench is required.

Centre Nut

Locking Nut
(Do not adjust)

Indicating Washer

Do not loosen
Gap
1560D-5.1 February 2000

10-22

Troubleshooting

Figure 10.15
Removing and Replacing SCRs (SCR2 shown)

Extracted SCR

Shorting bar hardware


removed

Locating pin

Gap between heatsinks


32 mm (1.26 inch) required

Figure 10.16
2300V Heatsink Module, 800A

Sharing Resistor

Snubber Capacitor
Snubber Resistors

Heatsink Assembly
Frame Assembly

1560D-5.1 February 2000

Gate Driver Board

Troubleshooting

10-23

Figure 10.17
3300 and 4160V, 800A Heatsink Module

Snubber Capacitor

Snubber Resistors

Snubber Capacitor

Heatsink Assembly
Sharing Resistors

Gate Driver Board

Figure 10.18
6900V, 800A Heatsink Module
Snubber Capacitors

Snubber
Resistors
Gate Driver
Boards

Heatsink Assembly
Sharing Resistors
Snubber Capacitors

Frame Assembly

1560D-5.1 February 2000

10-24

Troubleshooting

Snubber and Resistor Circuit


Testing

If the resistance checks from the Thyristor testing section were abnormal
and the thyristors checked out OK, there may be a problem in the snubber
or resistor circuits.
1. Remove all power from the equipment.
ATTENTION: To avoid shock hazard, ensure main power
has been disconnected before working on the controller,
motor or control devices. Verify that all circuits are voltage
free using a hot stick or appropriate voltage measuring
device. Failure to do so may result in burns, injury or death.
2. a) For units rated over 2000 volts:
Disconnect wires IL1, IT1, IL2, IT2, IL3, IT3 from the Voltage
Feedback board. On the 1562D, 400A, 2400V to 4160V, the voltage
feedback board is located on the back of the low voltage panel or
on the left side of the structure. Consult OEM documentation for
the location of the feedback board on the 1503D. Measure the
resistance from the end of each of these wires to the following
points on the gate-driver boards:
IL1 to Phase A cathode, top position
IT1 to Phase A cathode, bottom position
IL2 to Phase B cathode, top position
IT2 to Phase B cathode, bottom position
IL3 to Phase C cathode, top position
IT3 to Phase C cathode, bottom position
b) For units rated 1500 volts or less:
Disconnect wires 2L1, 2T1, 2L2, 2T2, 2L3, 2T3 from the Voltage
Feedback board. Measure resistors R7 to R12 and verify the
readings per the chart below.
The measured resistance based on the rated voltage of the MV
Dialog Plus should be per the chart below.

1560D-5.1 February 2000

Rated Voltage

Resistance 2%

1000 V

20 K

1300 V

30 K

1500 V

50 K

2400 V

75 K

3300 V

100 K

4160 V

150 K

6900 V

224 K

Troubleshooting

Snubber and Resistor Circuit


Testing (cont.)

10-25

The feedback voltages given are based on the stated system voltage. If the
actual system voltage is different, the feedback voltages will be scaled by
the actual system voltage divided by the value in the chart on page 10-8.
For example, if the actual system voltage is 2337 volts, the feedback
voltage should be (2337 / 2400) x (191 to 211), or 186 to 205 volts.
If these measurements are abnormal, the voltage divider resistor
board located behind the SCR/heatsink assemblies or next to the
left-hand sideplate, must be checked for proper connections or
replaced if necessary. See instructions for removing SCR stack
from unit on page 10-10.
3. Measure from each terminal (IL1, IT1, IL2, IT2, IL3, IT3) on the
Voltage Feedback board to RGND terminal (ground). Each reading
should be 12.5 kilohms to 12.9 kilohms. If measurements are abnormal,
remove the seven-pin, green connector from the lower edge of the
board and repeat the measurements. If still abnormal, replace the
Voltage Feedback board. If readings are normal, replace the seven-pin
connector, remove the Dialog Plus control module from the interface
board, and repeat the measurements. If still abnormal, replace the
Interface board. If readings are normal, replace the Dialog Plus control
module.
4. If no abnormal readings were found in points (2) and (3) above, check
the snubber components and sharing resistors by isolating them and
measuring values as follows (See Figures 10.19, 10.20 or 10.21):
RS 60 (200 & 400 A)
30 (800 A)
CS 0.5 or 0.68 F (200 & 400 A)
1.0 F (800 A)
RR 32.5 k total, taps at 2.5 k from each end.
Replace any out-of-spec components. See Renewal Parts listing in
Appendix B.
5. When repairs are complete, re-assemble all parts, check all fasteners,
and verify all connections are correct and tight. Make sure all barriers
and mechanical parts are in place and secured.
ATTENTION: Make sure ground wires from the Voltage
Feedback board are securely connected to the ground bar in
the low voltage panel. Failure to do so may result in severe
injury or equipment damage.
6.

Repeat Thyristor resistance checks (page 10-9) and Power Supply


Tests (page 3-6).

1560D-5.1 February 2000

10-26

Troubleshooting

Snubber Resistor Replacement

When replacing the surface-mount style snubber resistor used in this product,
it is very important to apply a thin layer (approximately 0.02 inches or
0.5 mm) of electrical joint compound to both the resistor mounting surface
and the surface to which it is mounted. Some compound may already be
present from the old resistor, but it is best to wipe the area clean and apply
a fresh layer with your finger or a lint-free cloth. This will ensure a good
thermal interface between the two surfaces, which is essential for optimum
performance and life of the resistor. A small container of compound will
be supplied with the replacement resistor; however, if more is required, it
can be ordered from Rockwell Automation by part number RU-6052.
When installing the mounting screws, alternately tighten each screw
gradually to ensure uniform pressure distribution over the mounting
surface. Wipe off any excess compound that may have squeezed out while
tightening the mounting screws.

1560D-5.1 February 2000

Self- Powered Gate Driver Board (SPGDB)

T
OV1
S1
C1

G1
C1

OV
Snub

G1
C1

GD1
C1

Cath

OV1

RS

HS2
Thermistor

RR1

CS
OV2
S2
C2

OV
Snub
Cath

Line

HS3

Figure 10.19
1500/2400 Volt Module Wiring

HS1

Thermistor

G2
C2

OV2

G2
C2

GD2

HS4
C2

Load

10-27

1560D-5.1 February 2000

RR1 ......................... Sharing Resistor


RS ........................... Snubber Resistor
CS ........................... Snubber Capacitor
HS1 HS4 .............. Heatsink
G1 G2 ................... Gate Lead (White)
C1 C2 ................... Cathode Lead (Red)

Troubleshooting

LEGEND:

10-28
Troubleshooting

1560D-5.1 February 2000


HS1

Self-Powered Gate Driver Board (SPGDB)


Thermistor
T
OV1

C1

OV
Snub

G1
C1

GD1
C1

Cath

S2
C2
C2

OV
Snub

Thermistor

G2
C2

OV2

G2
C2

C2

GD2

Cath

HS3

CS1
C3

OV3
S3
C3

OV4
S4
C4

OV
Snub

G3

Load

C3

Cath

G3
C3

OV3

CS2

GD3

Line

OV1

RS1
RR1

OV2

HS2

RR2

HS4

OV4
C4

OV
Snub
Cath

G4
GD4

G4
C4

RS2

C4
HS5

LEGEND:
RR1 RR2 .............. Sharing Resistor
RS1 RS ................ Snubber Resistor
CS1 CS2 .............. Snubber Capacitor
HS1 HS5 .............. Heatsink
G1 G4 ................... Gate Lead (White)
C1 C4 ................... Cathode Lead (Red)

Figure 10.20
3300/4160 Volt Module Wiring

S1

G1
C1

C2
OV2
OV3

RR1

HS1

C3

C1

Cath
GD1

CS1

G1

Cath

C4

RS1

Snub
OV

GD4
G4

HS2

C1

OV1

OV1

C4
S4
OV4

OV4

G2
C2

RR2

HS3

C4

Line

Thermistor

SPGDB

Figure 10.21
6900 Volt Module Wiring

Snub
OV

C1
S1

G1
C1

G3
C3
HS4

Self-Powered Gate Driver Board (SPGDB)


Thermistor

T
RS2

CS2

0V2
S2
C2
OV3
S3
C3

G4
C4

0V
Snub
Cath

G2
GD2

HS5
C2

0V
Snub
Cath

G5
C5

G3
GD3
C3

HS6

C5
C5

Cath
GD5

Snub
OV

C6

Cath

RS3
GD6
G6
CS3

SPGDB

Snub
OV

C6
S6
OV6

G6
C6
C5
HS7
OV5
OV6

RR3
LEGEND:

C6

10-29

1560D-5.1 February 2000

RR1 RR3 .............. Sharing Resistor


RS1 RS3 .............. Snubber Resistor
CS1 CS3 .............. Snubber Capacitor
HS1 HS7 .............. Heatsink
G1 G6 ................... Gate Lead (White)
C1 C6 ................... Cathode Lead (Red)

Troubleshooting

G5

S5
OV5

Load

10-30

Troubleshooting

1560D-5.1 February 2000

Chapter

11

Maintenance

Safety and Preventative

The Maintenance Technician should become familiar with the layout and
be aware of the basic system parameters. Only qualified technicians should
be allowed to work with this equipment under competent supervision.
General housekeeping is the key to maintaining power electronic and
electrical equipment. They are to be kept as dust free as possible. A
scheduled program of inspection will reduce the possibility of problems.

ATTENTION: Servicing energized industrial control


equipment can be hazardous. Severe injury or death can
result from electrical shock, burn, or unintended actuation
of controlled equipment. Recommended practice is to
disconnnect and lock out control equipment from power
sources, and allow any stored energy in capacitors to
dissipate. If it is necessary to work in the vicinity of
energized equipment, the safety related work practices of
NFPA 70E, Electrical Safety Requirements for Employee
Workplaces, must be followed.

Periodic Inspection

Note: For OEM-supplied components, refer to documentation provided by


the OEM for recommended periodic maintenance procedures.
Industrial control equipment should be inspected periodically. Inspection
intervals should be based on environmental and operating conditions, and
adjusted as indicated by experience. An initial inspection, within 3 or 4
months after installation, is suggested. Applicable parts of the following
guidelines should be used:

Contamination
If inspection reveals that dust, moisture or other contamination has reached
the control equipment, the source must be eliminated. This could indicate
an incorrect or ineffective enclosure, unsealed enclosure openings (conduit
or other) or incorrect operating procedures. Dirty, wet or contaminated parts
must be replaced unless they can be cleaned effectively by vacuuming or
wiping.

1560D-5.1 February 2000

11-2

Maintenance

Periodic Inspection (cont.)

ATTENTION: Allen-Bradley magnetic starters, contactors


and relays are designed to operate without lubrication do
not lubricate these devices since oil or grease on the pole
face (mating surfaces) of the operating magnet may cause
the device to stick in the "ON" mode. Erratic operation
can result with injury or death.
Some parts of other devices are factory lubricated if lubrication during
use or maintenance of these devices is needed, it will be specified in their
individual instructions. If in doubt, consult the nearest Rockwell Automation sales office for information.

Vacuum Bottles
The contacts in a vacuum bottle cannot be seen or examined directly.
They rely on the high vacuum to operate properly and to interrupt current.
Visually inspect the wear of the main contacts with the contacts closed.
When any part of the wear indicator, located on the front side of the hex
shaft, moves up into the bearing, replace all three vacuum bottles (see
Publication 1502-5.0).
The vacuum level should be tested periodically by applying high voltage
alternating current across the open bottle using a vacuum tester or Hi-Pot
equipment (see Publication 1502-5.0).

Terminals
Loose connections can cause overheating that can lead to equipment
malfunction or failure. Check the tightness of all terminals and bus bar
connections and securely tighten any loose connections. Replace any
parts or wiring damaged by overheating.

Coils
If a coil exhibits evidence of overheating (cracked, melted or burned insulation), it must be replaced. In that event, check for and correct overvoltage
or undervoltage conditions, which can cause coil failure. Be sure to clean
any residues of melted coil insulation from other parts of the device or
replace such parts.

1560D-5.1 February 2000

Maintenance

Periodic Inspection (cont.)

11-3

Solid-State Devices
Solid-state devices require little more than a periodic visual inspection.
Printed circuit boards should be inspected to determine whether all cables
are properly seated in their connectors. Board locking tabs should also be in
place. Necessary replacements should be made only at the PC board or
plug-in component level. Solvents should not be used on printed circuit
boards. Where blowers are used, air filters, if supplied, should be cleaned
or changed periodically depending on the specific environmental conditions
encountered. For additional information see NEMA Standards Publication
No. ICS 1.1 - 1987 entitled "Safety Guidelines for the Application, Installation
and Maintenance of Solid State Control".
ATTENTION: Use of other than factory recommended test
equipment for solid-state controls may result in damage to
the control or test equipment, or unintended actuation of the
controlled equipment.

Static-Sensitive Items
While performing maintenance on the MV SMC, special precautions must
be observed in handling or touching certain static-sensitive components in the
cabinet. Most circuit cards and SCRs can be damaged by Electro-Static
Discharge (ESD). If personnel will make contact with an ESD-sensitive
component during maintenance, they must be grounded. Grounding should
be accomplished with a wrist strap which is connected to an approved
ground.

Overload Maintenance After a Fault Condition


See NEMA Standards Publication No. ICS 2 Appendix A entitled
"Maintenance of Motor controllers after a fault condition".

Final Check Out


After maintenance or repair of industrial controls, always test the control
system for proper functioning under controlled conditions that avoid
hazards in the event of a control malfunction.

1560D-5.1 February 2000

11-4

Maintenance

Periodic Inspection (cont.)

"Keep Good Maintenance Records"


This rule will be most helpful in locating possible intermittent problems by
pointing to a particular area of recurring trouble within the overall system.
Furthermore, good maintenance records will help reduce major, costly
shutdowns by demanding the use of proper test equipment and an appropriate
inventory of spare parts. For additional information see NFPA 70B,
"RECOMMENDED PRACTICE FOR ELECTRICAL EQUIPMENT
MAINTENANCE", published by the National Fire Protection Association.

Power Components
Power components should be kept clean and free of dirt and obstructions.
This will avoid tracking and heat build-up, thereby increasing the life of
the device.

Control Components Electronic


The printed circuit boards are to be kept clean and free of any accumulations
of dirt and foreign materials.
Materials which create static electricity should never be allowed near circuit
boards while in the unit, or in storage. Caution should be used when one
is near or handling circuit boards. There are no other requirements, other
than housekeeping standards, that the maintenance program requires on
the logic control components.

Fans
Physically rotating and observing the fans for noise or binding will
indicate if fan failure is evident.

Interlocks
Verify that interlocks function as intended, and have not been forced,
damaged or removed.

Barriers
Verify that all barriers are in place and securely fastened.

1560D-5.1 February 2000

Appendix

Parameter Information
Table A.1
Parameter List
Group

Parameter Description
Voltage Phase A-B

Metering "

Faults

Basic Setup

Parameter
Number

Display
Units

Scale
Factor

Minimum

Maximum

Default
Setting

User
Setting

Volts

Voltage Phase B-C

Volts

Voltage Phase C-A

Volts

Current Phase A

Amps

10

Current Phase B

Amps

10

Current Phase C

Amps

10

Wattmeter !

kW

10

Kilowatt Hours !

kWh

Elapsed Time

Hours

Power Factor !

10

100

Motor Thermal Usage

11

Clear Fault

18

No

Fault Buffer #1 "

19

Fault Buffer #2 "

20

Fault Buffer #3 "

21

Fault Buffer #4 "

22

Fault Buffer #5 "

23

SMC Option "

14

Starting Mode

28

Ramp Time #1

30

Seconds

No, Yes

Standard, Soft Stop, Pump Control,


Preset Slow Speed Smart Motor Braking,
or Slow Speed with Braking
Soft Start, Current Limit
0

30

Soft Start
10

Initial Torque #1

31

% LRT

90

70

Current Limit Level

34

% FLC

50

600

50

Kickstart Time

35

Seconds

10

0.0

2.0

0.0 (Off)

Stall Delay

37

Seconds

10

0.0

10.0

0 (Off)

Energy Saver #

38

Off, On

Aux. Contacts 1 & 2

39

Normal, Up-to-speed

Up-to-speed

Off

Aux. Contact 3

40

Normal, Fault

Fault (1560D)
Normal (1562D)

Contact 3 Configuration

41

N.O., N.C.

N.C. (1560D)
N.O. (1562D)

Parameter Mgmt.

17

Ready, Default Init.


Recll Frm EE, Store in EE

Ready

"

Read-only capability.

The Series A SMC Dialog Plus module does not provide power functions when used in the MV Dialog Plus controller.

Not available with MV Dialog Plus.

1560D-5.1 February 2000

A-2

Parameter Information

Table A.1 (cont.)


Parameter List
Group

Parameter Description

Parameter
Number

Display
Units

Scale
Factor

Minimum

Maximum

Default
Setting

60 "

Control Options
Soft Stop
Soft Stop Time

42

Seconds

Starting Mode

28

Pump Stop Time

42

Seconds

Slow Speed Select

44

Low, High

High

Slow Speed Direction

45

Reverse, Forward

Forward

Slow Accel. Current

46

% FLC

450

Slow Running Current

47

% FLC

450

48

% FLC

400

Slow Speed Select

44

Slow Accel. Current

46

% FLC

450

Slow Running Current

47

% FLC

450

Braking Current

48

% FLC

400

Pump Control
Soft Start, Current Limit
and Pump Start
0

120 "

Soft Start
0

Preset Slow Speed


Basic Setup
(cont.)

SMB Smart Motor Braking


Braking Current
Slow Speed with Braking
Low, High

High

" Thermal capacity limits must not be exceeded. The base rating for MV Dialog units is 30 seconds max. Consult factory for higher settings.

1560D-5.1 February 2000

User
Setting

Parameter Information

A-3

Table A.1 (cont.)


Parameter List
Group

Advanced
Setup

Parameter
Number

Display Units

Scale
Factor

Dual Ramp

29

Ramp Time #2

32

Seconds

Initial Torque #2

33

% LRT

90

70

Undervoltage Level

52

% Line Voltage

0!

99

80

Undervoltage Delay

53

Seconds

99

Overvoltage Level

54

% Line Voltage

199

0 (Off)

Overvoltage Delay

55

Seconds

99

Jam Level

56

% FLC

999

0 (Off)

Jam Delay

57

Seconds

10

0.0

10.0

Parameter Description

Minimum

Maximum

No, Yes
0

Default
Setting
No

30

10

Unbalance Level

58

25

0 (Off)

Unbalance Delay

86

Seconds

99

Rebalance "

59

User
Setting

Off, On

Off

Underload Level

60

% FLC

99

0 (Off)

Underload Delay

61

Seconds

99

Phase Reversal

62

Starts per Hour

63

Restart Attempts

64

Restart Delay

65

Seconds

ETM Reset

15

Off, On

Off

Parameter Management

17

Ready, Default Init.


Recll Frm EE, Store in EE

Ready

Off, On

Off
99

60

" Not available with MV Dialog Plus.


! Do not set below 70%.

1560D-5.1 February 2000

A-4

Parameter Information

Table A.1 (cont.)


Parameter List
Group

Calibrate

Parameter
Number

Display Units

Scale
Factor

Overload Class

36

Off, 10, 15, 20 and 30

Off

Overload Reset

88

Manual Auto

Manual

Motor HP Rating

79

HP

10

0.0

6,553.5

0.0

Motor kW Rating

80

kW

10

0.0

6,553.5

0.0

Line Voltage

69

Volts

9999

350 #

Motor FLC

70

Amps

10

1.0

999.9

1.0

Service Factor

84

100

0.01

1.99

1.05

Motor Code Letter

72

LRC Ratio

81

10

Converter Rating

74

Parameter Description

Minimum

Maximum

A,B,C,D,E,F,G,H,J,K,L,
M,N,P,R,S,T,U and V
0.0

0.0

None, 20, 180, 630

20
5:5
Off

CT Ratio

75

Calibration

76

Off, Activate

Enter Calib. Amps

77

Amps

Current Phase A "

Amps

10

17

19.9

5, 50, 75, 100, 150,


200, 250, 300, 400,
500, 600, 750, 800,
1000, 1200:5

Parameter Management

Default
Setting

0.01

999.9

0.0

Ready, Default Init.


Recll Frm EE, Store in EE

Ready

"

Read-only capability.

The scale factor is 100 when Motor FLC, parameter 70, has a programmed value of up to 10.0 amps; above 10.0 amps, the scale factor is 10.

User to program for system voltage.

1560D-5.1 February 2000

User
Setting

Parameter Information

A-5

Table A.2
Parameter Text/Display Unit Cross-Reference
Parameter Number

Description

14

SMC Option

15

ETM Reset

17

Parameter
Management

18

Clear Fault

28

Starting Mode

29

Dual Ramp #

36

Overload Class

38

Energy Saver "

39

Aux. Contacts 1 & 2

40

Aux. Contact 3

41

Contact 3 Config.

44

Slow Speed Select $

45

Slow Speed direction %

59

Rebalance "

62

Phase Reversal

Setting Text

Display Unit

Standard
Soft Stop
Pump Control
Preset Slow Speed
Smart Motor Braking
Accu-Stop "
Slow Speed with Braking
Off
On
Ready
Default Init.
Recall From EE
Store in EE
No
Yes
Current Limit
Soft Start
Pump Start !
No
Yes
Off
10
15
20
30
Off
On
Normal
Up-to-speed
Normal
Fault
N.O.
N.C.
Low
High
Reverse
Forward
Off
On
Off
On

0
1
2
3
4
5
6
0
1
0
1
2
3
0
1
0
1
2
0
1
0
1
2
3
4
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1

" Not available with MV Dialog Plus.


! Pump Start is only available with the Pump Control option.
# Dual Ramp is only available with the standard controller.
$ Slow Speed Select is only available with the Preset Slow Speed option.
% Slow Speed Direction is only available with the Preset Slow Speed option.

1560D-5.1 February 2000

A-6

Parameter Information

Table A.2 (cont.)


Parameter Text/Display Unit Cross-Reference
Parameter Number

1560D-5.1 February 2000

Description

72

Motor Code Letter

74

Converter Rating

75

CT Ratio

88

Overload Reset

Setting Text

Display Unit

A
B
C
D
E
F
G
H
J
K
M
N
P
R
S
T
U
V
None
20
180
630
5:5
50:5
75:5
100:5
150:5
200:5
250:5
300:5
400:5
500:5
600:5
700:5
800:5
1000:5
1200:5
Manual
Auto

0
1
2
3
4
5
6
7
8
9
11
12
13
14
15
16
17
18
0
1
2
3
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
0
1

Appendix

Spare Parts
Table B.1
Bulletin 1503D 1000-1500 Volt, 200/400 Amp, 6-device
Qty per controller

Description

Part Number

180 A
6

Individual SCR, 5STP04D5200 (matching not required) !"

80173-005-01-R

Individual SCR, 5STP08G6500 (matching not required) !"

80173-007-01-R

360 A
Common Components
3
1
1
1
3
3
3
3
9
9
1

Gate Driver Board (2 devices)


Voltage Feedback Circuit Board
MV SMC Interface Circuit Board Assembly (120 Volt)
MV SMC Interface Circuit Board Assembly (230 Volt)
Snubber Resistor 60 ohm, 10%, 500 W
Snubber Capacitor (4.5 kV peak), 1000 V, 1.0 F
Snubber Capacitor (4.5 kV peak), 1300-1500V, 0.68 F
Sharing Resistor, 32.5 k, 225 W, Two 2.5 k Tap
Fiber-optic Cable, 2,5 m
Fiber-optic Cable, 5.0 m
120 V AC (North America)
Test Power Supply
Universal

80165-898-52
80165-938-51 or -52
80187-131-51
80187-131-53
80025-871-04
80025-812-01
80025-812-02
80025-753-01
80025-549-03
80025-549-01
80187-051-51
80187-245-51

! If desired, a complete factory assembled SCR/heatsink assembly with snubber resistor and capacitor can be purchased rather than
individual SCRs. See table below for part numbers :
Qty per controller
3
3
3
3

Description
180 Amp, 1000 Volt Controller
360 Amp, 1000 Volt Controller
180 Amp, 1300V and 1500V Controller
360 Amp, 1300V and 1500V Controller

Part Number
80157-863-55
80157-863-56
80157-863-54
80157-863-52

" Requires a thin film of electrical joint compound between base and mounting surface. Available with SCR replacement parts
or separately as Part Number 80025-783-51.

Note :

Reference only.
1503D For OEM products, refer to OEM-supplied documentation for specific spare parts list.
1560/1562D are Allen-Bradley manufactured starters. Refer to Service Manual for specific spare parts list.

1560D-5.1 February 2000

B-2

Spare Parts

Table B.2
Bulletin 1503D, 1560D, 1562D 2300 Volt, 200/400 Amp, 6-device
Qty per controller

Description

Part Number

200 A
Individual SCR, DCR820 or 5STP03D6500 (matching not required)
!"

80173-006-01-R

400 A
Individual SCR, DCR1020 or 5STP03D6500 (matching not required)
!"
Common Components
3
Gate Driver Board (2 devices) Series B
1
Voltage Divider Resistor Board 2300 V
1
Voltage Feedback Circuit Board
1
MV SMC Interface Circuit Board Assembly (120 Volt)
1
MV SMC Interface Circuit Board Assembly (230 Volt) Series B
3
Snubber Resistor 60 ohm, 10%, 500 W
3
Snubber Capacitor 0.68 F, 4510 V peak
3
Sharing Resistor, 32.5 k, 225 W, Two 2.5 k Tap
9
Fiber-optic Cable, 2,5 m
9
Fiber-optic Cable, 5.0 m
2
Bridge Rectifier
120 V
2
MOV
240 V
120 V AC (North America)
1
Test Power Supply
Universal
1
LV Control Panel, 110/120 V AC #
1
LV Control Panel, 220/230 V AC
3
Power Fuses #
2
Primary Fuses #
1
LV Fuses
1
Holding Coil, 120 V DC
1
Holding Coil, 230 V DC
1
Closing Coil, 120 V DC
1
Closing Coil, 230 V DC
1
Vacuum Bottles (set of 3)
3
Heater Elements #
2
20 Amp Contact Cartridge #
3
1-pole Blade Assembly (400 Amp) #
Special Lubricant (for Blade Assembly, 400 Amp)
6

80173-007-01-R
80165-898-52
80165-878-51
80165-938-51
80187-131-51
80187-131-53
80025-871-04
80025-812-02
80025-753-01
80025-549-03
80025-549-01
24808-451-01
80145-581-02
80145-581-07
80187-051-51
80187-245-51
80154-991-59
80187-226-52
Consult Engineering Data
Consult Engineering Data
Consult Engineering Data
80153-575-51
80153-575-52
80153-576-51
80153-576-52
80157-496-52
Consult Engineering Data
700-CPM
80145-566-51
40025-198-01

! If desired, a complete factory assembled SCR/heatsink assembly can be purchased rather than individual SCRs.
See table below for part numbers :
Qty per controller
3
3

Description
180 Amp, 2400 Volt Controller
360 Amp, 2400 Volt Controller

Part Number
80157-863-51
80157-863-52

" Requires a thin film of electrical joint compound between base and mounting surface. Available with SCR replacement parts
or separately as Part Number 80025-783-51.

# 1562D only.

Note :

1560D-5.1 February 2000

Reference only.
1503D For OEM products, refer to OEM-supplied documentation for specific spare parts list.
1560/1562D are Allen-Bradley manufactured starters. Refer to Service Manual for specific spare parts list.

Spare Parts

B-3

Table B.3
Bulletin 1503D, 1560D, 1562D 2300 Volt, 800 Amp, 6-Device
Qty per controller
3

Description

Part Number

Heatsink Assembly 800A with Thermistor

80187-123-51

Note : Due to stringent torquing specifications in this application, it is MANDATORY that the entire heatsink assembly
be replaced. Contact the Rockwell Automation factory.
3
1
1
1
6
3
3
9
9
2
2
1
1
1
3
2
1
1
1
1
3
2
3
3
3
3

SCR Gate Driver Board (2 devices)


Voltage Divider Resistor Board 2300 V
Voltage Feedback Circuit Board
MV SMC Interface Circuit Board Assembly (120V)
MV SMC Interface Circuit Board Assembly (230V)
Snubber Resistor 60 ohm
Snubber Capacitor 1.0 F
Sharing Resistor 32.5K, 225 W
Fiber-optic Cable, 2,5 m
Fiber-optic Cable, 5.0 m
Bridge Rectifier
MOV 120V
MOV 230V
Test Power Supply 120V AC (North America)
Test Power Supply Universal
LV Control Panel, 110/120 V AC !
LV Control Panel, 220/230 V AC
Power Fuses !
Primary Fuses "
LV Fuses
Pull-in and Hold-in Coil, 120 V DC
Pull-in and Hold-in Coil, 230 V DC
Vacuum Bottles (set of 3)
Heater Elements "
20 Amp Contact Cartridge "
Isolating Switch Blade Assembly (600A)
1-pole (moving blade assembly)
Isolating Switch Blade Assembly (600A)
1-pole (fixed blade assembly)
Isolating Switch Blade Assembly (800A)
1-pole (moving blade assembly)
Isolating Switch Blade Assembly (800A)
1-pole (fixed blade assembly)
Special Lubricant (for Blade Assembly)

80165-898-52
80165-878-51
80165-938-51
80187-131-51
80187-131-53
80025-871-04
80025-812-01
80025-753-01
80025-549-03
80025-549-01
24808-451-01
80145-581-02
80145-581-07
80187-051-51
80187-245-51
80154-991-59
80187-226-54
Consult Engineering Data
Consult Engineering Data
Consult Engineering Data
80025-697-01
Not available
80157-496-56
Consult Engineering Data
700-CPM
80157-709-51
80157-710-51
Consult the Rockwell
Automation factory
Consult the Rockwell
Automation factory
40025-198-01

! 1562D only.

Note : Reference only.


1503D For OEM products, refer to OEM-supplied documentation for specific spare parts list.
1560/1562D are Allen-Bradley manufactured starters. Refer to Service Manual for specific spare parts list.

1560D-5.1 February 2000

B-4

Spare Parts

Table B.4
Bulletin 1503D, 1560D, 1562D 3300 Volt, 200/400 Amp, 12-device
Qty per controller

Description

Part Number

180 A
SCR, DCR820 or 5STP03D6500 (matched set of 2) !"

80156-893-72-R

360 A
6
SCR, DCR1020 or 5STP03D6500 (matched set of 2) !"
Common Components
3
Gate Driver Board (4 devices) Series B
1
Voltage Divider Resistor Board 3300 V
1
Voltage Feedback Circuit Board
1
MV SMC Interface Circuit Board Assembly (120 Volt) Series B
1
MV SMC Interface Circuit Board Assembly (230 Volt) Series B
6
Snubber Resistor 60 ohm, 10%, 500 W
6
Snubber Capacitor 0.68 F, 4510 V peak
6
Sharing Resistor, 32.5 k, 225 W, Two 2.5 k Tap
15
Fiber-optic Cable, 2,5 m
15
Fiber-optic Cable, 5.0 m
2
Bridge Rectifier
120 V
2
MOV
230 V
120 V (North America)
1
Test Power Supply
Universal
1
LV Control Panel, 110/120 V AC #
1
LV Control Panel, 220/230 V AC
3
Power Fuses #
2
Primary Fuses #
2
LV Fuses
1
Holding Coil, 120 V DC
1
Closing Coil, 120 V DC
1
Vacuum Bottles (set of 3)
3
Heater Elements #
2
20 Amp Contact Cartridge #
3
1-pole Blade Assembly (400 Amp) #
Special Lubricant (for Blade Assembly, 400 Amp)

80156-894-72-R
80165-858-52
80165-878-52
80165-938-51
80187-131-51
80187-131-53
80025-871-04
80025-812-02
80025-753-01
80025-549-03
80025-549-01
24808-451-01
80145-581-02
80145-581-07
80187-051-51
80187-245-51
80154-991-59
80187-226-52
Consult Engineering Data
Consult Engineering Data
Consult Engineering Data
80153-575-51
80153-576-51
80157-496-52
Consult Engineering Data
700-CPM
80145-566-51
40025-198-01

" If desired, a complete factory assembled SCR/heatsink assembly can be purchased rather than individual SCRs.
See table below for part numbers :
Qty per controller
3
3

Description
180 Amp, 3300/4160 Volt Controller
360 Amp, 3300/4160 Volt Controller

Part Number
80157-864-51
80157-864-52

# Requires a thin film of electrical joint compound between base and mounting surface. Available with SCR replacement parts
or separately as Part Number 80025-783-51.

$ 1562D only.

Note :

1560D-5.1 February 2000

Reference only.
1503D For OEM products, refer to OEM-supplied documentation for specific spare parts list.
1560/1562D are Allen-Bradley manufactured starters. Refer to Service Manual for specific spare parts list.

Spare Parts

B-5

Table B.5
Bulletin 1503D, 1560D, 1562D 3300 Volt, 800 Amp, 12-device
Qty per controller
3

Description

Part Number

Heatsink Assembly 800A with Thermistor

80187-124-51

Note : Due to stringent torquing specifications in this application, it is MANDATORY that the entire heatsink assembly
be replaced. Contact the Rockwell Automation factory.
3
1
1

SCR Gate Driver Board (4 devices)


Voltage Divider Resistor Board 3300V
Voltage Feedback Circuit Board
MV SMC Interface Circuit Board Assembly (120V)
MV SMC Interface Circuit Board Assembly (230V)
Snubber Resistor 60 ohm
Snubber Capacitor 1.0 F
Sharing Resistor 32.5K, 225W
Fiber-optic Cable, 2,5 m
Fiber-optic Cable, 5.0 m
Bridge Rectifier
MOV 120V
MOV 230V
Test Power Supply 120V AC (North America)
Test Power Supply Universal
LV Control Panel, 110/120 V AC "
LV Control Panel, 220/230 V AC
Power Fuses "
Primary Fuses "
LV Fuses
Pull-in and Hold-in Coil, 120 V DC
Pull-in and Hold-in Coil, 230 V DC
Vacuum Bottles (set of 3)
Heater Elements "
20 Amp Contact Cartridge "
Isolating Switch Blade Assembly (600A)
1-pole (moving blade assembly)
Isolating Switch Blade Assembly (600A)
1-pole (fixed blade assembly)
Isolating Switch Blade Assembly (800A)
1-pole (moving blade assembly)
Isolating Switch Blade Assembly (800A)
1-pole (fixed blade assembly)
Special Lubricant (for Blade Assembly)

1
12
6
6
15
15
2
2
1
1
1
3
2
1
1
1
1
3
2
3
3
3
3

80165-858-52
80165-878-52
80165-938-51
80187-131-51
80187-131-53
80025-871-04
80025-812-01
80025-753-01
80025-549-03
80025-549-01
24808-451-01
80145-581-02
80145-581-07
80187-051-51
80187-245-51
80154-991-59
80187-226-54
Consult Engineering Data
Consult Engineering Data
Consult Engineering Data
80025-697-01
Not available
80157-496-56
Consult Engineering Data
700-CPM
80157-709-51
80157-710-51
Consult the Rockwell
Automation factory
Consult the Rockwell
Automation factory
40025-198-01

" 1562D only.

Note :

Reference only.
1503D For OEM products, refer to OEM-supplied documentation for specific spare parts list.
1560/1562D are Allen-Bradley manufactured starters. Refer to Service Manual for specific spare parts list.

1560D-5.1 February 2000

B-6

Spare Parts

Table B.6
Bulletin 1503D, 1560D, 1562D 4160 Volt, 200/400 Amp, 12-device
Qty per controller

Description

Part Number

180 A
SCR, DCR820 (matched set of 2) !"

80156-893-72-R

6
SCR, DCR1020 (matched set of 2) !"
Common Components
3
Gate Driver Board (4 devices) Series B
1
Voltage Divider Resistor Board 4160 V
1
Voltage Feedback Circuit Board
1
MV SMC Interface Circuit Board Assembly (120 Volt) Series B
1
MV SMC Interface Circuit Board Assembly (230 Volt) Series B
6
Snubber Resistor 60 ohm, 10%, 500 W
6
Snubber Capacitor 0.68 F, 4510 V peak
6
Sharing Resistor, 32.5 k, 225 W, Two 2.5 k Tap
15
Fiber-optic Cable, 2,5 m
15
Fiber-optic Cable, 5.0 m
2
Bridge Rectifier
120 V
2
MOV
230 V
120 V (North America)
1
Test Power Supply
Universal
1
LV Control Panel, 110/120 V AC #
1
LV Control Panel, 220/230 V AC
3
Power Fuses #
2
Primary Fuses #
1
LV Fuses
1
Holding Coil, 120 V DC
1
Closing Coil, 120 V DC
1
Vacuum Bottles (set of 3)
3
Heater Elements #
2
20 Amp Contact Cartridge #
3
1-pole Blade Assembly (400 Amp) #

80156-894-72-R

6
360 A

80165-858-52
80165-878-53
80165-938-51
80187-131-51
80187-131-53
80025-871-04
80025-812-02
80025-753-01
80025-549-03
80025-549-01
24808-451-01
80145-581-02
80145-581-07
80187-051-51
80187-245-51
80154-991-59
80187-226-52
Consult Engineering Data
Consult Engineering Data
Consult Engineering Data
80153-575-51
80153-576-51
80157-496-52
Consult Engineering Data
700-CPM
80145-566-51

! If desired, a complete factory assembled SCR/heatsink assembly can be purchased rather than individual SCRs.
See table below for part numbers :
Qty per controller
3
3

Description
180 Amp, 3300/4160 Volt Controller
360 Amp, 3300/4160 Volt Controller

Part Number
80157-864-51
80157-864-52

" Requires a thin film of electrical joint compound between base and mounting surface. Available with SCR replacement parts
or separately as Part Number 80025-783-51.

# 1562D only.

Note :

1560D-5.1 February 2000

Reference only.
1503D For OEM products, refer to OEM-supplied documentation for specific spare parts list.
1560/1562D are Allen-Bradley manufactured starters. Refer to Service Manual for specific spare parts list.

Spare Parts

B-7

Table B.7
Bulletin 1503D, 1560D, 1562D 4160 Volt, 800 Amp, 12-device
Qty per controller
3

Description

Part Number

Heatsink Assembly 800A with Thermistor

80187-124-51

Note : Due to stringent torquing specifications in this application, it is MANDATORY that the entire heatsink assembly
be replaced. Contact the Rockwell Automation factory.
3
1
1

SCR Gate Driver Board (4 devices)


Voltage Divider Resistor Board 4160V
Voltage Feedback Circuit Board
MV SMC Interface Circuit Board Assembly (120V)
MV SMC Interface Circuit Board Assembly (230V)
Snubber Resistor 60 ohm
Snubber Capacitor 1.0 F
Sharing Resistor 32.5K, 225W
Fiber-optic Cable, 2,5 m
Fiber-optic Cable, 5.0 m
Bridge Rectifier
MOV 120V
MOV 230V
Test Power Supply 120V AC (North America)
Test Power Supply Universal
LV Control Panel, 110/120 V AC "
LV Control Panel, 220/230 V AC
Power Fuses "
Primary Fuses "
LV Fuses
Pull-in and Hold-in Coil, 120 V DC
Pull-in and Hold-in Coil, 230 V DC
Vacuum Bottles (set of 3)
Heater Elements "
20 Amp Contact Cartridge "
Isolating Switch Blade Assembly (600A)
1-pole (moving blade assembly)
Isolating Switch Blade Assembly (600A)
1-pole (fixed blade assembly)
Isolating Switch Blade Assembly (800A)
1-pole (moving blade assembly)
Isolating Switch Blade Assembly (800A)
1-pole (fixed blade assembly)
Special Lubricant (for Blade Assembly)

1
12
6
6
15
15
2
2
1
1
1
3
2
1
1
1
1
3
2
3
3
3
3

80165-858-52
80165-878-53
80165-938-51
80187-131-51
80187-131-53
80025-871-04
80025-812-01
80025-753-01
80025-549-03
80025-549-01
24808-451-01
80145-581-02
80145-581-07
80187-051-51
80187-245-51
80154-991-59
80187-226-54
Consult Engineering Data
Consult Engineering Data
Consult Engineering Data
80025-697-01
Not available
80157-496-56
Consult Engineering Data
700-CPM
80157-709-51
80157-710-51
Consult the Rockwell
Automation factory
Consult the Rockwell
Automation factory
40025-198-01

" 1562D only.

Note :

Reference only.
1503D For OEM products, refer to OEM-supplied documentation for specific spare parts list.
1560/1562D are Allen-Bradley manufactured starters. Refer to Service Manual for specific spare parts list.

1560D-5.1 February 2000

B-8

Spare Parts

Table B.8
Bulletin 1503D, 1560D, 1562D 6900 Volt, 200/400 Amp, 18-device
Qty per controller

Description

Part Number

180 A
180A : Matched Set 3 SCRs DCR820 "

80156-893-73-R

360 A
3
360A : Matched Set 3 SCRs DCR1020 " #
Common Components
9
SCR Gate Driver Board (2 devices)
1
Voltage Divider Resistor Board 6900V
1
Voltage Feedback Circuit Board
MV SMC Interface Circuit Board Assembly (120V)
1
MV SMC Interface Circuit Board Assembly (230V)
9
Snubber Resistor 60 ohm
9
Snubber Capacitor 0.68 F
9
Sharing Resistor 32.5K, 225W
21
Fiber-optic Cable, 2,5 m
21
Fiber-optic Cable, 5.0 m
2
Bridge Rectifier
MOV 120V
2
MOV 230V
Test Power Supply 120V AC (North America)
1
Test Power Supply Universal
6
Voltage Divider Resistors, 74K 100W
1
LV Control Panel, 110/120 V AC "
1
LV Control Panel, 220/230 V AC
3
Power Fuses $
2
Primary Fuses $
1
LV Fuses
1
Holding Coil, 120 V DC
1
Closing Coil, 120 V DC
1
Vacuum Bottles (set of 3)
3
Heater Elements $
2
20 Amp Contact Cartridge $
3
1-pole Blade Assembly (400 Amp) $
Special Lubricant (for Blade Assembly, 400 Amp)
"

80156-894-73-R
80165-898-52
80165-878-53
80165-938-51
80187-131-52
80187-131-54
80025-871-04
80025-812-02
80025-753-01
80025-549-03
80025-549-01
24808-451-01
80145-581-02
80145-581-07
80187-051-51
80187-245-51
80025-588-05
80154-991-59
80187-226-52
Consult Engineering Data
Consult Engineering Data
Consult Engineering Data
80153-575-51
80153-576-51
80157-496-52
Consult Engineering Data
700-CPM
80145-566-51
40025-198-01

If desired, a complete factory assembled SCR/heatsink assembly can be purchased rather than individual SCRs.
See table below for part numbers :
Qty per controller
3
3

Description
180 Amp, 6900 Volt Controller
360 Amp, 6900 Volt Controller

Part Number
80187-140-51
80187-140-52

# Requires a thin film of electrical joint compound between base and mounting surface. Available with SCR replacement parts
or separately as Part Number 80025-783-51.

$ 1562D only.

Note :

1560D-5.1 February 2000

Reference only.
1503D For OEM products, refer to OEM-supplied documentation for specific spare parts list.
1560/1562D are Allen-Bradley manufactured starters. Refer to Service Manual for specific spare parts list.

Spare Parts

B-9

Table B.9
Bulletin 1503D, 1560D, 1562D 6900 Volt, 800 Amp, 18-device
Qty per controller
3

Description

Part Number

Heatsink Assembly 800A with Thermistor

80187-143-51

Note : Due to stringent torquing specifications in this application, it is MANDATORY that the entire heatsink assembly
be replaced. Contact the Rockwell Automation factory.
9
1
1

SCR Gate Driver Board (2 devices)


Voltage Divider Resistor Board 6900V
Voltage Feedback Circuit Board
MV SMC Interface Circuit Board Assembly (120V)
MV SMC Interface Circuit Board Assembly (230V)
Snubber Resistor 60 ohm
Snubber Capacitor 1.0 F
Sharing Resistor 32.5K, 225W
Fiber-optic Cable, 2,5 m
Fiber-optic Cable, 5.0 m
Bridge Rectifier
MOV 120V
MOV 230V
Test Power Supply 120V AC (North America)
Test Power Supply Universal
Voltage Divider Resistors, 74K 100W
LV Control Panel, 110/120 V AC "
LV Control Panel, 220/230 V AC
Power Fuses "
Primary Fuses "
LV Fuses
Pull-in and Hold-in Coil, 120 V DC
Pull-in and Hold-in Coil, 230 V DC
Vacuum Bottles (set of 3)
Heater Elements "
20 Amp Contact Cartridge "
Isolating Switch Blade Assembly (600A)
1-pole (moving blade assembly)
Isolating Switch Blade Assembly (600A)
1-pole (fixed blade assembly)
Isolating Switch Blade Assembly (800A)
1-pole (moving blade assembly)
Isolating Switch Blade Assembly (800A)
1-pole (fixed blade assembly)
Special Lubricant (for Blade Assembly)

1
18
9
9
21
21
2
2
1
6
1
1
3
2
1
1
1
1
3
2
3
3
3
3

80165-898-52
80165-878-53
80165-938-51
80187-131-52
80187-131-54
80025-871-04
80025-812-01
80025-753-01
80025-549-03
80025-549-01
24808-451-01
80145-581-02
80145-581-07
80187-051-51
80187-245-51
80025-588-05
80154-991-59
80187-226-54
Consult Engineering Data
Consult Engineering Data
Consult Engineering Data
80025-697-01
Not available
80157-496-56
Consult Engineering Data
700-CPM
80157-709-51
80157-710-51
Consult the Rockwell
Automation factory
Consult the Rockwell
Automation factory
40025-198-01

" 1562D only.

Note :

Reference only.
1503D For OEM products, refer to OEM-supplied documentation for specific spare parts list.
1560/1562D are Allen-Bradley manufactured starters. Refer to Service Manual for specific spare parts list.

1560D-5.1 February 2000

B-10

Spare Parts

Table B.10
Accessories
Qty per controller

Description

Part Number

Control Module (Standard)


Control Module (Soft Stop)
Control Module (Pump Control) #
Control Module (Slow Speed) "
Control Module (Smart Motor Brake) "
Control Module (Slow Speed with Brake) "

80187-194-01
80187-194-02
80187-194-03
80187-194-04
80187-194-05
80187-194-06

Converter Module

825-MCM20

Fanning Strip

Fan (120 V) #
Fan (240 V) #
Fuse Extractor

150-NFS
80025-248-01
80025-248-02
80144-491-02

! DO NOT substitute for another module without consulting the factory!


" DO NOT substitude LV pump control modules. The Medium Voltage Dialog controller uses a Dialog Plus Control Module
unique to Medium Voltage applications.

# For 1562D, 2400 to 4160V, 400A only.

Note :

1560D-5.1 February 2000

Reference only.
1503D For OEM products, refer to OEM-supplied documentation for specific spare parts list.
1560/1562D are Allen-Bradley manufactured starters. Refer to Service Manual for specific spare parts list.

Appendix

Accessories

Table C.1
Accessories
Description

Human Interface
Module

Communication
Module

Description/Used With

Catalog Number

IP30 (Type 1) Door Mount Bezel Kit


IP30 (Type 1) Programmer Only
IP65 (Type 4/12) Programmer Only
IP30 (Type 1) Analog Control Panel
IP30 (Type 1) Digital Control Panel
IP65 (Type 4/12) Digital Control Panel
ControlNet
Remote I/O
DH 485 or
RS232/422/485 (DF-1)
(120 V DC)
DeviceNet
DeviceNet (enhanced)
DH485 or
RS232/422/485 (DF-1)
(24 V DC)

1201-DMA
1201-HAP
1201-HJP
1201-HA1
1201-HA2
1201-HJ2
1203-CN1
1203-GD1

Flex I/O

Communication
Cables

Converter Modules

SLC Communication Module


1/3 meter, Male-Male
1 meter, Male-Male
3 meter, Male-Male
9 meter, Male-Male
1-12.5 A
Fanning Strip

1203-GD2
1203-GK5
1203-GV6
1203-GK2
1203-FB1
1203-FM1
1201-SM1
1202-C03
1202-C10
1202-C30
1202-C90
825-MCM20
150-NFS

1560D-5.1 February 2000

C-2

Accessories

1560D-5.1 February 2000

Medium Voltage Business, 135 Dundas Street, Cambridge, ON N1R 5X1 Canada, Tel: (1) 519 623-1810, Fax: (1) 519 623-8930

Publication 1560D-5.1 February 2000


Supersedes Publication 1560D-5.1 September 1999

1999 Rockwell International Corporation. All rights reserved. Printed in Canada.

Multifunctional
Motor Management

Bulletin 825 Smart Motor


Manager Protection Relay

Push the Limits


Maximize your motors capability with the Smart

Motor Manager (SMM ) Protection Relay.


Unmanaged current and heat are negative forces that
can shorten motor life and cause costly, unanticipated
downtime. The SMM Protection Relay is an intelligent
protection device that lets your motor safely reach its
maximum operating level, helping to avoid damage
and downtime, thereby lowering total cost of
ownership.
The device accomplishes this through current monitoring and sophisticated algorithms that model the motors
thermal conditions, resulting in effective motor management. Additionally, by keeping close watch on current,
the SMM protection relay guards against thermal overload, ground faults, and stalling. See inside pages for
options that fit your specific application.

Crushers, Mills, Mixers, Rollers

Starting Heavy Loads,


Short Starting Times, Wye-Delta

Medium Voltage Motors

Thermal overload

Start time monitoring

High overload/stalling

Underload

Ground (earth) fault (Holmgreen)

MST Option Card

Analog output for thermal utilization

Thermistor input (PTC)

Stalling during start

MLV Option Card

100 Platinum RTD input 7 (ambient temperature)


Remote I/O, DeviceNet, Modbus

100 Platinum RTD inputs 1 to 6 (stator, bearing)

Communications Options

Wye-Delta starting
Phase reversal

MMV Option Card

Short circuit

Ground (earth) fault (Core balance C.T.)

Damp Environments,
Mobile Equipment

Fans and Centrifuges

Basic Smart Motor Manager


Protection Relay

Dusty Environments

Conveyors, Cranes, Elevators

The Smart Motor Manager includes


the following protective functions.

High or Varying
Ambient Temperatures

Pumps and Compressors

Adjustable trip time

Protective Functions

Ideally Suited for These Applications


Pumps, compressors,

Fans, centrifuges

Crushers, mills,

Special motors and

Critical environmental

conveyors, cranes, elevators

starting heavy loads


stalling during starting
faulty bearings
defective fan blades

mixers, rollers

starting cycles

conditions

starting heavy loads


stalling during starting
and operation
fluctuating loads
brief overloads

starting heavy loads


very rapid starting
Wye-Delta starting
medium voltage motors
EEx-e motors (chemical
industry motors)

wide temperature fluctuations


high ambient temperatures
dusty environments
damp environments
mobile equipment

stalling during starting


and operation
intermittent loading
detecting submersible pumps
that run dry
belt breakages
very rapid starting
faulty bearings

DeviceNet is a trademark of the Open DeviceNet Vendor Association (O.D.V.A.). SMM is a trademark of Rockwell Automation, a core business of Rockwell International Corporation.

Features and Benefits


LED Fault Indicator
flashes to indicate a warning
constant LED indicates a trip

Intuitive User Interface


The Smart Motor Managers LCD
displays the following information
in easy-to-understand text:
operating data (e.g., motor current,
thermal load, phase imbalance,
and more)
programmable parameters
statistical data (e.g., controller and motor
operating time, elapsed time since last
trip and start, number
of starts, and more)

Test Key
verifies correct operation

Reset Key
allows you to reset a trip

Simple Operation
Four keys and an LCD that displays text
allow you to quickly and easily:
program parameters and monitor motor
conditions
troubleshoot motor faults

Easy Startup

Prevent Motor Damage

The Smart Motor Manager comes ready to control many applications.


The most popular settings come preset from the factory. Once youve
chosen the appropriate options, theres little or no programming needed.

The Smart Motor Manager warns you about conditions that may cause
motor failureallowing you to take corrective action before damage
occurs.

Make Full Use of Equipment

Reduced Chance of
Unscheduled Downtime

The Smart Motor Manager models a thermal image of the motor. This
allows maximum use of equipment, even with:
a fluctuating load commonly found in compressor, crusher, mill,
mixer, conveyor, and crane applications
brief overloads
heavy duty startup
phase imbalance

Based on parameters that you control, the Smart Motor Manager


monitors your motors operating status and warns you of impending
motor failure. This warning allows you to act before your motor fails,
protecting you from:
unscheduled downtime
expensive repairs

Bulletin 825

SMM Smart Motor Manager


0

Bulletin 825
0.52000 A Current
Range
Modular Construction
Built-in Keypad and LCD
Test and Reset Buttons
Alarm/Trip LED
NEMA 4 (IP65) Housing
Communication Options
Suitable for Low- and
Medium-Voltage
Applications

Smart Motor Manager


Cat. No. 825-M

TABLE OF CONTENTS
Description

Page

Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Product Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Approximate Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Description
The Bulletin 825 SMM Smart Motor Manager provides the tools necessary to obtain
optimal utilization of motors that operate critical processes. The Smart Motor Manager
can minimize unplanned shutdowns with its comprehensive protective, monitoring,
warning, and diagnostic capabilities. Protective features include: thermal overload,
phase loss, phase reversal, phase imbalance, rapid trip/mechanical jam, ground
(earth) fault, short circuit, over-temperature (thermistor input), underload, stator and
bearing RTD monitoring, start time monitoring, stall during start, and multiple starts.
Some of these features require the installation of an option card.

Conformity to Standards:

Approvals:

IEC 947-4
CSA C22.2 No. 14
UL 508

CE
PTB
CSA Certified
UL Listed

Your order must include:


Cat. no. of the Smart Motor Manager
selected with supply Voltage Suffix
Code.
Cat. no. of Converter Module selected.
If required, Cat. no. of any option cards
or accessories.

Bulletin 825

SMM Smart Motor Manager


Product Overview
Thermal Overload
Two-Body Simulation
Most thermal overload protective devices employ a one-body
thermal simulation model. This model assumes that a motors
thermal response is uniform throughout.
The Smart Motor Manager uses a two-body simulation to
calculate a more precise representation of a motors thermal
condition during all modes of operation. A two-body simulation
incorporates the temperature rise characteristics of both the
stator windings and the iron mass of the motor into the thermal
image.
Starting: In a two-body simulation, the fast rise in the winding
temperature and the much slower conduction of heat to the iron
during starting are correctly simulated.
Running: While the motor is running, both the iron and current
imbalance losses are entered into the model. The optional
addition of the ambient temperature into the simulation improves
the level of motor use, even in cases where the temperature is
subject to considerable fluctuations.
Stopped: The different cooling rates of a self-cooled motor while
running and at rest are taken into account by two separate time
constants. The simulation includes the faster cooling of the
windings relative to the temperature of the iron mass after
switching off the motor, as well as the slower cooling of the motor
as a whole.
Thermal Capacity Utilization
Thermal capacity utilization is the motor I2t value that the Smart
Motor Manager calculates with the two-body simulation. This
value can be accessed via the front panel keypad/LCD under
the Actual Values menu. When the value reaches 100%, a
thermal (overload) trip occurs.
Adjustable Settings
To allow maximum utilization of a motor, the Smart Motor
Manager provides the following adjustable settings that allow
the installer to match the electronic thermal overload protection
to the time-current response of the motor:
Full Load Current
Locked Rotor Current
Locked Rotor Time
The thermal capacity of the iron is particularly important at
low-level overloads; allowance for it in the thermal image
enables the overload reserves of the motor to be used without
risking a premature trip.

Product Selection Page 10


Accessories Page 11
Specifications Page 13
Approximate Dimensions Page 21

Adjustable Ratio of Cooling Time Constants


The ratio of the cooling time constant when the motor is
stationary to the cooling time constant when the motor is running
allows for the different cooling rates in each of these states. The
factory-programmed default value is 2.5; this value is correct for
the majority of self-cooled motors. For forced-cooled and special
motors, especially those that respond either very quickly or
slowly, it may be necessary to modify this value.
Tripping Time Display
In conditions when an overload is likely to occur, the time to trip
is continuously displayed on the Smart Motor Managers
front-panel LCD. This allows corrective action to be taken so
that production may continue uninterrupted.
Reset Time Display
Following a thermal trip, the Smart Motor Manager cannot be
reset until the temperature in the thermal image has fallen to the
reset level, which has a factory-programmed default value of
50% of thermal utilization.
Thermal Warning
The Smart Motor Manager provides the capability to alert in the
event of an impending overload trip. The thermal warning level
has an adjustable range of 5099% of thermal utilization, and
the warning can be assigned to any of the available auxiliary
relays.

Motor Temperature Monitoring


Direct motor temperature monitoring can provide enhanced
protection against influences that are independent of current,
such as ambient temperature and obstructed motor ventilation.
Doing so requires a motor with temperature sensors embedded
in the windings. The Smart Motor Manager offers two options
for direct temperature monitoring.
Thermistor Input: The option card (Cat. No. 825-MST) allows
connection of a maximum of six positive temperature coefficient
(PTC) thermistors in series. The resistance of a thermistor
increases immediately when its rated response temperature is
exceeded. The Smart Motor Manager provides an
instantaneous trip when the measures thermistor response
resistance level is achieved.
RTD Input: The option card (Cat. No. 825-MMV) allows
connection of six 100 platinum resistant temperature
detectors (RTDs) for monitoring motor winding and bearing
temperature. A seventh input for monitoring the ambient
temperature is also available. User-adjustable settings are
provided for programming separate warning and trip
temperature values. The monitored temperatures are displayed
through the Actual Values menu.

Bulletin 825

SMM Smart Motor Manager


Product Overview, Continued
Ground Fault

Rapid Trip/Mechanical Jam

Motor insulation breakdown usually results in a leakage current


to the grounded parts of the machine or, in the case of a power
cable, the protective conduit. In grounded power systems, the
fault current that develops can rise rapidly to a very high value.
The Smart Motor Manager offers the following ground fault
sensing options.

When a driven load is jammed, causing the motor to stall, undue


stress is applied to the transmission elements (gears, bearings,
motor shaft, etc.). Additionally, as the motor stalls, its current
draw begins to increase to the level of its locked rotor current
rating.

Residual Method (Holmgreen)


The Smart Motor Manager uses the Holmgreen method with the
basic unit as standard. This method calculates the ground fault
current by summing the individual phase currents. In a "healthy"
motor where there is no residual current flowing to ground, the
three-phase currents sums to zero. The Holmgreen method is
best suited for use on either solidly grounded power systems or
those grounded through a low impedance. The trip setting has
an adjustable range of 10100% of the motors full load current
rating.
Zero Sequence Method (Core Balance)
The option card (Cat. No. 825-MST) allows the user to connect
a core balance transformer (Cat. No. 825-CBCT), which
measures the ground fault current directly from the three-phase
motor conductors passing through it. This method is best suited
for use on high-impedance grounded power systems. It is also
preferred when a sensitive measurement is required. Both trip
and warning settings are available with adjustable ranges from
5 mA50 A.

Imbalance/Phase Loss
The Smart Motor Manager continuously monitors and calculates
the current imbalance of an operational motor. The measured
current imbalance is entered into the thermal image calculation
to simulate the resulting increased motor heating.
User-adjustable trip and warning settings for current imbalance
are available with a preset range of 580% of full-load current.
Phase loss, a severe form of imbalance, is one of the primary
causes of motor failure. A phase loss can occur as a result of a
blown fuse or a poor electrical connection. Under a phase loss
condition, the current draw of the remaining two powered
phases increases by as much as 1.73 times the normal
operating current. The Smart Motor Manager offers two options
for obtaining phase loss protection.
Basic Unit: With the basic unit, phase loss protection is gained
by using the current imbalance (asymmetry) settings.
Cat. No. 825-MLV: This option card provides terminals for
connection to the three-phase power system. With the
connection made before the motor-starting contactor, a phase
loss condition is recognized even while the motor is stopped.
The Smart Motor Managers phase loss protection provides a
preset delay of 2 s prior to a trip.

The Smart Motor Manager provides the capability to quickly take


a motor off line in the event of a mechanical jam, thereby
reducing the potential for mechanical damage. It can also
monitor and warn of impending jam situations.
User-adjustable trip and warning settings are available with a
range of 16 times the motor full-load current.

Underload
A sudden drop in motor current can signal conditions such as:
Pump cavitation
Tool breakage
Belt breakage
In these instances rapid fault detection can help minimize
damage and aid in reducing production downtime.
Additionally, monitoring for underload can provide enhanced
protection for motors that are cooled by the medium being
handled (e.g., submersible water pumps). Such motors can
become overheated despite being underloaded. This can result
from an absence or insufficient amount of the medium (due to
clogged filters, closed valves, etc.).
The adjustment range of the underload trip and warning settings
is 25100% of the motors full load current rating.

Short Circuit
In the event of a short circuit (phase-to-phase or
phase-to-ground), excessive currents, typically much greater
than a motors locked rotor current rating, are generated. Given
the magnitude of this current, it is generally preferable or
necessary to interrupt three-phase power to the motor through
the branch-protecting circuit breaker rather than the
motor-starting contactor due to the differences in the
short-circuit withstand rating.
In the event of a short circuit, the Smart Motor Manager trips
output relay #1 of the option card (Cat. No. 825-MST) regardless
of other protective functions, actuating the circuit breaker with
adequate breaking capacity. To prevent the contactor from
opening under short-circuit conditions, its main relay is blocked
from operating at currents greater than or equal to 12 times the
motors full-load current rating. Tripping is delayed by 50 ms.

Product Selection Page 10


Accessories Page 11
Specifications Page 13
Approximate Dimensions Page 21

Bulletin 825

SMM Smart Motor Manager


Product Overview, Continued
Start Time Monitoring

Outputs

The Smart Motor Manager furnishes a setting for the installer to


define the time that the motor should accelerate the load to full
speed. The adjustment is 1240 s.

Output Relays

Start time monitoring begins when the motors starting inrush


current is recognized (current is greater than 110% of the
motors full-load current rating). Acceleration to full speed is
deemed to have been completed when the starting inrush
current has fallen below 110% of the motors full-load current
rating.
Start time monitoring is independent of thermal overload
protection.

Speed Switch Input


The Cat. No. 825-MST option card provides input terminals for
connection of a speed switch. This enables the Smart Motor
Manager to detect a stalled motor during start and react
immediately to take the motor off-line; this reduces the risk of
damage to either the motor or the driven load.

Two-Speed Motor Protection


In the case of two-speed motors, the Smart Motor Manager
provides a second motor current rating setting. Activating control
input #2 of the option card signals the Smart Motor Manager to
begin protection based on this second setting.

Control Functions
Contactor Operation
The Smart Motor Manager allows control relays #2 and #3 on
the Cat. No. 825-MST option card to be operated over an
automation network (e.g., DeviceNet via the Cat. No. 825-MDN
communication card). The relays will actuate the motor-starting
contactor(s).
Wye-Delta Control
With the Cat. No. 825-MLV option card installed, the Smart
Motor Manager can control the transition from wye to delta. The
command to transition is issued when the starting current has
dropped to the motors full-load current rating, thus minimizing
the associated current transients.
Emergency Restart
If a critical process requires the restart of the motor, the Smart
Motor Manager provides two terminals that, when bridged,
return the stored thermal capacity utilization to zero so that an
emergency restart can be initiated.

Product Selection Page 10


Accessories Page 11
Specifications Page 13
Approximate Dimensions Page 21

The basic unit provides a main relay and an alarm relay. The
main relay can be operated either as electrically held or
non-fail-safe. The Cat. No. 825-MST option card offers three
additional auxiliary relays. Two additional auxiliary relays are
available with the Cat. No. 825-MLV option card.
Isolated Analog Output
The Cat. No. 825-MST option card provides an isolated
420 mA analog output signal. This can be set to indicate one
of the following:
Motor current (as a percentage of the motors full-load current
rating)
Maximum RTD temperature measured
Thermal capacity utilization

Monitoring and Diagnostic Display


The Smart Motor Manager provides the following useful
operating motor data via the Actual Values and Recorded
Values menus.
Actual Values
Operating current (average of three-phase)
Operating current (individual phase values)
Thermal capacity utilization
Tripping time (thermal overload)
Reset time (thermal overload)
Percent current imbalance
Ground fault current
RTD temperature measurements
Recorded Values
Running times
Number of starts
Cause of five most recent trips
Pre-trip Actual Value data
Number of trips by fault type
Time duration of a power failure

Communications
The Smart Motor Manager provides a dedicated communication
expansion slot for connection to the following automation
networks:
DeviceNet
Modbus
Remote I/O
This can enhance process operation by allowing the user to do
the following via the network:
Control the motor starter
Modify settings
Access operational, diagnostic, and historical data

Bulletin 825

SMM Smart Motor Manager


Product Overview, Continued
Basic and Optional Features
Option Cards

Basic
Bulletin 825

Cat. No. 825-MST

Cat. No. 825-MLV

Cat. No. 825-MMV

100 Platinum RTD Inputs #1#6


(Stator/Bearings)

100 Platinum RTD Input #7


(Ambient Temp.)

Features
Thermal Overload
Phase Imbalance (Asymmetry)
Jam (High Overload/Stalling)
Underload
Ground (Earth) Fault (Holmgreen)
Starting Time Monitor
Limited Starts Per Hour
Emergency Start
Short Circuit
Ground (Earth) Fault (Core Balance CT)
Stalling During Start
Thermistor Input (PTC)
Analog Output for Thermal Utilization
Two-Speed Motor Protection
Wye-Delta (Star-Delta) Starting
Phase Reversal (Sequence)
Phase Failure

Available

Possible Combinations of Option Cards with Basic Unit


Basic
Bulletin 825-M

Option Cards
Cat. No. 825-MST

Cat. No. 825-MLV

Cat. No. 825-MMV

The features and protective functions provided by each option card can be monitored through the communication network with any of the
communication cards.
A single communication card (DeviceNet, Modbus or Remote I/O) can be used with any combination of option cards.
Available in shown combination.

Product Selection Page 10


Accessories Page 11
Specifications Page 13
Approximate Dimensions Page 21

Bulletin 825

SMM Smart Motor Manager


Product Selection
Smart Motor Manager Basic Unit
Description

Cat. No.

Basic Unit
Programmable electronic motor overload protection relay
with communication capability
Thermal Overload
Phase Imbalance
Jam (High Overload)
Underload
Ground (Earth) Fault
Starting Time Monitor
Limited Starts per Hour

825-M

Control Voltage Suffix Code

The cat. no. as listed is incomplete. Select a control Voltage Suffix Code from the table below to complete the cat. no. Example: Cat. No. 825-M
for 120V power supply becomes Cat. No. 825-MD.
Voltage AC

24V

120220V

220240V

380415V

440V

Voltage DC

2448V

50/60 Hz

KD

AJ

GB

Code

Z48

Converter Module
Description

Converter Module
Connection to the Smart
Motor Manager is made by
a cable wire plug provided
as standard with the
converter module.

Cat. No. 825-MCM180

Current Range (A)

Cat. No.

0.52.5

825-MCM2

2.520

825-MCM20

20180

825-MCM180

IEC:160630
UL/CSA: 160434

825-MCM630

IEC:160630
UL/CSA: 160630

825-MCM630N

Cat. No. 825-MCM630

Up to 2000 A when using primary current transformers.

Core Balance Current Transformer


Description

Measure from earth current 0.5...10 A

Product Overview Page 6


Accessories Page 11
Specifications Page 13
Approximate Dimensions Page 21

10

Current Ratio

Cat. No.

100:1

825-CBCT

Bulletin 825

SMM Smart Motor Manager


Option Cards /Accessories
Description

Cat. No.

MST option Features


Short Circuit
Ground (Earth) Fault (Core Balance CT)
Stalling During Start
Thermistor Input (PTC)
Analog Output
Two-speed Motor Protection

825-MST

MLV option Features


Wye-Delta (Star-Delta) Starting
Phase Reversal (Sequence)
Phase Failure (Motor Supply)

825-MLV

MMV option Features


100 Platinum RTD Inputs #1#6 (Stator/Bearings)
100 Platinum RTD Input #7 (Ambient Temperature)

825-MMV

Communication Card
DeviceNet DeviceNet Conformance Tested (Passed)

825-MDN

Modbus

3600-MB5

Remote I/O

3600-RIO

Bus Bars for Cat. No. 825-MCM180 Features


Terminals: M8
4 x 16 x 100mm
Weight: 230 g

825-MVM

Terminal Cover Provides touch protection for Cat. No.


825-MCM converter modules (two pieces per set)
For use with Cat. Nos.
825-MCM2
825-MCM20
825-MCM180
825-MCM630N

CAB6-HA1
CAB6-HA1
CAB6-HA2
CAB6-HA3

Main Terminal Set Dual connection 3-pole terminal lug


block providing touch protection (2 blocks, 6 lugs per set)
For use with Cat. Nos.
825-MCM180 (with Cat. No. 825-MVM bus bar kit)
825-MCM630N

CAB6-HB2
CAB6-HB3

Thermal Utilization Meter

825-MTUM

Option cards include a connector set.


Cat. Nos. 825-MLV and 825-MMV occupy the same slot, therefore only one of the option cards may be used at one time.
Available from Prosoft Technology, Inc. (not an Allen-Bradley product). Cat. references to third-party products are provided for informational
purposes only. Prosoft Technology, Inc., is solely responsible for the accuracy of information, supply, and support of this product. For further
information regarding this particular referenced product, please contact Prosoft Technology, Inc., at (661) 664-7208 or your local PTI distributor.
This terminal set can only be used for applications less than 420A and can only be installed on the load side of the converter module.

Product Overview Page 6


Specifications Page 13
Approximate Dimensions Page 21

11

Bulletin 825

SMM Smart Motor Manager


Accessories
Description

Cat. No.
825-FPM

Panel Mounting Frame

Connector Sets
Provided as Standard
with option card

Cat. No. 825-FPM

For use with Cat. No. 825M


MST
MMV
MLV

Connection cable (replacement)


825M to 825-MCM connection

825-MCA

825-MPS

Power Supply Module (replacement)

Cat. No. 825-MPS

825-CSB
825-CSST
825-CSMV
825-CSLV

Control Voltage Suffix Code


The cat. no. as listed is incomplete. Select a control Voltage Suffix Code from the table below to complete the Cat. No. Example: Cat.
No. 825-MPS for 120V power supply becomes Cat. No. 825-MPSD.

12

Voltage AC

24V

120220V

220240V

380415V

440V

Voltage DC

2448V

50/60 Hz

KD

AJ

GB

Code

Z48

Bulletin 825

SMM Smart Motor Manager


Specifications
Controls

6
4
1

Values
Actual
Set
Recorded

Mode Selection
Display current operating data
Setting mode
(set, change, save, and store parameters)
Display recorded data

Reset

Reset trips

Single Line
(two lines of text are displayed alternately)

Select

Select functions and enter/change operating


parameters

LCD

Settings
Change
Enter

Entry
Enable entry
Save entry

Fault Indicator LED


Blinking
Warning
Continuous
Trip

Test

Test functions
(Alarm, trip, trip time)

Settings
The following parameters must be programmed for every application. The other parameters (e.g., high overload, asymmetry) have
factory-set values, which are correct for most applications.
Main Settings
Rated motor current or operating current Ie
Use of a primary current transformer
Current ratio of primary current transformer
Locked-rotor current
Locked-rotor time

Setting Range

Factory Setting

0.5...2000 A
No/Yes
1...2000
2.5...12 Ie
1...600 s

20 A
No
1
6 Ie
10 s

If, instead of the permissible locked-rotor time, the maximum starting time is known, the approximate locked-rotor time is calculated as follows:
Locked rotor time = Starting time 1.4
Special Settings
Connection of main relay (MR)
Connection of alarm relay (AL)
Reset of thermal trip
Reset at...% thermal utilization
Reset PTC trip
Cooling constant motor ON/OFF ratio
Motor insulation class
Communication

Setting Range

Factory Setting

Electrically held/non-fail-safe
Non-fail-safe/electrically held
Manual/automatic
10...100%
Manual/automatic
1...5
B/E/F
DeviceNet
Remote I/O
Modbus

Electrically held
Non-fail-safe
Manual
50%
Manual
2.5
B

Product Overview Page 6


Product Selection Page 10
Accessories Page 11
Approximate Dimensions Page 21

13

Bulletin 825

SMM Smart Motor Manager


Specifications, Continued
Function Overview
Function
Factory
Setting

Setting
Range

Tripping Delay
Factory
Setting

Relays

Range

Factory
Setting

Selection

Factory
Setting

Protective Functions
Bulletin 825-M basic unit
Thermal overload
Asymmetry/Phase loss
High overload/Stalling
Underload
Underload delay
Earth fault (Holmgreen)
Start time monitoring
Limited number of starts per hour

On
On
On
Off
On
On
Off
Off

5...80%
1...6 Ie
25...100%

10...100%

1...10

35%
2.4 Ie
75%

50%

1...5 s
0.5...25 s
1...60 s
0...240 s
0.1...5 s
1...240 s

2.5 s
0.5 s
10 s
0s
0.5 s
10 s

MR
All
All
All

All
All
All

MR
MR
MR
MR

MR
MR
MR

Option 825-MST
Short circuit
Earth fault (core balance transformer)
Stalling during start
PTC Thermistor input

Off
Off
Off
Off

4...12 Ie
5 mA...50 A

10 Ie
1A

20...990 ms
0.1...5 s

50 ms
0.5 s

800 ms

#1
All
All
All

#1
MR
MR
MR

Option 825-MLV
Phase sequence (motor supply)
Phase loss (motor supply)

Off
Off

1s
2s

All
All

MR
MR

Option 825-MMV
100 Platinum RTD inputs #1...#6 (stator, bearings)
100 Platinum RTD input #7

Off
Off

50...200C

50C

<8 s

MR, AL#1...3

MR

Alarm Functions
Bulletin 825-M basic unit
Thermal utilisation (% load)
Asymmetry (% Ie)
High overload (% IIe)
Underload

Off
Off
Off
Off

50...99%
5...80%
1...6 Ie
25...100%

75%
20%
2 Ie
75%

AL,#1...5
AL,#1...5
AL,#1...5
AL,#1...5

AL
AL
AL
AL

Option 825-MST
Earth fault (core balance transformer)

Off

5 mA...50 A

500 mA

AL,#1...5

AL

Option 825-MMV
100 Platinum RTD inputs #1...#6 (stator, bearings)

Off

50...200C

50C

AL,#1...5

AL

Via external speed switch (control input #1); output relays and time delay as with high overload.
Includes ambient temperature in the thermal image.
Only one relay can be selected per function; MR = main relay, AL = alarm relay, auxiliary relays #1...#5.

Product Overview Page 6


Product Selection Page 10
Accessories Page 11
Approximate Dimensions Page 21

14

Bulletin 825

SMM Smart Motor Manager


Specifications, Continued
Function Overview
Function
Factory
Setting

Setting Range

Tripping Delay

Factory
Setting

Relays

Range

Factory
Setting

Selection

Factory
Setting

70%
Y11Y12

4...60 min.

60 min.

0...100%
5...200C
0...200% Ie

Off

Off
Off

0...240 s
0...240 s

1s
2s

#2
#2

Off
Off
Off
Off
Off
Off
Off
Off

Off
Off

0.5...2000 A

20 A

0...240 s
0...240 s

1s
2s

#3
#3

Off
Off
Off
Off
Off
Off
Off
Off

Y-:
1.1 Ie

Y-:
1...240 s

10 s

Range

Control Functions
Bulletin 825-M basic unit
Warm start (% of cold trip)
Emergency start
Option 825-MST
Analog output
assigned to:
- Thermal utilisation
- PT100 max. Temperature
- I Motor
Control Auxiliary Relays #2, #3
via communication
Control Input #1: (24V AC/DC; 8 mA)
Alternatively, one of two functions may be selected:
Pick-up delay, relay #2
Drop-out delay, relay #2
Disabling of protective functions:
- Asymmetry/phase loss
- High overload/stalling
- Earth fault
- Short circuit
- Underload
- Limited starts per hour
- Thermistor PTC
- 100 Platinum RTD
Control Input #2: (24V AC/DC; 8 mA)
Alternatively, one of three functions can be selected:
Pick-up delay, relay #3
Drop-out delay, relay #3
Set 2nd rated current
Disabling protective functions:
- Asymmetry/phase loss
- High overload/stalling
- Earth fault
- Short circuit
- Underload
- Limited starts per hour
- Thermistor PTC
- 100 Platinum RTD
Option 825-MLV
Star-Delta starting

Off
Off

50...100%
Jumper
Terminals

On

4...20 mA

Off

Y: #4
: #5

Only one relay can be selected per function; MR = main relay, AL = alarm relay, relays #1...#5

Product Overview Page 6


Product Selection Page 10
Accessories Page 11
Approximate Dimensions Page 21

15

Bulletin 825

SMM Smart Motor Manager


Specifications, Continued
Bulletin 825-M Basic Unit and Bulletin 825-M Converter Module
Ambient Conditions
Temperature
Operation
Storage
Transport

5...+60C
40...+60C
40...+60C

Climatic Withstand
Damp heat IEC 68-2-3
Climatic cycling IEC 68-2-30

40oC, 92% relative humidity, 56 days


25/40C, 21 Cycles

Protection Class
Bulletin 825, enclosed in panel
Terminals

IP65
IP20

Vibration Resistance
per IEC 68-2-6
Shock Resistance
per IEC 68-2-27

10...150 Hz, 3 G
30 G, shock duration 18 ms, half of a sin wave in x, y, z directions
Rated Voltage Ue

Primary Control Circuit

825-MCM2

825-MCM20

825-MCM630
825-MCM630N
825-MCM180

Motor Circuit
per IEC, SEV, VDE 0660
per CSA, UL

400V AC
240V AC

660V AC
600V AC

1,000V AC
600V AC

Control Circuit
Main relay (MR) 95...98, supply A1, A2
Phase-sequence protection L1, L2, L3
per IEC 947
per SEV
per CSA, UL
Alarm relay (AL) 13/14, Auxiliary Relays #1, #4, #5
per IEC 947
per SEV
per CSA, UL
Auxiliary Relays #2, #3
Control Inputs #1, #2

400V AC
380V AC
240V AC
400V AC
250V AC
240V AC
120V AC/30V DC
24V AC/DC
Electrical Ratings

Test Voltage

825-MCM2

825-MCM20

825-MCM630
825-MCM630N
825-MCM180

Motor Circuit
per IEC 947-4

Uimp 2.5 kV

Uimp 6 kV

Uimp 8 kV

Control Circuit
Control circuits against each other and against all other sets
Main relay (MR) 95...98, supply A1, A2
Phase sequence protection L1, L2, L3
Alarm relay (AL) 13/14, Auxiliary relays #1, #4, #5
per IEC 947-4
Core-balance transformer k, I
Auxiliary relays #2, #3
Control inputs #1, #2
per IEC 947-4

Uimp 4 kV

Uimp 2.5 kV
EMC Standard

Noise emission
Noise proof

per EN 50 081-1 and EN 50 081-2


per EN 50 082-1 and EN 50 082-2

Standards

IEC 947-4, CSA C22.2 No. 14, UL 508

Approvals

CE, UL-Listed, CSA, PTB

The measuring inputs PT100 and PTC, 4...20 mA analog output and the RS 485 communication interface are not isolated from one another.
Approved by the PTB (Physikalisch-Technische Bundesanstalt, Physical Testing Institute, Federal Republic of Germany) for the protection of
motors used in explosion hazard areas (EEx e).
Product Overview Page 6
Product Selection Page 10
Accessories Page 11
Approximate Dimensions Page 21

16

Bulletin 825

SMM Smart Motor Manager


Specifications, Continued
Bulletin 825-M Basic Unit and Bulletin 825-MCM Converter Module
Supply
50/60 Hz: 22...24, 33...36, 44...48, 110...120,
220...240, 380...415, 440V AC
24...48, 72...120V DC
AC 0.85...1.1 Us, DC 0.80...1.1 Us
AC 13 VA, DC 10 W max.
With the appropriate supply cable rating, the supply module is
short-circuit proof

Nominal supply voltage Us


Permissible voltage fluctuation
Power consumption
Short-circuit protection

Relays
Contact Data of Output Relays, Main Relay (MR) 95...96
Contacts

1 N.O. and 1 N.C. contact, electrically insulated

Nominal operating voltage per UL, CSA: pilot duty 240V

[V]

Continuous thermal current

[A]

24

110...125

220...250

380...440

Rated operating current

AC-15

[A]

1.2

Maximum permissible switching current (cos = 0.3)

AC-15

[A]

30

30

12

Rated operating current


(L/R = 300 ms), no protection network necessary

DC-13

[A]

0.2

Max. rated current of back-up fuse

[A]

0.3

fast (D) 16; slow (DT) 10, 500V Type gG

Alarm relay (AL), Auxiliary relays #1, #4, #5


Contacts

1 N.O. contact each

Continuous thermal current

[A]

Maximum permissible switching voltage

[V]

400 AC, 125 DC

Nominal operating current


cos = 1
cos = 0.4, L/R = 7 ms

[A]
[A]

Maximum switching power


cos = 1
cos = 0.4, L/R = 7 ms
- per UL/CSA

[VA/W]
[VA/W]
[V]

4 at 250V AC or 30V DC
2 at 250V AC or 30V DC
1250/150
500/60
240; 1 A pilot duty

Auxiliary relays #2, #3


Contacts

1 N.O. contact each

Continuous thermal current

[A]

Maximum permissible switching voltage

[V]

48 AC, 30 DC

Maximum switching power


cos = 1
cos = 0.4, L/R = 7 ms

[W]
[W]

150
60

Terminals
Bulletin 825-M Plug-in Terminals
per UL
per VDE

[mm2]
[mm2]
[AWG No.]
Nominal gauge:
[mm2]

0.5...2.5, single-wire
0.5...1.5, double-wire
22...14

[mm2]
[AWG No.]

2 x 2.5/1 x 4
2 x 20...14/1 x 20...12

Range of gauges:

Main circuit
825-MCM2, 825-MCM20

Terminals:

825-MCM180

Aperture:
or bus bars:
Bus bars

825-MCM630(N)

[mm]
[mm]
[mm]

1.5

max. 19
20/16 x 4
25 x 8

Product Overview Page 6


Product Selection Page 10
Accessories Page 11
Approximate Dimensions Page 21

17

Bulletin 825

SMM Smart Motor Manager


Specifications, Continued
Bulletin 825-M Basic Unit and Bulletin 825-MCM Converter Module
Main Current Transformers for the Motor Circuit
When Bulletin 825-M is used as a secondary relay with Cat. Nos. 825-MCM2, 825-MCM20
Min. rated operating voltage
Min. rated primary current I1n
Rated secondary current
Class and nominal overcurrent factor
Power rating
Rated frequency

[V]
[A]
[A]

[Hz]

Burden
Power consumption at maximum rated current
Continuous thermal current
Thermal current during 1 s
Rated frequency

[VA]
[A]
[A]
[Hz]

Nominal operating voltage of motors


Nominal operating current of motor
1 or 5
5 P 10 ext. 120%
According to power consumption in leads and measuring circuits
50/60
825-M + 825-MCM2
0.1 per Phase
3
250
50/60

825-M + 825-MCM20
0.4 per Phase
24
600
50/60

General Notes on 825-MCM


An open-circuit secondary is permitted, since the burden is installed in
the detection module

No-load
Current transformer (P = Protection): 1% error at rated current (Ie)
5% error at rated overcurrent (10 Ie)
Rated thermal current = 120% Ie
For starting current 10 Ie: Class 5 P 20
The current transformer error is added to the Bulletin 825-M error.
2.5 A with Cat. No. 825-MCM2, 20 A with Cat. No. 825-MCM20

Core Balance Current Transformer


Recommended Core Balance Current Transformer (cable-type)
Nominal ratio

Kn =

Minimum detectable earth fault


Pick-up current of Bulletin 825 earth fault protection

Burden: Bulletin 825-M measuring circuit


Power consumption at max. rated current 0.5 A
Continuous thermal current
Thermal current during 1 sec
Frequency

[VA]
[VA]
[A]
[Hz]

0.4
0.5
25
50/60

Short-Circuit Protection

Selection of circuit breaker or fuse and associated contactor

The line-side circuit breaker or fuse must ensure that the engine will
start, while still switching off short-circuit currents fast enough. Because
of the latter, the fuse selected should always be as small as
possible.
The lowest possible fuse rating depends on the starting current of the
motor and the tripping time set on the Bulletin 825-M.

Short-Circuit coordination of the starter must always be considered

The contactor receives its tripping signal when the Bulletin 825 trips and
must interrupt all currents up to the point of intersection of the time/
current characteristics of the Bulletin 825 and circuit breaker or fuse.
When starting large motors, the main contacts on the contactor are
subjected to high thermal loads so that if the motor starting time exceeds
a certain limit, the maximum permissible current has to be reduced.
The fuse or contactor rating must also allow for the prospective
short-circuit current. The Bulletin 825-MCM converter modules are
short-circuit proof. The contactor coordination diagrams are available
upon request.

Product Overview Page 6


Product Selection Page 10
Accessories Page 11
Approximate Dimensions Page 21

18

Bulletin 825

SMM Smart Motor Manager


Specifications, Continued
Bulletin 825-M Basic Unit and Bulletin 825-MCM Converter Module
Response During Supply Voltage Failure
If the supply voltage fails, the setting data is retained

Supply voltage failure > 30 ms

All attracted output relays drop out


LED extinguishes
The timer for duration of supply failure starts (max. 8 h)
The current and recorded data are memorized
LCD extinguishes

Recovery of the supply voltage

Start of initialization routine


The time of occurrence and the duration of the supply voltage failure are recorded
Thermal image is calculated and updated
All output relays return to the state they were in before the supply failure
LCD and LED are active

Automatic Recognition of the Converter Module


In the event of a fault, the output relay MR trips and the type of fault appears on the LCD
The Bulletin 825-M <-> 825-MCM link
Agreement between the rated current set and the current range of the Bulletin 825-MCM
The supervisory circuits

Bulletin 825-M devices regularly check

Bulletin 825-MTUM Device for Indicating Thermal Utilisation, PT 100 max., Imotor
Display range
Utilisation
Wire
Front
Panel cutout
Mounting depth

0...100 ( Ie at rated current Ie)


2 x 2.5
96 x 96
91.5 x 91.5 (0/+ 0.5)
55

[%]
[mm2]
[mm]
[mm]
[mm]

Power Supply Module


Permissible voltage fluctuation
Power consumption
Short-circuit protection

[Us]
[VA/W]

AC 0.85...1.1, DC 0.80...1.1
AC 13/DC 10
The power supply module is short-circuit proof
Weights

Bulletin 825-M with power supply module


Bulletin 825-M without power supply module
Power supply module

825-MPS

[g]
[g]
[g]

1000
710
290

Options

825-MPB
825-MST
825-MLV
825-MMV

[g]
[g]
[g]
[g]

125
90
90
90

Converter modules

825-MCM2
825-MCM20
825-MCM180
825-MCM630
825-MCM630N

[g]
[g]
[g]
[g]
[g]

570
570
860
3120
5460

Core balance transformer


Thermal utilisation indicator
Mounting frame
PC Option kit
T connector
Stub cable

825-CBCT
825-MTUM
825-FPM
825-VISU
825-PTS
825-PTL2
825-PTL4
825-PCB1
825-PCE
825-BC
825-CBC9

[g]
[g]
[g]
[g]
[g]
[g]
[g]
[g]
[g]
[g]
[g]

500
180
860
125
75
40
45
95
20
59/m
15

825-MVM
825-MVM2

[g]
[g]

230
230

Bus cable segment


Bus termination
Bus cable
Bus cable connector
Bus bar for Cat. No. 825-MCM180

Product Overview Page 6


Product Selection Page 10
Accessories Page 11
Approximate Dimensions Page 21

19

Bulletin 825

SMM Smart Motor Manager


Specifications, Continued
Short-Circuit Protection of Medium- and High-Voltage Motors with Option 825-MST
Main Circuit
3-phase current evaluation

Bulletin

825-MCM

825

Converter Module U1
825-MCM2
825-MCM20
Main current transformer U2...A/5 A or...A/1 A
See Specifications for selection
Core balance transformer U3
5 mA...50 A
Output to Bulletin 825-M: 5...500 mA

Cat. No. 825-M for short-circuit protection

Control Circuit

825-M

QM
QA
K1
F1
S1
S0
Us
H1
H2
H3
MR
#1

Impulse contact control

Product Selection Page 10


Accessories Page 11
Specifications Page 13
Approximate Dimensions Page 21

20

Circuit breaker
Shunt trip coil
Contactor
825-M
ON button
OFF button
Control voltage
Indicator: contact closed
Indicator: Bulletin 825 tripped
(except for short-circuit protection)
Indicator: short-circuit trip
Main output relay
Auxiliary relay, short-circuit indicator

Bulletin 825

SMM Smart Motor Manager


Approximate Dimensions
Dimensions are shown in millimeters. Dimensions are not intended to be used for manufacturing purposes.

Bulletin 825-M Mounting


Bulletin 825-M devices are suitable for both flush- and surface
mounting.
Flush Mounting

Surface Mounting
Bulletin 825-M devices can be installed on a mounting frame
(Cat. No. 825-FPM). The terminals can then be easily accessed
without unmounting the device.

138 + 1
-0

90

170

max. 6 mm

6.5

10
150

170
138 + 1
-0

144

170
144

165

Mounting Depth

Mounting position

22.5

22.5
90

22.5

21

Bulletin 825

SMM Smart Motor Manager


Approximate Dimensions, Continued
Dimensions are shown in millimeters. Dimensions are not intended to be used for manufacturing purposes.

Bulletin 825-MCM Converter Module


e

e3

b1

d3
b
b2

d1

e2

c1

e2

d2
a

Cat. No. 825-MCM2...825-MCM180

Cat. No. 825-MCM630

Cat. No. 825-MCM630N

Dimensions
Cat. No.

c1

d1

d2

d3

e1

e2

38.5

825-MCM2

120

85

102

66

5.3

5.3

100

55

2 x 2.5
mm 2

825-MCM20

120

85

102

66

5.3

5.3

100

55

2 x 2.5
mm 2

38.5

825-MCM180

120

102

72

5.3

5.3

100

55

38.5

825-MCM630

155

145

156

118

6.3

6.3

135

88

11

M10

48

825-MCM630N

155

145

177

118

6.3

6.3

135

88

11

M10

48

b1

b2

75

/
100/118

For snapping on to DIN Rail (EN 50 022-35 x 15 or 35 x 7.5).


Cat. No. 825-MCM180; with bus bar or max. 19 mm aperture for looping the conductors.
With Cat. No. 825-MVM.
Cat. No. 825-MVM2
See below for bus bars for Cat. No. 825-MCM180.

Bus Bars
Terminal Dimensions
Cat. No.

Bottom

Top

825-MVM

M8

M8

Product Overview Page 6


Product Selection Page 10
Accessories Page 11
Specifications Page 13

22

Bulletin 825

SMM Smart Motor Manager


Approximate Dimensions, Continued
Dimensions are shown in millimeters. Dimensions are not intended to be used for manufacturing purposes.

Core Balance Current Transformer


Optional Test
Winding

Secondary
Winding

35
150

200
175

80
110
175

Cat. No. 825-CBCT

Product Overview Page 6


Product Selection Page 10
Accessories Page 11
Specifications Page 13

23

Bulletin 825

SMM Smart Motor Manager


Notes

24

Application-Specific Options
The Smart Motor Manager Protection Relay offers the flexibility of different options
to fit your specific applications. (See the table on page 3 for protection options.)

Communication Options
With the appropriate card, your SMM Protection Relay can
communicate via: DeviceNet, Remote I/O, and Modbus.

Basic Smart Motor Manager


Protection Relay
Basic unit, no additional cards included .

MLV or MMV Option Card


Cards provide enhanced protection and control
functions in addition to the standard features of
the basic unit. (Cat. Nos. 825-MLV, 825-MMV )

MST Option Card


Card provides additional protection
over the base unit. (Cat. No. 825-MST )

This card comes standard with


the base unit. (Cat No. 825-M)

Motor Thermal Load Indicator


Connects to the MST option card and
provides an indication of thermal activity
in your motor. (Cat. No. 825-MTUM)

Converter Module

See chart on page 3 for details.


Incomplete catalog number. See page 10 for full number.

Plugs into RJ-45 connection of the Basic Bulletin


Smart Motor Manager Protection Relay card and
monitors motor current consumption.
(Cat. No. 825-MCM)

Complete Automation Solutions


At Rockwell Automation we understand you need to rely on world-class
products that provide Complete Automation Solutions. For nearly a century,
customers around the world have experienced the reliability of Allen-Bradley
products from Rockwell Automation your Complete Automation supplier.

Publication 825-BR001B-EN-P October 2000


Supercedes Publication 0825-1.0.1 January 1998

2000 Rockwell International Corporation. All rights reserved. Printed in USA.

Classifying code or document type

ABB Oy
MV Induction Machines

PERFORMANCE DATA OF MOTOR

Department/Author

Date of issue

Lang.

Rev. date

Our ref.

PIE/M. Ikonen

14.10.02

En

27.01.03

8908HD300

Customer ref.

Saving Ident

Rev./Changed by

Pages

Pipa Norte

8002644C

C/M. Ikonen

1/2

Driven Machine: Crusher


Machine type code
Machine type
Mounting designation
Protected by enclosure
Method of cooling
Insulation
Service factor
Standards
Ambient temperature, max.
Altitude, max.
Duty type
Rated output
Voltage
Frequency
Speed
Current
Locked rotor Amps
Locked rotor torque
Breakdown torque
No load current
Rated torque
Load characteristics

HXR 400LK6
Squirrel cage motor
Horizontal
TEFC
TEFC
Class F
1.15 temp. rise 100 C RTD
NEMA MG1
40 C
7217 ft.a.s.l.
Continuous
500 HP
4160 V
50 Hz
988 rpm
66 Amps
550 % Code F
130 %
200 %
24 Amps
2658 lb-ft
Load %
Current Amps
Efficiency % Power Factor
100
66
95,4
0,83
75
51
95,5
0,80
50
38
95,0
0,71
Connection of stator winding
Star
Direction of rotation
Bi-directional
Sound pressure level: (sinus supply, no load)
75 dB(A), tol. + 3 dB(A), 3 ft
Inertia rotor / load
441,6 lb-ft / 9848 lb-ft
Maximum stalling time
18 s (warm)
Starting time
12 s (U=Un)
21 s (U=0,85 Un)
Number of consec. starts
4 / 2 (cold/warm)
Maximum number of starts
1000 / year
This performance data is final and the motor will be manufactured accordingly.

ABB Oy
MV Induction
Machines

Visiting Address
Strmbergintie 1 B
HELSINKI

Postal Address
P.O.Box 186
FIN-00381 HELSINKI
Finland

Telephone
+358 10 222 000

Telefax
+358 10 222 3565

Classifying code or document type

ABB Oy

PERFORMANCE DATA OF MOTOR

MV Induction Machines
Department/Author

Date of issue

Lang.

Rev. date

Our ref.

PIE/M. Ikonen

14.10.02

En

27.01.03

8908HD300

Customer ref.

Saving Ident

Rev./Changed by

Pages

Pipa Norte

8002644C

C/M. Ikonen

2/2

Machine type code: HXR 400LK6


Rated output
Voltage
Frequency
Speed
Current

500 HP
4160 V
50 Hz
988 rpm
66 Amps

Power Factor
Rated torque
Locked rotor Amps
Locked rotor torque
Breakdown torque

0,83
2658 lb-ft
550 %
130 %
200 %

600

300

500

250

400

200

300

150

200

100

100

50

0
0

10

20

30

40

50

60

70

80

% Torque

% Current

Torque and Current vs. Speed

0
100

90

% Speed
A, V=100%
T, V=100%

A, V=95%
T, V=95%

A, V=90%
T, V=90%

A, V=85%
T, V=85%

A, V=80%
T, V=80%

Load Torque

ABB Oy
MV Induction
Machines

Visiting Address
Strmbergintie 1 B
HELSINKI

Postal Address
P.O.Box 186
FIN-00381 HELSINKI
Finland

Telephone
+358 10 222 000

Telefax
+358 10 222 3565

Classifying code or document type

ABB Oy
MV Induction Machines

DATOS DE MOTOR

Department/Author

Date of issue

Lang.

Rev. date

Our ref.

PIE/M. Ikonen

14.10.02

Sp

27.01.03

8908HD300

Customer ref.

Saving Ident

Rev./Changed by

Pages

Pipa Norte

8002646C

C/M. Ikonen

1/2

Mquina accionada: Machacadora


Tipo de motor
Tipo de rotor
Forma constructiva
Proteccin motor
Refrigeracin
Aislamiento
Factor de servicio
Normas
Temperatura ambiente, max.
Altitud, max.
Servicio
Potencia nominal en eje
Tensin
Frecuencia
Velocidad
Corriente
Corriente rotor bloqueado
Par rotor bloqueado
Par mximo
Corriente en vaco
Par nominal
Caractersticas en carga
Carga %

HXR 400LK6
Jaula de Ardilla
Horizontal
TEFC
TEFC
Clase F
1.15 calentamiento 100 C RTD
NEMA MG1
40 C
7217 ft.s.n.m.
Continuo
500 HP
4160 V
50 Hz
988 rpm
66 Amps
550 % Code F
130 %
200 %
24 Amps
2658 lb-ft
Corriente
Rend. %
Factor Pot.
Amps
100
66
95,4
0,83
75
51
95,5
0,80
50
38
95,0
0,71
Conexin del bobinado del estator
Estrella
Sentido de rotacin
Bi-direccional
Nivel de ruido: (aliment. senoidal, en vaco)
75 dB(A), tol. + 3 dB(A), 3 ft
Inercia rotor / carga
441,6 lb-ft / 9848 lb-ft
Tiempo max. rotor bloqueado
18 s (Caliente)
Tiempo arranque
12 s (U=Un)
21 s (U=0,85 Un)
Nmero arranques consecutivos
4 / 2 (Fro/Caliente)
Max. nmero de arranques
1000 / ao
Estos datos son finales y el motor ser fabricado segn estos.

ABB Oy
MV Induction
Machines

Visiting Address
Strmbergintie 1 B
HELSINKI

Postal Address
P.O.Box 186
FIN-00381 HELSINKI
Finland

Telephone
+358 10 222 000

Telefax
+358 10 222 3565

Classifying code or document type

ABB Oy

DATOS DE MOTOR

MV Induction Machines
Department/Author

Date of issue

Lang.

Rev. date

Our ref.

PIE/M. Ikonen

14.10.02

Sp

27.01.03

8908HD300

Customer ref.

Saving Ident

Rev./Changed by

Pages

Pipa Norte

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C/M. Ikonen

2/2

Tipo de motor: HXR 400LK6


Potencia nominal en eje
Tensin
Frecuencia
Velocidad
Corriente

500 HP
4160 V
50 Hz
988 rpm
66 Amps

Factor Pot.
Par nominal
Corriente rotor bloqueado
Par rotor bloqueado
Par mximo

0,83
2658 lb-ft
550 %
130 %
200 %

% Corriente

Par y Corriente en Funcin de la Velocidad


600

300

500

250

400

200

300

150 % Par

200

100

100

50

0
0

10

20

30

40

50

60

70

80

90

0
100

% Velocidad
A, V=100%
T, V=100%

A, V=95%
T, V=95%

A, V=90%
T, V=90%

A, V=85%
T, V=85%

A, V=80%
T, V=80%

Par resistente

ABB Oy
MV Induction
Machines

Visiting Address
Strmbergintie 1 B
HELSINKI

Postal Address
P.O.Box 186
FIN-00381 HELSINKI
Finland

Telephone
+358 10 222 000

Telefax
+358 10 222 3565

ABB

TEST REPORT

TEST REPORT FOR ASYNCHRONOUS MACHINES

Customer:
Project:
Order ref.:

ABB AUTOMATION PRODUCTS GMBH


Krupp/Crusher motor for copper mine, Chile
APR/VLM241858, Krupp/Crusher motor for
copper mine

Machine:
Work nr:
Serial nr:

HXR 400LK6
8908HD300
4572698

Date:

20.01.2003

Approved on the behalf of manufacturer:


Tarmo Juntunen

ABB OY, Electrical Machines


Visiting Address
Strmbergintie 1
HELSINKI

Postal Address
P.O. Box 186
FIN-00381 HELSINKI
Finland

Telefax (Group)
+358 10 22 22330
Telefax (Test Floor)
+358 10 22 23692

ABB

TEST REPORT

Customer:

Machine:

Page:

ABB AUTOMATION PRODUCTS GMBH

HXR 400LK6

2/4

Order ref.:

Work nr:

Serial nr:

Revision

APR/VLM241858, Krupp/Crusher motor for copper mine

8908HD300

4572698

Project:

Approved:

Krupp/Crusher motor for copper mine, Chile

Report rev:
Tarmo Juntunen

Ratings
Machine:
Standards

NEMA MG 1

Insulation class
Temperature class
Ambient temp. max
f [Hz]

Conn.

50,0

F
B
40,0 C

IM 1001
IP TEFC

P [H.P.]

U [V]

500

4160

I [A]

p.f.

Direction n [rpm]

66 0,83

Table of contents / Test Program


1) Visual inspection
2) Insulation resistances before tests
3) Resistance measurement of windings and elements
4) Short circuit point
5) Direction of rotation and phase sequence
6) Vibration measurement
7) No-load point
8) High voltage test
9) Insulation resistances after tests

<==>

Duty

988 Continuous

ABB

TEST REPORT

Customer:

Machine:

Page:

ABB AUTOMATION PRODUCTS GMBH

HXR 400LK6

3/4

Order ref.:

Work nr:

Serial nr:

Revision

APR/VLM241858, Krupp/Crusher motor for copper mine

8908HD300

4572698

Project:

Approved:

Krupp/Crusher motor for copper mine, Chile

Report rev:

Tarmo Juntunen

1) Visual inspection
Version

Test bay

PIT 60

Notes:

Author:

OK

Tarmo Juntunen

2) Insulation resistances before tests


== 21,1 C
Winding
Stator

R [Mohm]
39400

U [V]
1000
Temperature detectors
Stator

R [Mohm]
505000

U [V]
500

3) Resistance measurement of windings and elements


== 20.0 C
Winding
Stator

Ruv [ohm]

Ruw [ohm]

Rvw [ohm]

0,39350

0,39350

0,39340

== 21,1 C
Terminals
1- 2, 3
4- 5, 6
7- 8, 9
10-11,12
13-14,15
16-17,18

R [ohm]
107,9
108,1
108,2
108,1
108,2
108,2

Position
T3-phase
T2-phase
T1-phase
T3-phase
T2-phase
T1-phase

Detector
PYR PT100LG4/4EX
PYR PT100LG4/4EX
PYR PT100LG4/4EX
PYR PT100LG4/4EX
PYR PT100LG4/4EX
PYR PT100LG4/4EX

4) Short circuit point


Conn.
Y

f [Hz]
50,0

U1 [V]
907,0

I1 [A]
66,0

P1 [kW]
p.f.
17,9 0,173

[C]
21,1

Ik [A]
302,53

5) Direction of rotation and phase sequence


Result
Notes:

U-V-W | L1-L2-L3 | ==> (CW)


OK

6) Vibration measurement
Operating conditions
f = 50,0 Hz
U = 4160 V
Measured values
Bearing position Horizontal
D-END
0,625
ND-END
0,508

I = 24,4 A
Vertical
0,590
0,488

Axial
0,634

Mounting Rigid
Measuring equipment
Unit
Meas. device
mm/s PEAK
CSI 1910, PIT60
mm/s PEAK
CSI 1910, PIT60

Un [V]
4160

ABB

TEST REPORT

Customer:

Machine:

Page:

ABB AUTOMATION PRODUCTS GMBH

HXR 400LK6

4/4

Order ref.:

Work nr:

Serial nr:

Revision

APR/VLM241858, Krupp/Crusher motor for copper mine

8908HD300

4572698

Project:

Approved:

Krupp/Crusher motor for copper mine, Chile

Report rev:

Tarmo Juntunen

7) No-load point
Conn.
Y

f [Hz]
50,0

U1 [V]
4160,0

I1 [A]
24,43

P1 [kW]
p.f.
6,9 0,039

[C]
31,1

Direction
CW

8) High voltage test


Stator

U [V]
10400

t [min]
1

f [Hz] Temperature detectors


Stator
50

U [V]
1500

t [min]
1

f [Hz]
50

9) Insulation resistances after tests


== 31,1 C
Winding
Stator

R1 [Mohm]
16700

t1 [s]
60

U [V]
1000
Temperature detectors
Stator

No of pages:

End of report

R [Mohm]
505000
Printed:

U [V]
500
22.1.2003
Tarmo Juntunen

Safety Instructions
AMA, AMB, AMG, AMH, AMK, AML, AMS, AMZ, HS, HXR

General

General safety regulations, specific agreements made for each work


site and safety precautions shown in this document must be
observed at all times.
2

Intended use

Electric machines have dangerous live and rotating parts and may
have hot surfaces. All operations serving transport, storage,
installation, connection, commissioning, operation and maintenance
shall be carried out by responsible skilled persons (in conformity
with EN 50 110-1 / DIN VDE 0105 / IEC 60364). Improper handling
may cause serious personal injury and damage to property. Danger!
These machines are intended for industrial and commercial
installations as components as defined in the Machinery Directive
(MD) 89/392/EEC. Commissioning is prohibited until conformity of
the end product with this directive has been established (follow
particular local safety and installation rules as e.g. EN 60204).
These machines comply with the harmonized series of standards
EN 60034 / DIN VDE 0530. Their use in hazardous areas is
prohibited unless they are expressly designed for such use (follow
additional instructions).
On no account, use degrees of protection IP 23 outdoors.
Air-cooled models are typically designed for ambient temperatures
of -20C up to +40C and altitudes of 1000 m above sea level.
Ambient temperature for air-/water-cooled models should be not
less than +5C (for sleeve-bearing machines, see manufacturer's
documentation). By all means, take note of deviating information on
the rating plate. Field conditions must conform to all rating plate
markings.
3

Transport, storage

Immediately report damage established after delivery to transport


company. Stop commissioning, if necessary. Lifting eyes are
dimensioned for the weight of the machine, do not apply extra loads.
Ensure the use of correct lifting eyes. If necessary, use suitable,
adequately dimensioned means of transport (e.g. rope guides).
Remove shipping braces (e.g. bearing locks, vibration dampers)
before commissioning. Store them for further use.
When storing machines, make sure of dry, dust and vibrarion free
location (danger of bearing damage at rest). Measure insulation
resistance before commissioning. At values of 1k per volt of
rated voltage, dry winding. Follow manufacturer's instructions.
4

Installation

Make sure of even support, solid foot or flange mounting and exact
alignment in case of direct coupling. Avoid resonances with
rotational frequency and double mains frequency as a result of
assembly. Turn rotor and listen for abnormal slip noises. Check
direction of rotation in uncoupled state.
Follow manufacturers instructions when mounting or removing
couplings or other drive elements and cover them with a touch
guard. For trial run without output elements, lock or remove the shaft
end key. Avoid excessive radial and axial bearing loads (note
manufacturer's documentation). The balance of the machine is
indicated as H = Half and F = Full key. With half-key models, the
coupling too, must be half-key balanced. In case of protruding,
visible part of the shaft end key, establish mechanical balance.

Electrical connection

All operations must be carried out only by skilled persons on the


machine at rest. Before starting work, the following safety rules must
be strictly applied:

De-energize!

Provide safeguard against reclosing!

Verify safe isolation from supply!

Connect to earth and short!

Cover or provide barriers against neighbouring live parts!

De-energize auxiliary circuits (e.g. anti-condensation heating)!

Exceeding of limit values of zone A in EN 60034-1 / DIN VDE


0530-1 - voltage 5%, frequency 2%, waveform and symmetry leads to higher temperature rise and affects the electromagnetic
compatibility. Note rating plate markings and connection diagram in
the terminal box.
The connection must be so made that permanent safe electrical
connection is maintained. Use appropriate cable terminals. Establish
and maintain safe equipotential bonding.
The clearances between uninsulated live parts and between such
parts and earth must not be below the following values: 8 mm at
UN 550 V, 10 mm at UN 725 V, 36 mm at UN 3.3 kV, 60 mm
at UN 6.6 kV and 100 mm at UN 11 kV.
No presence of foreign bodies, dirt or moisture is allowed in the
terminal box. Close unused cable entrance holes and the box itself
in a dust- and watertight manner. Lock the key when the machine is
run without coupling. For machines with accessories, check
satisfactory functioning of these before commissioning.
The proper installation (e.g. segregation of signal and power lines,
screened cables etc.) lies within the installer's responsibility.
6

Operation

Vibration severity in the "satisfactory" range (Vrms 4.5 mm/s)


according to ISO 3945 is acceptable in coupled-mode operation. In
case of deviations from normal operation - e.g. elevated temperature,
noises, vibrations - disconnect machine, if in doubt. Establish cause
and consult manufacturer, if necessary.
Do not defeat protective devices, not even in trial run. In case of
heavy dirt deposits, clean cooling system at regular intervals. Open
closed condensate drain holes from time to time.
Grease the bearings during commissioning before start-up.
Regrease antifriction bearings while the machine is running. Follow
instructions on lubrication plate. Use right kind of grease. In case of
sleeve-bearing machines, observe time-limit for oil-change and if
equipped with oil supply system make sure the system is working.
7

Maintenance and servicing

Follow manufacturer's operating instructions. For further details, see


the comprehensive Users Manual. Preserve these safety
instructions!

Make necessary ventilation and cooling system connections. The


ventilation must not be obstructed and the exhaust air, also of
neighbouring sets, not taken in directly.

Safety and Ex-instructions-EN

ABB Industry Oy

2001-02-14

1(2)

Additional Safety Instructions for Electrical


Motors for Hazardous Areas
Note
These instructions must be followed to ensure safe and proper
installation, operation and maintenance of the motor. They should
be brought to the attention of anyone who installs, operates or
maintains this equipment. Ignoring the instruction may invalidate the
warranty.

Warning
Motors for hazardous areas are specially designed to comply with
official regulations concerning the risk of explosion. If improperly
used, badly connected, or alter, no matter how minor, their reliability
could be in doubt.
Standards relating to the connection and use of electrical apparatus
in hazardous areas must be taken into consideration, especially
national standards for installation. Only trained personnel familiar
with these standards should handle this type of apparatus.

IEC 60079-7;
IEC 60079-15;
IEC 1241-1-1
BS 5000:16;

ABB machines (valid only for group II) can be installed in areas
corresponding to following marking:
Zone (IEC) Category (EN)

The Low Voltage Directive 73/23/EEC amended by Directive


93/68/EEC

EMC Directive 89/336/EEC, amended by Directives 92/31/EEC


and 93/68/EEC

Certificate of Incorporation with respect to the Machinery


Directive 89/392/EEC, amended by Directives 91/368/EEC,
93/44/EEC and 93/68/EEC

All ABB Ex-machines, which have a CE-mark on the rating


plate comply with the ATEX Directive 94/9/EC

Validity
These instructions are valid for the following ABB Industrys
electrical motor types, when the machine is used in explosive
atmospheres.

Increased safety EEx e, Ex e


- AMA Induction Machines, sizes 315 to 500
- HXR Induction Machines, sizes 315 to 560

Dust Ignition Protection (DIP)


- AMA Induction Machines, sizes 315 to 500
- HXR Induction Machines, sizes 315 to 560
(Additional information may be required for some machine types
used in special applications or with special design.)

Reception check
-

Immediately upon receipt check the machine for external


damage and if found, inform the forwarding agent without
delay.

Check all rating plate data, especially voltage, winding


connection (star or delta), category, type of protection and
temperature marking.

Warning !
Disconnect and lock out before working on the machine or the
driven equipment. Ensure no explosive atmosphere is present while
the work is in progress.
Starting and Re-starting
-

The maximum number of the sequential starts has been


declared in machines technical documents.

The new starting sequence is allowed after the machine has


cooled to the ambient temperature (-> cold starts) or to
operating temperature (-> warm starts).

Check before starting that all earthing and equipotentialing


couplings are effectively connected.

Do not remove any earthing or equipotentialing cables, which


has been assembled by the manufacturer.

Do not make any removal or adjustment in terminal boxes,


which could decrease clearances or creepage distances
between any parts.

Do not install any new equipment to terminal boxes without


asking for advises from ABB Industry Oy.

Be sure that air gap between rotor and stator is measured after
any maintenance for the rotor or bearings. The air gap shall be
the same in any point between stator and rotor.

Centralise the fan to the centre of the fanhood or the air guide
after any maintenance. The clearance shall be at least 1% of
the maximum diameter of the fan and in accordance with
standards.

Conformity
As well as conforming to the standards relating to mechanical and
electrical characteristics, motors designed for explosive
atmospheres must also conform to the following IEC or CENELEC
standards:

IEC 60079-2;

Safety and Ex-instructions-EN

Clearances, creepage distances and separations

Pressurisation EEx pe, Ex pe, EEx p, Ex p


- AMA Induction Machines, sizes 315 to 500
- HXR Induction Machines, sizes 315 to 560
- AMZ Synchronous Machines, sizes 710 to 2500

EN 50016;
EN 50019;
EN 50021;
EN 50281-1-1
IEC 60079-0;

EEx p, EEx pe ,EEx e


Ex p, Ex pe ,Ex e
Ex nA ,Ex N, EEx nA

Earthing and Equipotentialing

Non-sparking Ex nA, Ex N, EEx nA


- AMA Induction Machines, sizes 315 to 500
- HXR Induction Machines, sizes 315 to 560
- AMZ Synchronous Machines, sizes 710 to 2500

General norm concerning explosion-proof


material.
Std. concerning EEx p protection
Std. concerning EEx e protection
Std. concerning EEx nA protection
Std. concerning Dust Ignition Protection
Std. concerning General Requirements for
Explosive Atmospheres
Std. concerning Ex p protection

Notice following rules during any operations!

EN 50014;

Marking

Atmosphere (EN);
G explosive atmosphere caused by gases
D explosive atmosphere caused by dust

Declaration of Conformity
All ABB machines comply with:

Std. concerning Ex e protection


Std. concerning Ex nA protection
Std. concerning Dust Ignition Protection
Std. concerning Ex N protection

Connections in terminal boxes


-

All connections in main terminal boxes must be made with Exapproved connectors, which are delivered with the machine by
the manufacturer. In other cases ask an advice from ABB
Industry.

All connections, in auxiliary terminal boxes, as marked


intrinsically safe circuits (Ex i) must be connected to proper
safety barriers.

Note !
If there are any conflicts between this instruction and user manual,
this document is prevailing.

ABB Industry Oy

2001-02-14

2(2)

Instrucciones de seguridad
AMA, AMB, AMG, AMH, AMK, AMZ, HXR
1

Generales

En todo momento deben observarse las normativas generales relativas a la


seguridad, los acuerdos concretos para cada centro de trabajo y las
precauciones de seguridad indicadas en este documento.

Uso previsto

Los motores elctricos pueden tener superficies calientes y constan de piezas


con corriente y piezas giratorias que pueden ser peligrosas. Todas las
operaciones relacionadas con el transporte, almacenamiento, instalacin,
conexin, puesta en marcha, funcionamiento y mantenimiento deben ser
realizadas por personal debidamente cualificado (de conformidad con
EN 50 110-1 / DIN VDE 0105 / IEC 60364). El manejo inadecuado puede
causar lesiones personales graves y daos en la propiedad. Peligro!
Estos motores se han diseado para instalaciones industriales y comerciales
como componentes segn se define en la directiva sobre mquinas
89/392/EEC. Est prohibida su puesta en funcionamiento hasta que se haya
establecido la conformidad del producto final con esta directiva (seguir reglas
locales de instalacin y seguridad como, por ejemplo, EN 60204).
Estos motores cumplen las series armonizadas de las normativas EN 60034 /
DIN VDE 0530. Est prohibida su utilizacin en zonas peligrosas a menos
que se hayan diseado expresamente para tal uso (seguir instrucciones
adicionales).
Bajo ningn concepto, utilice grados de proteccin IP 23 en exterior. Los
modelos refrigerados por aire estn diseados normalmente para
temperaturas ambiente de -20C hasta +40C y altitudes de 1000 m por
encima del nivel del mar. La temperatura ambiente para modelos refrigerados
por aire/agua no debera ser inferior a los +5C (para motores con cojinetes
deslizantes, consulte la documentacin del fabricante). Preste atencin a la
informacin de desviacin de la placa de caractersticas. Las condiciones de
uso deben cumplir todos los marcados de la placa de caractersticas.

Transporte, almacenamiento

Comunique de inmediato a la empresa de transportes los daos establecidos tras


la entrega. Interrumpa la puesta en funcionamiento, si es necesario. Los
cncamos de elevacin se dimensionan para el peso del motor, no aplique
cargas adicionales. Asegrese de utilizar los cncamos de elevacin
adecuados. Si es preciso, utilice medios de transporte adecuados y
correctamente dimensionados (por ejemplo, guas de cable). Retire los
soportes de envo (por ejemplo, bloqueos de rodamientos, amortiguadores de
vibraciones) antes de poner el motor en funcionamiento. Gurdelos para
futuros usos.
Asegrese de almacenar los motores en un lugar seco, sin polvo y que no
est sometido a vibraciones (peligro de deterioro de los rodamientos durante
el almacenamiento). Mida la resistencia del aislamiento antes de ponerlos en
funcionamiento. A valores de 1k por voltio de voltaje nominal, seque el
devanado. Siga las instrucciones del fabricante.

Instalacin

Cubrir o proporcionar proteccin frente a las piezas con corriente


contiguas

Desconectar los
anticondensacin)

Siga las instrucciones del fabricante al montar o desmontar acoplamientos u


otros elementos de accionamiento y cbralos con una proteccin de contacto.
Para el funcionamiento de prueba sin elementos de salida, bloquee o retire la
chaveta del eje. Evite las sobrecargas radiales y axiales del rodamiento
(tenga en cuenta la documentacin del fabricante). El equilibrado del motor
se indica como H = media chaveta y F = chaveta entera. En los modelos de
media chaveta, el acoplamiento tambin debe estar equilibrado con media
chaveta. En caso de que sobresalga la parte visible de la chaveta del eje,
establezca un equilibrio mecnico.
Efecte las conexiones necesarias de los sistemas de ventilacin y
refrigeracin. La ventilacin no debe estar bloqueada y el aire de salida,
tambin el de los conjuntos contiguos, no debe entrar directamente.

auxiliares

Desconectar de la fuente de energa

Proporcionar proteccin contra reconexin

Comprobar el aislamiento seguro con respecto a la fuente de energa

Conectar a tierra y cortocircuitar

ejemplo,

calefaccin

Las separaciones entre las piezas con corriente no aisladas y entre estas
piezas y tierra no deben ser inferiores a los siguientes valores: 8 mm
a UN 550 V, 10 mm a UN 725 V, 36 mm a UN 3,3 kV, 60 mm
a UN 6,6 kV y 100 mm a UN 11 kV.
En la caja de bornes no puede haber cuerpos extraos o polvo, ni permitirse
la condensacin de humedad. Cierre los orificios de entrada de cables que no
se utilicen de forma estanca y sin polvo. Fije la chaveta cuando la mquina
est funcionando sin acoplamiento. En el caso de los motores con
accesorios, compruebe su funcionamiento antes de poner en funcionamiento
el motor.
La correcta instalacin (por ejemplo, separacin de las lneas de alto voltaje y
de las de seales, cables apantallados, etc.) es responsabilidad del
instalador.

Funcionamiento

En funcionamiento en modo acoplado, se puede aceptar un nivel de vibracin


dentro de la gama "satisfactoria" (Vrms 4.5 mm/s) segn ISO 3945. En caso
de que se produzcan desviaciones con respecto al funcionamiento normal,
por ejemplo, temperaturas altas, ruidos, vibraciones, desconecte el motor en
caso de duda. Establezca la causa y consulte al fabricante, si es preciso.
No desactive los dispositivos de proteccin, ni siquiera durante el
funcionamiento de prueba. Si se acumula suciedad en grandes cantidades,
limpie el sistema de refrigeracin a intervalos peridicos. Abra de vez en
cuando los orificios de drenaje de condensacin cerrados.
Engrase los cojinetes durante la puesta en marcha, antes de arrancar.
Engrase de nuevo los cojinetes de rodamientos con el motor en marcha. Siga
las instrucciones de la placa de lubricacin. Utilice el tipo adecuado de grasa.
En los motores con cojinetes deslizantes, observe el tiempo lmite para el
cambio de aceite y, si estn equipados con un sistema de suministro de
aceite, compruebe que dicho sistema funciona.

Mantenimiento y reparaciones

Siga las instrucciones de funcionamiento del fabricante. Para ms detalles,


consulte el Manual del Usuario. Conserve estas instrucciones de seguridad.

Convertidores de frecuencia.

En aplicaciones con convertidor de frecuencia, es necesario utilizar una


toma a tierra exterior para igualar el potencial entre la carcasa y la mquina
accionada, a menos que ambas mquinas estn montadas sobre la misma
base metlica. En motores con carcasas superiores a IEC 280, utilice un
conductor plano de 0.75 x 70 mm o, como mnimo, dos conductores
cilndricos de 50 mm. La distancia entre los conductores cilndricos debe ser
como mnimo de 150 mm.
Esta disposicin no tiene una funcin de seguridad elctrica; el objetivo es
igualar los potenciales. Cuando se montan el motor y el reductor en una
misma bancada de acero comn, no es necesario realizar conexiones
equipotenciales.
Conexiones equipotenciales

U1
PE

V1

Platina

W1

Cables

3~M
> 150 mm

0.75 mm

(por

La conexin debe realizarse de tal forma que se mantenga una conexin


elctrica permanente y segura. Utilice terminales de cable adecuados.
Establezca y mantenga una conexin equipotencial segura.

Conexin elctrica

Todas las operaciones deben ser realizadas por personal cualificado con el
motor parado. Antes de realizar cualquier tarea de este tipo, deben aplicarse
estrictamente las siguientes reglas de seguridad:

Safety and Ex-instructions-SP

circuitos

Si se superan los valores lmite de la zona A en EN 60034-1 / DIN VDE 05301 - voltaje 5%, frecuencia 2%, forma de onda y simetra -, se puede
producir un aumento de la temperatura con efecto en la compatibilidad
electromagntica. Observe los marcados de las placas de caractersticas y el
diagrama de conexin de la caja de bornes.

Asegrese de disponer de un soporte uniforme, base resistente o brida de


montaje y una alineacin exacta en caso de acoplamiento directo. Evite las
resonancias con la frecuencia de giro y dobles principales frecuencias como
resultado del montaje. Gire el rotor y est atento a la presencia de ruidos de
deslizamiento anormales. Compruebe la direccin de giro en estado sin
acoplar.

Mquina accionada

70 mm

min 50 mm

Para satisfacer los requisitos de compatibilidad electromagntica (EMC)


utilicen slo cables y conectores aprobados para tal propsito (vase
instrucciones para convertidores de frecuencia).

ABB Oy Electrical Machines

2002-06-01

1(2)

Instrucciones de seguridad adicionales para


motores elctricos en reas peligrosas

IEC 60079-15;
IEC 1241-1-1
BS 5000:16;

Nota
Hay que seguir estas instrucciones para ofrecer una instalacin, un
funcionamiento y un mantenimiento correctos y seguros del motor.
Cualquiera que instale, opere o realice el mantenimiento de este
equipo debe tenerlas en cuenta. Ignorar estas instrucciones puede
invalidar la garanta.

Atencin
Los motores para reas peligrosas estn diseados especialmente
para satisfacer las normas oficiales referentes al riesgo de
explosin. Si se utilizan incorrectamente, si estn mal conectados o
sufren alguna modificacin, aunque sta sea menor, pueden perder
su fiabilidad.
Es necesario tener en cuenta las normas referentes a la conexin y
uso de aparatos elctricos en zonas peligrosas, especialmente las
normas nacionales sobre instalacin. nicamente personal
cualificado y familiarizado con dichas normas debera manejar este
tipo de mquinas.

Norma sobre la proteccin Ex nA


Norma sobre la proteccin por combustin de
polvo
Norma sobre la proteccin Ex N

Los motores de ABB (vlido slo para el grupo II) pueden instalarse
en zonas que correspondan a los siguientes marcados:
Zona (IEC) Categora (EN)
1

Marcado
EEx p, EEx pe ,EEx e
Ex p, Ex pe ,Ex e
Ex nA ,Ex N, EEx nA

Atmsfera (EN);
G atmsfera explosiva causada por gases
D atmsfera explosiva causada por polvo
Comprobacin de recepcin
-

A su recepcin, verifiquen inmediatamente si el motor


presenta daos externos y, en tal caso, informen sin demora
al agente de ventas correspondiente.

Comprueben los datos de la placa de caractersticas,


especialmente la tensin, la conexin del devanado (estrella o
tringulo), la categora, el tipo de proteccin y el tipo de
temperatura.

Tenga en cuenta las siguientes reglas durante todas las


operaciones!

Declaracin de conformidad
Todos los motores ABB deben cumplir:

Atencin

La directiva sobre baja tensin 73/23/CEE modificada por la


directiva 93/68/CEE

La directiva sobre compatibilidad electromag-ntica (EMC)


89/336/CEE, modificada por la 92/ 31/CEE y la 93/68/CEE

Desconecte antes de hacer cualquier comprobacin en el motor o


el equipo accionado. Asegrese de que no hay atmsfera explosiva
mientras se realizan los trabajos.

La declaracin de incorporacin en relacin a la directiva sobre


mquinas
89/392/CEE,
modificada
por
91/368/CEE,
93/44/CEE y 93/68/CEE

Arrancar y rearrancar

Los motores ABB con la marca CE en la placa de


caractersticas cumplen la directiva ATEX 94/9/EC

El nmero mximo de arranques en secuencia se indican en


la documentacin tcnica del motor.

La nueva secuencia de arranque se puede utilizar una vez que


el motor se ha enfriado a temperatura ambiente (-> arranques
en fro) o a la temperatura de funcionamiento (-> arranques en
caliente).

Validez
Estas instrucciones son vlidas para los siguientes tipos de
motores elctricos de ABB, cuando se utilizan en atmsferas
explosivas.
Antichispas Ex nA, Ex N, EEx nA
- Motores de induccin AMA, tamaos 315 a 500
- Motores de induccin AMB, tamaos 560 a 630
- Motores de induccin HXR, tamaos 315 a 560
- Motores sncronos AMZ, tamaos 710 a 2500

Conexiones a tierra y equipotenciales


-

Antes de arrancar, compruebe que todos los cables


equipotenciales y de toma de tierra estn bien conectados.

No retire ningn cable equipotencial o de toma de tierra que


haya montado el fabricante.

Holguras, longitudes de frotamiento y separaciones

Seguridad aumentada EEx e, Ex e


- Motores de induccin AMA, tamaos 315 a 500
- Motores de induccin AMB, tamaos 560 a 630
- Motores de induccin HXR, tamaos 315 a 560
Presurizacin EEx pe, Ex pe, EEx p, Ex p
- Motores de induccin AMA, tamaos 315 a 500
- Motores de induccin AMB, tamaos 560 a 630
- Motores de induccin HXR, tamaos 315 a 560
- Motores sncronos AMZ, tamaos 710 a 2500
Motores protegidos contra atmsferas explosivas polvorientas
- Motores de induccin AMA, tamaos 315 a 500
- Motores de induccin AMB, tamaos 560 a 630
- Motores de induccin HXR, tamaos 315 a 560

No elimine ningn componente ni realice ajuste alguno en las


cajas de bornes que pueda reducir las separaciones o
longitudes de frotamiento entre las piezas.

No instale ningn equipamiento nuevo en las cajas de bornes


sin consultar primero con ABB Oy.

Compruebe que el entrehierro entre el rotor y el esttor se


mide despus de realizar cualquier tarea de mantenimiento
del rotor o de los rodamientos. Este espacio debe ser igual en
cualquier punto entre el esttor y el rotor.

Coloque el ventilador en el centro de la campana de


ventilacin o de la gua de aire despus de realizar cualquier
tarea de mantenimiento. La separacin debe ser como mnimo
el 1% del dimetro mximo del ventilador segn las normas.

(Ciertos tipos de motores utilizados en aplicaciones especiales o


con diseo especial requerirn informacin adicional.)

Conexiones de las cajas de bornes

Conformidad

Todas las conexiones de las cajas de bornes principales


deben realizarse con conectores Ex- aprobados que son
entregados con la mquina por el fabricante. En otros casos
consulte a ABB Oy.

Todas las conexiones, en las cajas de bornes auxiliares,


marcados como circuitos de seguridad intrnseca (Ex i) deben
conectarse con apropiadas barreras de seguridad.

Adems de cumplir con las normas relacionadas con las


caractersticas mecnicas y elctricas, los motores diseados para
atmsferas explosivas deben cumplir las siguientes normas IEC o
CENELEC:
EN 50014;
EN 50016;
EN 50019;
EN 50021;
EN 50281-1-1
IEC 60079-0;
IEC 60079-2;
IEC 60079-7;

Norma general sobre los materiales


antiexplosivos
Norma sobre la proteccin EEx p
Norma sobre la proteccin EEx e
Norma sobre la proteccin EEx nA
Norma sobre la proteccin por combustin de
polvo
Norma relativa a los requisitos generales para
atmsferas explosivas
Norma sobre la proteccin Ex p
Norma sobre la proteccin Ex e

Safety and Ex-instructions-SP

Accesorios
-

Podr encontrar informacin adicional sobre los accesorios en


sus manuales correspondientes.

Nota
En caso de que estas instrucciones no coincidan con las del
manual del usuario, este documento tiene prioridad.

ABB Oy Electrical Machines

2002-06-01

2(2)

NEMA Induction motor


Machine Instructions

GB

ES

11

Motores NEMA de jaula de ardilla


Instrucciones

ABB Automation

Typical cutaway view of a squirrel cage induction,


horizontal motor
Tipica vista interna de un motor de induccin de jaula
de ardilla horizontal

ABB Motors

Machine instructions

Installation

Warning
These instructions must be followed to ensure safe
and proper installation, operation and maintenance
of the motor. They should be brought to the
attention of all the persons who install, operate or
maintain this equipment.

Uncrating and inspection

General information
ABB Motors are all fully factory tested and inspected before shipping. Damage during shipment and
storage can occur. Motors not correctly matched to
the power supply and/or the load will not operate
properly. These instructions are intended as a
guide to identify and eliminate these problems
before they are overlooked or cause further
damage.

Acceptance
Check carefully for any damage that may have
occured in transit. If any damage or shortage is
discovered, do not accept until an appropriate
notation on the freight bill is made. Any damage
discovered after receipt of equipment should be
immediately reported to the carrier.

Storage
A. Keep motors clean.
1. Store indoors.
2. Keep covered to eliminate airborne dust and
dirt.
3. Cover openings for ventilation, conduit
connections, etc. to prevent entry of rodents,
snakes, birds, and insects, etc.
B. Keep motors dry.
1. Store in a dry area indoors.
2. Temperature swings should be minimal to
prevent condensation.
3. Space heaters are recommended to prevent
condensation.
4. Treat unpainted flanges, shafts, and fittings
with a rust inhibitor.
5. Check insulation resistance before putting
motor into service.
C. Keep bearings lubricated.
1. Once per month, rotate shaft several turns to
distribute grease in bearings.
2. If unit has been stored more than one year,
add grease before start-up.

Transportation
Machines fitted with cylindrical-roller and/or angular
contact ball bearings shall be fitted with locking
devices during transport.

ABB Motors

After uncrating, check for any damage which may


have been incurred in handling. The motor shaft
should turn freely by hand. Repair or replace any
loose or broken parts before attempting to use the
motor.
Check to be sure that motor has not been exposed
to dirt, grit, or excessive moisture in shipment or
storage before installation.
Measure insulation resistance (see operation).
Clean and dry the windings as required.
Never start a motor which has been wet without
drying it thoroughly.

Safety
Motors should be installed, protected and fused in
accordance with latest issue of National Electric
Code, NEMA Standard Publication No. MG 2 and
local codes.
Eyebolts or lifting lugs are intended for lifting the
motor only. These lifting devices should never be
used when lifting or handling the motor with other
equipment (i.e. pumps, gear boxes, fans or other
driven equipment) as a single unit. Be sure the
eyebolt is fully threaded and tight in its mounting
hole.
Eyebolt lifting capacity ratings is based on a lifting
alignment coincident with the eyebolt centerline.
Eyebolt capacity reduces as deviation from this
alignment increases. See NEMA MG 2.
Rotating parts such as pulleys, couplings, external
fans, and shaft extensions should be permanently
guarded.

Location
In selecting a location for the motor, consideration
should be given to environment and ventilation. A
motor with the proper enclosure for the expected
operating condition should be selected.
The ambient temperature of the air surrounding the
motor should not exceed 40C (104F) unless the
motor has been especially designed for high
ambient temperature applications. The free flow of
air around the motor should not be obstructed.
The motor should never be placed in a room with a
hazardous process, or where flammable gases or
combustible material may be present, unless it is
specifically designed for this type of service.

1. Drip proof (open) motors are intended for use


indoors where atmosphere is relatively clean, dry
or non-corrosive.
2. Totally enclosed motors may be installed where
dirt, moisture and corrosion are present, or in
outdoor locations.

Electrical connections
Caution
Install and ground per local and national codes.
Consult qualified personnel with questions or if
repairs are required.

Refer to ABB for application assistance.

Floor mounting
Motors should be provided with a firm, rigid foundation, with the plane of four mounting pads flat
within .010 for 56 to 210 frame; .015 from 250
through 500 frame. This may be accomplished by
shims under the motor feet. For special isolation
mounting, contact ABB for assistance.

V-belt drive
1. Select proper belts and sheaves, do not over
belt. Excessive belt load will damage bearings.
Sheaves should be in accordance to NEMA
spec. MG-1 or as approved by the manufacturer
for a specific application.
2. Align sheaves carefully to avoid axial thrust on
motor bearing. The drive sheave on the motor
should be positioned toward the motor so it it as
close as possible to the bearing.
3. When adjusting belt tension, make sure the
motor is secured by all mounting bolts before
tightening belts.
4. Adjust belt tension to belt manufacturers recommendations. Excessive tension will decrease
bearing life.

Direct connected drive


Flexible or solid shaft couplings must be properly
aligned for satisfactory operation. On flexible
couplings, the clearance between the ends of the
shafts should be in accordance with the coupling
manufacturers recommendations or NEMA
standards for end play and limited travel in
coupling.
MISALIGNMENT and RUN-OUT between direct
connected shafts will cause increased bearing
loads and vibration even when the connection is
made by means of a flexible coupling. Excessive
misalignment will decrease bearing life. Proper
alignment, per the specifications of the coupling
being used, is critical.
Some large motors are furnished with roller
bearings. Roller bearings should not be used for
direct drive.

Warning
1. Disconnect power before working on motor or
driven equipment. It is necessary to make sure
that the rotor of the motor can neither be
energized electrically nor start to rotate by any
other means.
2. Motors with automatic thermal protectors will
automatically restart when the protector
temperature drops sufficiently. Do not use
motors with automatic thermal protectors in
applications where automatic restart will be
hazardous to personnel or equipment.
3. Motors with manual thermal protectors may start
unexpectedly after protector trips. If manual
protector trips, disconnect motor from power line.
After protector cools (five minutes or more) it can
be reset and power may be applied to motor.
4. Discharge all capacitors before servicing motor.
5. Always keep hands and clothing away from
moving parts.
6. Never attempt to measure the temperature rise
of a motor by touch. Temperature rise must be
measured by thermometer, resistance, imbedded
detector, or thermocouple. The temperature of
the outlet of the motor may be hot to touch
during normal operation.
7. Electrical repairs should be performed by trained
and qualified personnel only.
8. Failure to follow instructions and safe electrical
procedures could result in serious injury or
death.
9. If safety guards are required, be sure the guards
are in use.
1. All wiring, fusing, and grounding must comply
with National Electrical Codes and local codes.
2. To determine proper wiring, rotation and voltage
connections, refer to the information and diagram
on the name plate, separate connection plate or
decal. If the plate or decal has been removed,
contact ABB for assistance.
3. Use the proper size of line current protection and
motor controls as required by the National
Electrical Code and local codes. Recommended
use is 125% of full amps as shown on the name
plate for motors with 40C ambient and a service
factor over 1.0. Recommended use is 115% of
full load amps as shown on the name plate for all
other motors. Do not use protection with larger
capacities than recommended. Three phase
motors must have all three phases protected.

ABB Motors

Thermal protector information


The motors can be provided with thermal protection
device on request or as standard. The name plate
or a tape in the motor will indicate one of the
following:
1. Motor sizes 48 to 365 are not thermally protected. Motor without thermal protection will have
nothing stamped on the name plate about
thermal protection.
2. Motor sizes 404 and above have as standard 3
PTC thermistors for 150C connected in series in
the stator winding, other sizes on request.

Warning
Windings should be discharged immediately after
measurement to avoid risk of electric shock.
Insulation resistance is halved for each 20C rise
in ambient temperature.
2. If the reference resistance value is not attained,
the winding is too damp and must be oven dried.
Oven temperature should be 90C (194F) for
12-16 hours followed by 105C (223F) for 6-8
hours.

If the motor has separate connection diagrams,


follow the instructions given.

Drain hole plugs, if fitted, must be removed


during heating.

Changing rotation

Windings drenched in sea water normally need


to be rewound.

1. Keep hands and clothing away from rotating


parts.
2. Before the motor is coupled to the load, determine proper rotation.
3. Check rotation by jogging or bumping. Apply
power to the motor leads for a short period of
time, enough to just get motor shaft to rotate a
slight amount to observe shaft rotating direction.
4. Three phase - interchange any two (2) of the
three (3) line leads. Single phase - reconnect per
the connection diagram on the motor.

Reduced voltage starting


Motors used on reduced voltage starting, should be
carefully selected based upon power supply limitations and driven load requirements. The motors
starting torque will be reduced when using reduced
voltage starting. The elapsed time on the start step
should be kept as short as possible. Refer to ABB
for application assistance.

Operation
Warning
Disconnect and lock out before working on motor or
driven equipment.
Windings should be discharged immediately after
measurement to avoid risk of electric shock.

Before initial starting


1. Measure insulation resistance before
commissioning and when winding dampness is
suspected:

3. See that voltage and frequency stamped on


motor and control name plates correspond with
that of the power line.
4. Check all connections to the motor and control
with the wiring diagram.
5. Be sure rotor turns freely when disconnected
from the load. Any foreign matter in the air gap
should be removed.
6. Leave the motor disconnected from the load for
the initial start; it is desirable to operate the
motor without load for about one hour to test for
any localized heating in bearings and windings.
Check for proper rotation. Check for correct and
balanced voltage at the motor terminals. Check
no load amps.

Allowable voltage and frequency


range
If voltage and frequency are within the following
range, motors will operate, but with somewhat
different characteristics than obtained with correct
name plate values.
1. Voltage: Within 10% above or below the value
stamped on the name plate. On three phase
systems the voltage should be balanced within
1%. A small voltage unbalance will cause a
significant current unbalance.
2. Frequency: Within 5% above or below the value
stamped on the name plate.
3. Voltage and frequency together: Within 10%
(providing frequency above is less than 5%)
above or below values stamped on the name
plate.

Resistance, measured at 25C, shall exceed the


reference value, ie
R

20 x U
1000 + 2P

M ohm (measured with 500 V dc


Megger)

where U = voltage, P = output power, kW.

ABB Motors

Operation with inverters


When a squirrel cage motor is used with an inverter
the following must be done:
1. Always check:
a. The motor and inverter ratings.
b. Insulation level of motor.
c. Earth connection of motor and the driven
equipment.
2. Check if the motor will be operating at high
speeds:
a. Bearing type and lubrication.
b. Fan characteristics.
c. Critical speeds.
d. Maximum torque.
3. Check if the motor will be operating at low
speeds:
a. Bearing type and lubrication.
b. Motors cooling system.
c. Magnetic noise.

Cleanliness
Keep both the interior and exterior of the motor free
from dirt, water, oil and grease. Motors operating in
dirty places should be periodically disassembled
and thoroughly cleaned.

Condensation drain plugs


All the motors are equipped with closable plastic
drain plugs in the drain holes. The plugs are open
on delivery. When mounting the motors, make sure
that the drain holes face downwards. In the case of
vertical mounting, the upper plug must be hammered home completely. In very dusty environments,
both plugs should be hammered home.

5. Check the bearing condition by listening for


unusual noise, vibration measurement, bearing
temperature, inspection of spent grease or SPM
bearing monitoring.
When changes of conditions occur, dismantle the
motor, check the parts and replace if necessary.

Lubrication
Motors with permanently greased bearings.
Motors up to frame size 210 are normally provided
with permanently greased bearings of 2Z type.
Bearing types are specified in the name plate and
the respective product catalogues. Motors provided
with Z-bearings can be regreased by dismantling
the motor, cleaning the bearings and bearing
housings, and filling these with new grease to 5070%.
Guidelines for regreasing intervals are:
1. 20,000 to 40,000 duty hours for 4 pole or greater
motor.
2. 10,000 to 20,000 duty hours for 2 pole motors.
The shorter times are valid for larger frame sizes.
Motors with grease nipples.
Lubricate the motor while running. If grease outlet
plug fitted, remove temporarily when lubricating, or
permanently with automatic lubrication.
Warning
Always keep hands and clothing away from moving
parts.
If the motor is provided with a lubrication information plate, follow the values given, otherwise use
values as follows:
Amount of grease

Service
Warning
Disconnect and lock out before working on motor or
driven equipment.
Caution
Overgreasing bearings can cause premature
bearing and/or motor failure. The amount of grease
added should be carefully controlled.

General inspection
1. Inspect the motor at regular intervals.
2. Keep the motor clean and ensure free ventilation
flow.
3. Check the condition of shaft seals (i.e. V-ring)
and replace if it is necessary.
4. Check the conditions of connections and mounting and assembly bolts.

Frame size

Drive-end
grams
80
120
160
200
400
500
600

250
280
320
360
40_
44_-50_
58_

ounces
3
4.5
6
7
15
18
22

Non-drive end
grams
ounces
50
2
75
3
100
4
145
5
400
15
400
15
500
18

Ball bearings; lubrication intervals in duty hours


Frame
size

Grams

250-280
320-360
40_-44_
50_
58_

20
25
35
50
60

r/min
3600 3000

1800

1500

1000

3200
1800
800
800
-

6000
5500
5000
4600
4000

7000
6500
6000
5500
5000

9000
8500
8000
7500
7000

4200
3100
2000
2000
1000

500900
10000
9000
8500
8000
8000

Roller bearings; lubrication intervals in duty hours


320-360
40_-44_
50_
58_

25
35
50
60

900
400
400
-

1500
1000
1000
-

4300
3300
2700
2200

5000
4500
3800
3200

6500
6300
6000
5500

ABB Motors

7000
6800
6500
6000

The table is prepared for horizontally mounted


motors. Lubrication intervals for vertical motors are
half of the above values.
The grease amount in the table is used if small
quantities of fresh grease are replaced at regular
intervals as above.
As an alternative, when the machine is provided
with grease escape valves, fresh grease may be
pressed into the bearings until the old grease is
totally replaced.
The table values are based on 80C (176F)
bearing temperature. The values should be halved
for every 15K (59R) increase in bearing temperature. If the maximum bearing temperature is 70C
(158F), the table values may be doubled.
Warning
The maximum operating temperature of the grease
and bearings must not be exceeded.
Higher speed operation, i.e. inverter applications, or
lower speed with heavy loading will require shortened lubrication intervals. Consult ABB Motors in such
cases.

NOTE
For high speed motors (i.e. larger 2-pole motors),
check that the fn factor of the grease is sufficiently
high.
fn = Dm x n
Dm = average bearing diameter (mm)
n = rotational speed (rpm)
Warning
Many greases can cause skin irritation and eye
inflammation. Follow any precautions specified by
the manufacturer.

Spare parts
When ordering spare parts, the full type designation
and product code as stated on the name plate must
be specified.
If the machine is stamped with a serial
manufacturing number, this should also be given.

Typically a doubling of speed will require a reduction of lubrication intervals to approx. 50% of values
tabulated above.
Suitability of bearings for high speed operation
must also be checked.

Lubricants
When regreasing, use only special ball bearing
grease with the following properties:
1. Good quality lithium base or lithium complex
grease.
2. Base oil viscosity 100-140 cST at 40C (104F).
3. Consistency NI GI grade 2 or 3.
4. Temperature range -30C to +120C (-22F to
+248F), continuously.
Greases with the correct properties are available
from all the major lubricant manufacturers.
If the make of grease in changed and compatibility
is uncertain, lubricate several times at short intervals in order to displace the old grease.
Highly loaded and/or slowly rotating bearings
require EP-grease. If lubrication intervals are short
due to bearing temperatures of 80C (176F) or
above, use high temperature greases which
normally permit approximately 15 K higher bearing
temperatures.
If the ambient temperature is below 25C (-13F)
consult ABB Motors regarding the possible use of
low temperature grease.

ABB Motors

Troubleshooting
Warning
1. Disconnect power before working on motor or
driven equipment. It is necessary to make sure
that the rotor of the motor can neither be
energized electrically nor start to rotate by any
other means. Apply this also for the driven
equipment.
2. Motors with automatic thermal protectors will
automatically restart when the protector temperature drops sufficiently. Do not use motors with
automatic thermal protectors in applications
where automatic restart will be hazardous to
personnel or equipment.
3. Motors with manual thermal protectors may start
unexpectedly after protector trips. If manual
protector trips, disconnect motor from power line.
After protector cools (five minutes or more) it can
be reset and power may be applied to motor.
4. Discharge all capacitors before servicing motor.
5. Always keep hands and clothing away from
moving parts.
6. Never attempt to measure the temperature rise
of a motor by touch. Temperature rise must be
measured by thermometer, resistance, imbedded
detector, or thermocouple. The temperature of
the outlet of the motor may be hot to the touch
during normal operation.
7. Electrical repairs should be performed by trained
and qualified personnel only.
8. Failure to follow instructions and safe electrical
procedures could result in serious injury or
death.
9. If safety guards are required, be sure the guards
are in use.

If trouble is experienced in the operation of the


motor, make sure that:
1. The bearings are in good condition and operating
properly.
2. There is no mechanical obstruction to prevent
rotation in the motor or in the driven load.
3. The air gap is uniform.
4. All bolts and nuts are tightened securely.
5. Proper connection to drive machine or load has
been made.
In checking for electrical troubles, be sure that:
1. The line voltage and frequency correspond to the
voltage and frequency stamped on the rating
plate of the motor.
2. The voltage is actually available at motor
terminals.
3. The fuses and other protective devices are in
proper condition.
4. All connections and contacts are properly made
in the circuits between the control apparatus and
motor.

ABB Motors

These instructions do not cover all details or variations in equipment nor provide for every possible condition
to be met in connection with installation, operation or maintenance. Should additional information be desired
for the purchasers purposes, the matter should be referred to the nearest ABB Sales Office.

Motor trouble shooting chart


Your motor service and any trouble shooting must be handled by qualified persons who have proper tools
and equipment.
TROUBLE

CAUSE

WHAT TO DO

Motor fails to start

Blown fuses
Overload trips
Improper power supply

Replace fuses with proper type and rating.


Check and reset overload in starter.
Check to see that power supplied agrees with
motor name plate and load factor.
Check connections with diagram supplied with
motor.
Indicated by humming sound when switch is
closed. Check for loose wiring connections. Also
see that all control contacts are closing.
Check to see if motor and drive turn freely. Check
bearings and lubrication.
Indicated by blown fuses. Motor must be rewound.
Remove end bells, locate with test lamp.
Look for broken bars or end rings.
Reduce load.

Improper line connections


Open circuit in winding or control switch

Mechanical failure
Short circuited stator
Poor stator coil connection
Rotor detective
Motor may be overloaded
Motor stalls

One phase may be open


Wrong application
Overload
Low voltage
Open circuit

Check lines for open phase.


Change type or size. Consult manufacturer.
Reduce load.
See the name plate voltage is maintained. Check
connection.
Fuses blown, check overload relay, stator and
push buttons.

Motor runs and then dies


down

Power failure

Check for loose connections to line, to fuses and to


control.

Motor does not come up


to speed

Not applied properly


Voltage too low at motor terminals
because of line drop

Open primary circuit

Consult supplier for proper type.


Use higher voltage or transformer terminals or
reduce load. Check connections. Check
conductors for proper size.
Check load motor is supposes to carry at start.
Look for cracks near the rings. A new rotor may be
required as repairs are usually temporary.
Locate fault with testing device and repair.

Motor takes too long to


accelerate and/or draws
high amp

Excessive load
Low voltage during start
Defective squirrel cage rotor
Applied voltage too low

Reduce load.
Check for high resistance. Adequate wire size.
Replace with new rotor.
Get power company to increase power tap.

Wrong rotation

Wrong sequence of phases

Reverse connections at motor or at switchboard.

Motor overheats while


running underload

Overload
Frame or bracket vents may be clogged
with dirt and prevent proper ventilation of
motor
Motor may have one phase open

Reduce load.
Open vent holes and check for a continuous
stream of air from the motor.

Starting load too high


Broken rotor bars or loose rotor

Grounded coil
Unbalanced terminal voltage

ABB Motors

Check to make sure that all leads are well


connected.
Locate and repair.
Check for faulty leads, connections and
transformers.

TROUBLE

CAUSE

WHAT TO DO

Motor vibrates

Motor misaligned
Weak support
Coupling out of balance
Driven equipment unbalanced
Defective bearings
Bearings not in line
Balancing weights shifted
Polyphase motor running single phase
Excessive end play

Realign.
Strengthen base.
Balance coupling.
Rebalance driven equipment.
Replace bearings.
Line up properly.
Rebalance motor.
Check for open circuit.
Adjust bearing or add shim.

Unbalanced line current


on polyphase motors
during normal operations

Unequal terminal volts


Single phase operation
Unbalanced voltage

Check leads and connections.


Check for open contacts.
Correct unbalanced power supply.

Scraping noise

Fan rubbing air shield


Fan striking insulation
Loose on bedplate

Remove interference.
Clear fan.
Tighten holding bolts.

Noisy operation

Airgap not uniform


Rotor unbalance

Check and correct bracket fits or bearing.


Rebalance.

Hot bearings general

Bent or sprung shaft


Excessive belt pull
Pulleys too far away
Pulley diameter too small
Misalignment

Straigthen or replace shaft.


Decrease belt tension.
Move pulley closer to motor bearing.
Use larger pulleys.
Correct by realignment of drive.

Hot bearings ball

Insufficient grease
Deterioration of grease or lubricant
contaminated
Excess lubricant

Maintain proper quality of grease in bearing.


Remove old grease, wash bearings thoroughly in
kerosene and replace with new grease.
Reduce quantity of grease, bearing should not be
more than 1/2 filled.
Check alignment, side and end thrust.
Replace bearing, first clean housing thoroughly.

Overloaded bearing
Broken ball or rough races

10

ABB Motors

Instrucciones de puesta
en marcha
Advertencia
Se deben seguir estas instrucciones para asegurar
una instalacin correcta, segura y un funcionamiento y mantenimiento adecuados del motor. Se
debe asegurar de que el personal que lo instale, lo
ponga en marcha y efecte el mantenimiento, las
conozcan.

Informacin general
Todos los motores de ABB se prueban e
inspeccionan antes de su expedicin. Pueden
daarse durante la expedicin y almacenamiento.
Los motores que no se conectan adecuadamente a
la red y/o a la carga no funcionaran correctamente.
Estas instrucciones sirven como gua para
identifica y eliminar esos problemas antes de que
sea demasiado tarde y pueden causar daos.

Aceptacin
Comprobar cuidadosamente los daos posibles
que puedan haber ocurrido durante el transporte. Si
se descubre algn dao o deficiencia, no se debe
aceptar el motor sin antes hacer la correspondiente
notificacin al transportista.

Almacenamiento
A. Mantener los motores limpios.
1. Almacenarlos en lugares cubiertos.
2. Mantenerlos cubiertos para eliminar el polvo
y la suciedad
3. Tapar los canales de ventilacin y las
aberturas de las cajas de conexin, etc.
para prevenir la entrada de roedores,
serpientes, pjaros e insectos.
B. Mantener los motores secos.
1. Almacenarlos en lugares secos y cubiertos
2. Para prevenir condensaciones evitar
fluctuaciones de temperatura.
3. Se recomiendan resistencias calefactoras
para prevenir la condensacin
4. Tratar las partes no pintadas, ejes y otros
accesorios con inhibidor anticorrosivo.
5. Comprobar la resistencia de aislamiento
antes de ponerlos en servicio.
C. Mantener los rodamientos engrasados.
1. Una vez cada mes, hacer girar el eje varias
vueltas para repartir la grasa en el
rodamiento.
2. Si el motor ha estado almacenado ms de
un ao, engrasar antes de ponerlo en
marcha.

ABB Motors

Transporte
Los motores que lleven rodamientos de rodillos y/o
de contacto angular deben ser suministrados con
un dispositivo de bloqueo para el transporte.

Instalacin
Desempaque e inspeccin
Despus del desempaque, comprobar si se ha
daado el motor, debido a su manejo. El eje debe
girar libremente accionndolo con la mano.
Reparar o reponer las partes aflojadas o rotas
antes de poner en marcha el motor.
Comprobar que el motor no tenga polvo, suciedad
o humedad excesiva.
Medir la resistencia de aislamiento (ver funcionamiento). Limpiar y secar el bobinado si es
necesario.
Nunca poner en marcha el motor que se haya
mojado sin haberlo secado completamente.

Seguridad
Los motores se deben instalar con sus
protecciones y fusibles adecuados de acuerdo con
las normas de National Electric Code, normas
NEMA Publicacin No. MG2 y recomendaciones
locales.
Hay unos cncamos previstos solo para el movimiento del motor. No se deben utilizar estos
cncamos para el movimiento del motor con otros
equipos (bombas, reductores, ventiladores u otros
equipos) que formen una unidad. Asegurarse de
que los cncamos estn completamente atornillados en sus respectivos agujeros roscados.
La capacidad de carga de estos cncamos est
basada en el levantamiento alineado con su lnea
central. Su capacidad se reduce cuando hay
desviaciones de este alineamiento. Ver NEMA
MG2.
Las partes giratorias tales como poleas, acoplamientos, ventiladores externos, y segundas salidas
de eje deben estar permanentemente protegidas.

Lugar de funcionamiento
Al seleccionar el lugar de funcionamiento del motor,
se debe haber considerado el ambiente y la
ventilacin. Se debe seleccionar un motor con una
carcasa de proteccin apropiadas para las
condiciones de funcionamiento deseadas.
La temperatura ambiente no ser superior a 40C
(104F) a menos que ya se haya seleccionado el
motor para temperaturas ambientes superiores. Se
debe asegurar una ventilacin sin obstculos al
rededor del motor..

11

El motor no se debe colocar en lugares con


procesos peligrosos, o donde existan, gases
inflamables o material combustible, a menos que
haya sido especialmente diseado para estos
ambientes.
1. Los motores abiertos son adecuados para
funcionar en locales protegidos y donde existan
atmsferas limpias, secas y no corrosivas.
2. Los motores totalmente cerrados pueden ser
instalados donde haya suciedad, humedad y
corrosin o a la intemperie.
Consultar con las agencias de ABB.

Cimentacin
Los motores se den instalar sobre una base firme y
rgida, en un plano, que tenga cuatro pernos de
anclaje, nivelado con .010 para carcasa de 56 a
210, y .015 para carcasas de 250 a 500. Se deben
colocar galgas debajo de las patas del motor para
que quede completamente alineado. Para
cimentaciones especiales consultar con ABB.

Acople por correas V


1. Seleccionar las correas y poleas adecuadamente, no poner ms correas de lo necesario.
Una carga excesiva de las correas daara a
los rodamientos. Las poleas deben estar de
acuerdo con NEMA MG-1 o aprobadas por el
fabricante para una aplicacin especifica.
2. Alinear las poleas cuidadosamente para evitar
cargas axiales en los rodamientos del motor.
La polea de accionamiento del motor debe
estar colocada lo ms cerca posible del
rodamiento.
3. Al ajustar el tiro de las correas, asegurarse de
que el motor est bien sujeto en los anclajes.
4. Ajustar el tiro de las correas a las recomendaciones del fabricante. Un tiro excesivo reducir
la vida de los rodamientos.

Acople directo a la carga


Los acoplamientos directos o flexibles deben estar
bien alineados para obtener un funcionamiento
satisfactorio. En los acoplamientos flexibles, el
espacio entre los finales de los ejes debe estar de
acuerdo con las recomendaciones del fabricante o
a las normas NEMA.
Un mal alineamiento y salto entre ejes con
acoplamiento directo causar un incremento de la
carga en los rodamientos y vibraciones an cuando
el acoplamiento sea flexible. Un desalineamiento
excesivo reducir la vida de los rodamientos. Un
alineamiento correcto, segn las especificaciones
del acople utilizado, es fundamental.
Algunos motores grandes se suministran con
rodamientos de rodillos. No deben utilizarse
rodamientos de rodillos para acoplamiento directos.

12

Conexiones elctricas
Precaucin
Siempre conectar a una tierra efectiva segn los
cdigos nacionales. Consultar con personal
cualificado por si son necesarias mejoras o
reparaciones en la instalacin.
Advertencia
1. Siempre desconectar el voltaje antes de
trabajar con un motor o equipo. Es necesario
asegurarse de que el rotor del motor nunca se
pueda poner a girar.
2. Los motores equipados con protectores trmicos pueden rearmarse automticamente
cuando la temperatura de dichos protector
disminuya. Nunca utilizar motores con
protectores trmicos automticos en aplicaciones donde un rearme automtico pueda ser
peligroso para el personal o el equipo.
3. Los motores con protectores trmicos manuales pueden rearmarse inesperadamente
despus de su disparo. Si el protector manual
dispara, desconectar el motor de la lnea
elctrica. Despus del enfriamiento del
protector (unos 5 minutos o ms) puede ser
rearmado y volver a conectar la lnea elctrica
del motor.
4. Descargar todos los capacitores antes de
manipular un motor.
5. Siempre mantener alejadas las manos y ropas
de la partes en movimiento.
6. Nunca intentar medir la temperatura de un
motor con el tacto. Las temperaturas deben
medirse con un termmetro, resistencia o
termopar. La temperatura en el conducto de
salida del aire de un motor puede estar muy
caliente para tocarla durante el funcionamiento
normal.
7. Las reparaciones elctricas debe ser efectuadas por personal cualificado.
8. De no seguirse las instrucciones y los procedimientos elctricos de seguridad pueden causar
accidentes y hasta la muerte.
9. Si se requieren protecciones de seguridad,
asegurarse de que no han caducado.
1. Los cableados, los fusibles y las tierras deben
cumplir con National Electrical Codes y normas
locales.
2. Para determinar las conexiones correctas,
sentido de giro y voltaje, ver la informacin de
la placa de caractersticas y placas adicionales.
Si la placa de caractersticas se ha perdido,
contactar con ABB para informacin.
3. Utilizar el calibre correcto de la proteccin de
lnea y controles del motor segn National
Electrical Codes y normas locales. Una
prctica recomendada es 125% de la corriente
nominal de la placa de caractersticas del
motor a 40C de temperatura ambiente y factor
de servicio 1.0. Utilizar 115% de la corriente
ABB Motors

nominal segn la placa de caractersticas para


otros motores. Nunca utilizar protecciones de
mayor capacidad que las recomendadas. Los
motores trifsicos deben tener una proteccin
trifsica.

Informacin de protectores
trmicos
Sobre pedido o como estandar los motores pueden
ser suministrados con protectores trmicos. Una
placa de caractersticas o una calcomana indicar
una de las modalidades siguientes:
1. Los motores tamaos 48 al 365 no llevan
proteccin trmica y por lo tanto no se indica
en la placa de caractersticas.
2. Los motores 404 y superiores llevan como
estandar 3 termistores PTC para 150C, en el
devanado del estator, conectados en serie.
Para los otros tamaos de motores sobre
demanda.
Si los motores llevan diagrama de conexiones
separado, seguir sus instrucciones.

Cambio de sentido de giro


1. Mantener las manos y la ropa alejadas de las
partes giratorias.
2. Antes de que el motor sea acoplado a la
carga, verificar el sentido de giro.
3. Comprobar el sentido de giro con impulsos.
Conectar la lnea a las terminales del motor por
poco tiempo, justo para hacer girar el rotor
media vuelta para saber su sentido de giro.
4. Para giro en sentido contrario invertir 2 de los 3
hilos de lnea. En motores monofsicos
reconectar segn el esquema de conexiones
del motor.

Voltaje de arranque reducido


Los motores previstos para arranque con voltaje
reducido deben ser cuidadosamente seleccionados
con respecto a la lnea elctrica y a la carga. El par
de arranque del motor se reducir al disminuir el
voltaje. El tiempo de arranque debe ser lo ms
corto posible. Consultar a ABB para asistencia de
aplicacin.

ABB Motors

Funcionamiento
Advertencia
Desconectar y bloquear antes de trabajar con un
motor o equipo.
Los bobinados deben descargarse inmediatamente
despus de las mediciones para evitar choques
elctricos.

Antes de la primera puesta en


marcha
1. Medir la resistencias de aislamiento antes de
conectarlo o cuando se sospecha un posible
fallo en le bobinado.
La resistencia, medida a 25C, debe ser
superior al valor de referencia
R

20 x U M ohm (medico con un Megger


1000 + 2P
de 500 V dc)

U = voltaje, P = potencia en kW
Advertencia
Los devanados deben descargarse
inmediatamente despus de las mediciones
pera evitar choques elctricos.
La resistencia de aislamiento se reduce a la
mitad para cada 20C de incremento de
temperatura ambiente.
2. Si no se alcanza la resistencia de referencia, el
devanado es demasiado hmedo y debe
secarse en un horno a la temperatura de 90C
(194F) durante 12-16 horas y seguidamente a
105C (223F) durante 6-8 horas. Se deben
quitar los tapones de drenaje durante el
calentamiento. Cuando haya entrado en los
bobinados, agua de mar, es necesario
rebobinar el motor.
3. Ver si voltaje y la frecuencia indicada en la
placa de caractersticas corresponde a los de
la lnea elctrica.
4. Comprobar las conexiones del motor y los elementos de control con el diagrama.
5. Asegurarse de que el rotor gira libremente al
desconectar la carga. Se debe quitar todo
objeto extrao en el entrehierro.
6. Dejar el motor desconectado de la carga al
ponerlo en marcha por primera vez; es mejor
dejar funcionando el motor durante 1 hora, sin
carga, para probar y localizar calentamiento en
los rodamientos y bobinados. Comprobar el
giro correcto. Comprobar si el voltaje es
correcto y balanceado. Comprobar la corriente
de vaco.

13

Rango de voltaje y frecuencia


permitidos

Mantenimiento

Si el voltaje y la frecuencia estn dentro de los


rangos siguientes, el motor funcionar, pero con
caractersticas algo diferentes de las de la placa de
caractersticas.

Advertencia
Desconectar y bloquear el motor antes de trabajar
con l o el equipo accionado.

1. Voltaje: Dentro del 10% arriba y abajo del valor


de la placa de caractersticas. En lneas
elctricas trifsicas los voltajes deberan estar
equilibrados dentro de un 1%. Un desequilibrio
pequeo podra significar una variacin de la
corriente.
2. Frecuencia: Dentro del 5% arriba y abajo del
valor nominal.
3. Voltaje y frecuencia juntos: Dentro del 10%
(siempre que la frecuencia arriba sea menor
del 5%) arriba o abajo del valor nominal.

Precaucin
Engrasar demasiado un rodamiento puede causar
averas prematuras. La cantidad de grasa debe ser
cuidadosamente controlada.

Funcionamiento con inversores


Cuando un motor de rotor en corto circuito se utiliza
con un inversor debe hacerse lo siguiente:
1. Siempre comprobar:
a) Los datos nominales del motor e inversor
b) Nivel de aislamiento del motor
c) Conexin a tierra del motor y del equipo
accionado
1. Comprobar si el motor funcionar a alta
velocidad:
a) Tipo de rodamientos y lubricacin
b) Caractersticas del ventilador
c) Velocidades crticas
d) Par mximo
1. Comprobar si el motor funcionar a baja
velocidad:
a) Tipo de rodamiento y lubricacin
b) Sistema de ventilacin del motor
c) Ruido magntico

Limpieza
Mantener el interior y exterior del motor limpio de
suciedad, agua, aceite y grasa. Los otros que
deban funcionar en lugares sucios, deben
desmontarse peridicamente y limpiarse bien.

Tapones de drenaje
Todos los motores van equipados con tapones de
drenaje que pueden tapar los agujeros correspondientes. Estos tapones normalmente deben
estar abiertos. Al montar el motor, asegurarse de
que el tapn de drenaje est situado en la parte
ms baja. En caso de montaje vertical, el tapn
situado en la parte superior debe tapar completamente el agujero. En lugares muy polvorientos,
se deben tapar los dos agujeros.

14

Inspeccin General
1. Inspeccionar el motor a intervalos regulares.
2. Mantener el motor limpio y asegurar de que la
ventilacin es efectiva.
3. Comprobar el estado del sellado de los ejes (ej.
V-ring) y cambiarlo si es necesario.
4. Comprobar el estado de las conexiones y los
tornillos de montaje.
5. Comprobar el estado de los rodamientos
escuchando ruidos anormales, midiendo las
vibraciones, temperatura de los rodamientos,
inspeccionando la grasa sobrante o
controlando con el aparato SPM.
Cuando hay cambios en las condiciones de
funcionamiento, desmontar el motor, comprobar las
partes y cambiarlas si es necesario.

Lubricacin
Motores con lubricacin de por vida.
Los motores hasta el armazn 210 llevan rodamientos 2Z y estn normalmente lubricados de por
vida. Los tipos de rodamientos se indican en la
placa de caractersti8cas y en los catlogos. Los
motores con rodamientos del tipo Z pueden ser
lubricados desmontndolos, limpindolos as como
a su caja de rodamientos y llenndolos de grasa
hasta el 50-70%.
Los intervalos de lubricacin son:
1. De 20,000 a 40,000 horas de servicio para
motores de 4 polos y superiores
2. De 10,000 a 20,000 horas de servicio para
motores de 2 polos
Para armazones mayores los intervalos deben ser
menores.
Motores con engrasadores
Lubricar los motores en marcha. Si estos llevan
una proteccin de salida de grasa, quitarla temporalmente para lubricar, o permanentemente con
lubricacin automtica.
Advertencia
Siempre mantener las manos y la ropa alejados de
las partes mviles.

ABB Motors

Si el motor va equipado con una placa de


lubricacin, seguir los valores indicados en ella, de
lo contrario utilizar los valores siguientes:

Lubricantes
Al engrasar, utilizar solo grasa especial para rodamientos de bolas con las siguientes propiedades:

Cantitad de grasa
Armazn
tamao
250
280
320
360
40_
44_-50_
58_

Lado acople
gramos
onzas
80
3
120
4.5
160
6
200
7
400
15
500
18
600
22

Lado ventilador
gramos
onzas
50
2
75
3
100
4
145
5
400
15
400
15
500
18

Rodamientos de bolas; intervalos de lubricacin en horas


de servicio
Armazn
tamao

Gramos

r/min
3600 3000

1800

1500

1000

250-280
320-360
40_-44_
50_
58_

20
25
35
50
60

3200
1800
800
800
-

6000
5500
5000
4600
4000

7000
6500
6000
5500
5000

9000
8500
8000
7500
7000

4200
3100
2000
2000
1000

500900
10000
9000
8500
8000
8000

Rodamientos de rodillos; intervalos de lubricacin en horas


de servicio
320-360
40_-44_
50_
58_

25
35
50
60

900
400
400
-

1500
1000
1000
-

4300
3300
2700
2200

5000
4500
3800
3200

6500
6300
6000
5500

7000
6800
6500
6000

La tabla es vlida para motores en montaje horizontal. Los intervalos de lubricacin para motores
verticales se reducen a la mitad de dichos valores.

1. Grasa de buena calidad con base de litio o


compuesto de litio.
2. Viscosidad bsica 100-140 cST a 40C (104F)
3. Consistencia NI GI grado 2 3
4. Rango de temperatura -30C a + 120C (-22F
a + 248F) servicio continuo.
Los fabricantes ms importantes de lubricantes
suministran las grasas con estas propiedades.
Si se cambia la marca de la grasa y su compatibilidad es dudosa, engrasar varias veces a intervalos
cortos para desplazar toda la grasa vieja.
Los rodamientos con cargas elevadas y/o velocidades de giro bajas requieren grasas EP. Si los
intervalos de lubricacin son cortos debido a
temperaturas de los rodamientos de 80C (176 F)
o superiores, utilizar grasas de alta temperatura
que permiten 15K ms de temperatura.
Si la temperatura ambiente es por debajo de 25C
(-13F) consultar con ABB para utilizar posible
grasas de baja temperatura.
NOTA
Para motores de alta velocidad (por ejemplo
motores grandes de 2 polos) comprobar que el
factor fn de la grasa es suficientemente alto.
Fn = Dm x n

La cantidad de grasa indicada en la tabla es vlida


si se inyecta grasa fresca en pequeas cantidades
a intervalos regulares como se indican.

Dm = dimetro medio del rodamiento (mm)


n = velocidad de giro (r/min)

Como alternativa, cuando el motor lleva engrasadoras, se debe inyectar grasa fresca a la caja de
rodamientos hasta que la grasa vieja queda
totalmente reemplazada.

Advertencia
Mucha grasa pueden irritar la piel e inflamar los
ojos. Seguir las indicaciones del fabricante.

Los valores de la tabla estn basados en temperatura de rodamientos de 80C (176F). Los valores
se reducen a la mitad por cada 15 k (59R) de
aumento de temperatura en los rodamientos. Si la
temperatura mxima del rodamiento es 70C
(158F) los valores de la tabla pueden doblarse.
Advertencia
No se debe sobrepasar la temperatura mxima de
funcionamiento de la grasa ni del rodamiento.

Recambios
Si se pide recambios, se debe indicar la denominacin completa y el cdigo del producto indicado
en la placa de caractersticas.
Si el motor tiene un nmero de serie del fabricante,
se debe indicar tambin.

Para altas velocidades de funcionamiento, por


ejemplo para aplicaciones con variadores de
frecuencia, o para velocidades bajas con cargas
pesadas, son necesarios intervalos de lubricacin
ms cortos, consultar con ABB Motors.
Normalmente a doble velocidad es necesario
reducir los intervalos de lubricacin al 50% de los
valores de la tabla.
Es necesario comprobar si se requieren rodamientos para alta velocidad.

ABB Motors

15

Rastreo de averas
Advertencia
1. Desconectar la lnea antes de trabajar en el
motor o la carga. Es necesario asegurarse de
que el rotor nunca pueda ponerse en marcha ni
recibir corriente elctrica. Esto mismo aplica
para el equipo de carga.
2. Los motores equipados con protectores trmicos automticos se rearman automticamente
cuando la temperatura del protector se reduce
suficientemente. No utilizar motores con protectores trmicos automticos en aplicaciones
en donde un rearme automtico pueda ser
peligroso para el personal o el equipo.
3. Los motores con protectores trmicos manuales pueden rearmarse inesperadamente
despus del disparo. Si el protector manual
dispara, desconectar el motor de la lnea.
Despus de que se enfre el protector (5
minutos o ms) puede rearmarse y conectar
otra vez el motor a la lnea.
4. Descargar los capacitores antes de una
revisin del motor.
5. Siempre mantener las manos y la ropa lejos de
las partes mviles.
6. Nunca intentar medir la temperatura del motor
con las manos. sta siempre debe medirse con
un termmetro, resistencia, o termopar, La
temperatura del ducto de salida de un motor
puede estar muy caliente al tacto durante su
funcionamiento.
7. Las reparaciones elctricas debe ser efectuadas solo por personal capacitado y cualificado.
8. El no seguir con las instrucciones y
procedimientos de seguridad elctrica puede
ser causa de accidentes muy serios e incluso
la muerte.
9. Si se requiere protecciones de seguridad,
asegurarse de que no estn caducadas.

16

Si se observa algn problema durante el funcionamiento del motor, asegurarse de que:


1. Los rodamientos estn en buenas condiciones
y funcionando correctamente.
2. No existe ningn impedimento mecnico que
impida el giro del motor o del equipo
accionado.
3. El entrehierro es uniforme.
4. Todos los tornillos y tuercas estn apretados.
5. Que se han hecho las conexiones correctas al
equipo accionado.
Cuando se comprueben las fallas elctricas,
asegurarse de que:
1. El voltaje y frecuencia de la lnea corresponden
a los valores indicados en la placa de caractersticas del motor.
2. Llegue voltaje a las terminales del motor.
3. Los fusibles y los dispositivos de proteccin
estn en condiciones correctas.
4. Las conexiones y contactos estn correctos en
los circuitos entre los aparatos de control y el
motor.

ABB Motors

ABB Motors

17

Estas instrucciones no cubren todas las situaciones que se pueden presentar en cuanto a instalacin,
funcionamiento y mantenimiento. En el caso de requerir ms informacin pueden contactar con las oficinas
de ventas de ABB.

Cuadro de rastreo de averas


El mantenimiento y cualquier rastreo de averas debe ser efectuado por personal cualificado que disponga
de las herramientas y equipos apropiados.
Avera

Causa

Que hacer

Motor se avera al arrancar

Fusible fundido
Proteccin de sobrecarga
dispara
Lnea de suministro
incorrecta
Circuito abierto en el
bobinado o interruptor de
control
Avera mecnica

Cambiar fusible tamao y potencia apropiados.


Comprobar y rearmar el trmico en el arrancador.

Estator en corto circuito


Conexin bobinado estator
defectuoso
Rotor defectuoso
Motor sobrecargado
Motor no arranca

Una fase puede estar abierta


Aplicacin incorrecta
Sobrecarga
Voltaje bajo
Circuito abierto

Comprobar que la lnea est de acuerdo con la placa


de caracterstica y el factor de carga.
Se oye un zumbido cuando se conecta el interruptor.
Comprobar si hay alguna conexin suelta o algn
contacto que no cierra.
Comprobar que el motor y la carga giren libremente.
Comprobar los rodamientos y la lubricacin.
Resultado fusibles fundidos. Rebobinar el motor.
Sacar el amarre de las cabezas de bobina y comprobar
con el tester.
Barras o anillo de corto circuito cortados.
Reducir la carga.
Comprobar conexiones.
Cambiar tamao, consultar fabricante.
Disminuir la carga.
Comprobar si el voltaje de la placa de caractersticas se
mantiene. Comprobar conexiones.
Fusibles fundidos, comprobar el rel de sobrecarga, el
estator y los pulsadores.

El motor arranca y luego


disminuye en velocidad

Avera en la lnea de
alimentacin

Comprobar conexiones flojas en la lnea a los fusibles y al


control .

El motor no alcanza su velocidad

Aplicacin incorrecta
Voltaje demasiado bajo en
las terminales del motor
debido a cada de voltaje en
la lnea
Carga de arranque
demasiado alta
Barras del rotor rotas o rotor
que gira sobre el eje
Circuito primario abierto

Consultar al sumnistrador para un tamao correcto.


Utilizar voltaje ms elevado o transformador o reducir la
carga o comprobar las conexiones y los cables que sean
del tamao adecuado.

El motor tarda mucho en acelerar


y/o consume demasiado

Carga excesiva
Bajo voltaje al arranque
Barras del rotor defectuosas
Voltaje de lnea demasiado
bajo

Comprobar la carga del motor al arranque.


Comprobar roturas cerca de los anillos de cortos circuito.
Ser necesario un rotor nuevo.
Comprobar avera con el tester y reparar.
Comprobar si hay resistencia elevada. Dimetro
adecuado de cables.
Nuevo rotor.
Aumentar el voltaje de lnea.

Giro incorrecto

Secuencia de fases
equivocada

Invertir dos cables de lnea.

El motor se sobrecalienta cuando


se carga

Sobrecarga
Carcasa o protector del
ventilador llenos de suciedad
que impidan la ventilacin
correcta
Fase abierta en el motor
Fase a tierra
Desequilibrio de voltaje

Reducir carga.
Limpiar el motor.

18

Comprobar conexiones.
Localizar y reparar.
Comprobar conexiones y transformador.

ABB Motors

Avera

Causa

Que hacer

El motor vibra

Desalineado
Soporte dbil
Acople desequilibrado
Equipo accionado
desequilibrado
Rodamientos defectuosos
Rodamientos desalineado
Pesos de equilibrado perdido
Funciona como monofasico
Excesivo juego axial

Alinear
Reforzar
Equilibrar
Equilibrar
Cambiarlos
Alinearlos
Equilibrar el rotor
Circuito abierto
Ajustar rodamiento

Desequilibrio en la corriente de
lnea en motores trifasicos durante
su funcionamiento

Voltaje desigual en las


terminales
Funcionamiento en
monofasicos
Voltaje desequilibrado

Ruido de rozaduras

Ventilador roza con protector

Corregir anomala

Funcionamiento ruidoso

Entrehierro no es uniforme
Desequilibrio en el rotor

Corregir tapas o rodamientos


Equilibrar

Calentamiento general en los


rodamientos

Eje doblado
Tiro excesivo en la polea
Polea muy separada del motor
Dimetro de la polea muy
pequeo
Mala alineacin

Cambiar eje o reforzar


Reducir la tensin
Poner polea ms cerca del motor
Usar polea de mayor dimetro

Calentamiento en rodamientos de
bolas

Lubricacin insuficiente
Deterioramiento de la grasa o
contaminada
Demasiada grasa
Rodamientos sobrecargado
Bolas rotas o pistas de
rodadura daada

Poner la grasa y cantidad suficiente


Sacar la grasa, limpiar los rodamientos con kerosene y
poner grasa nueva
Los rodamientos deben llenarse solo hasta la
Comprobar alineacin y esfuerzos radiales y axiales
Cambiar rodamiento y limpiar la caja cuidadosamente

ABB Motors

Comprobar cables y conexiones


Comprobar contactos abiertos
Corregir el desequilibrio en la lnea

Corregir y alinear bien

19

LV Motors
Manufacturing sites (*) and some of the biggest sales companies.
Australia
ABB Industrial Systems
Pty Limited
P.O.Box 126
Lilydale, VIC 3140
tel. +61 (0) 3 9735 7222
fax + 61 (0) 3 9735 7282
Austria
ABB Industrie
& Gebudesysteme GmbH
Wienerbergstrasse 11 B
A-1810 Wien
tel. +43 (0) 1 601 09 0
fax +43 (0) 1 601 09 8305
Belgium
Asea Brown Boveri S.A.-N.V.
Hoge Wei 27
B-1930 Zaventem
tel. +32 (0) 2 718 6311
fax +32 (0) 2 718 6657
Brazil
Asea Brown Boveri Ltda
P.O.Box 00975
06020-902 Osasco -SP
tel. +55 (0) 11 704 9111
fax +55 (0) 11 702 1991
Canada
Asea Brown Boveri, Inc.
200 Chisholm Dr.,
Milton, Ontario L9T 5E7
tel. +1 905 875 4500
fax +1 905 875 0077
China*
ABB Yuejin Motors (Shanghai)
Company Limited
8 Guang Xing Rd.,Rong Bei
Town, Songjiang County,
Shanghai 201613
tel. +86 21 5774 2188
fax +86 21 5774 2364
Chile
Asea Brown Boveri S.A.
P.O.Box 581-3
Santiago
tel. +56 (0) 2 5447 100
fax +56 (0) 2 5447 405
Denmark*
ABB Motors A/S
Petersmindevej 1
DK-5000 Odense C
tel. +45 66 147 096
fax +45 65 912 912

Finland*
ABB Motors Oy
P.O.Box 633
FIN-65101 Vaasa
tel. +358 (0) 10 22 4000
fax +358 (0) 10 22 47372
France
ABB Industrie
15, rue Sully
F-69153 Dcines Charpieu
Cedex
tel. +33 (0) 472 054 040
fax +33 (0) 472 020 345
Germany
ABB Elektromotoren GmbH
P.O.Box 10 03 46
D-68003 Mannheim
tel. +49 (0) 621 3810
fax +49 (0) 621 381 6820
Hong Kong
Asea Brown Boveri Ltd
3 Dai Hei Street
Tai Po Industrial Estate
Tai Po New Territories
Hong Kong
tel. +852 292 938 38
fax +852 292 935 05
India*
Asea Brown Boveri Ltd
P.O.Box 16
Faridabad 121 001
tel. +91 (0) 129 233 313
fax +91 (0) 129 234 288
Indonesia
P.T. Abdibangun Buana
P.O.Box 3781
Jakarta 10002
tel. +62 (0) 21 314 9115
fax +62 (0) 21 315 3963
Ireland
Asea Brown Boveri Ltd
Components Division
Belgard Road
Tallaght, Dublin 24
tel. +353 (0) 1 405 7300
fax +353 (0) 1 405 7327
Italy*
ABB Industria S.p.a.
Motor Division
Viale Edison 50
I-20099 Sesto S. Giovanni,
Milano
tel. +39 (0) 2 262 321
fax +39 (0) 2 262 32723

ABB Motors
Business Area Marketing Communications
P.O.Box 633
FIN-65101 Vaasa Finland
tel. +358 10 22 4000
fax +358 10 22 43575
www.abb.com/motors

Japan
ABB Industry K.K.
2-39, Akasaka 5-Chome
Minato-Ku
Tokyo 107
tel. +81 (0) 3 556 38605
fax +81 (0) 3 556 38615
Korea
ABB Industrial Systems Co.Ltd.
Oksan Bldg, 12 Fl,
157-33, Samsung-dong,
Kangnam-Ku, Seoul 135-090
tel. + 82 2 528 2327
fax.+ 82 2 528 3490
Mexico*
ABB Sistemas, S.A. de C.V.
P.O.Box M-2434
06000 Mexico D.F.
tel. +52 5 328 1400
fax +52 5 328 1694
The Netherlands
ABB Componenten B.V.
P.O.Box 532
NL-2900 AM Capelle a/d Ijssel
tel. +31 (0) 10 258 2250
fax +31 (0) 10 4586559
New Zealand
ABB Service Division
P.O.Box 22167
Otahuhu, Auckland
tel. + 64 (0) 9 276 6016
fax + 64 (0) 9 276 1303
Norway
ABB Industri AS
P.O.Box 6540 Rodelkka
N-0501 Oslo 5
tel. +47 22 872 000
fax +47 22 872 541
Singapore
Asea Brown Boveri Pte Ltd
P.O.Box 95
Pasir Panjang Post Office
Singapore 9111
tel. +65 775 3777
fax +65 778 0222

Sweden*
ABB Motors AB
S-721 70 Vsters
tel. +46 (0) 21 329 000
fax +46 (0) 21 124 103
Switzerland
ABB Normelec AG
Badenerstrasse 790
Postfach
CH-8048 Zrich
tel. +41 (0) 1 435 6666
fax +41 (0) 1 435 6603
Taiwan
Asea Brown Boveri Ltd
P.O.Box 81-54
Taipei
tel. +886 (0) 2 579 9340
fax + 886 (0) 2 577 9434
Thailand
Asea Brown Boveri Ltd
P.O.Box 2087
Bangkok 10501
tel. +66 (0) 2 249 4825
fax +66 (0) 2 249 8479
The United Kingdom
ABB Motors Ltd
South Point
Sutton Court Road
Sutton, Surrey SM1 4 TY
tel. +44 (0) 181 395 8585
fax +44 (0) 181 395 8991
USA
ABB Industrial Systems Inc.
Drive Products & Systems
P.O.Box 372
Milwaukee
WI 53201-0372
tel. +1 414 785 3416
fax +1 414 785 0397
Venezuela
Asea Brown Boveri S.A.
P.O.Box 6649
Carmelitas,
Caracas 1010A
tel. +58 (0) 2 238 2422
fax +58 (0) 2 239 6383

Spain*
ABB Motores S.A.
P.O.Box 81
E-08200 Sabadell
tel. +34 (9) 3 728 8500
fax +34 (9) 3 728 8554

BA ABB Motor/Nema Machine Instructions 98-09

Technical
Information
TI 189F/00/en

Ultrasonic Measurement
prosonic FDU 8086

Operating Instructions
015081-1007

Sensors for non-contact, continuous


measurement of level and flow.
Suitable for use in explosion hazardous areas.

Application
Prosonic FDU is a series of nine
ultrasonic sensors with different
measuring ranges for continuous, noncontact measurement of level and flow.
FDU 80, 80 F
Liquids: 5 m (16 ft)
Solids: 2 m (6.5 ft)
FDU 81, 81 F
Liquids: 10 m (32 ft)
Solids: 5 m (16 ft)
FDU 82
Liquids: 20 m (65 ft)
Solids: 10 m (32 ft)
FDU 83
Liquids: 25 m (82 ft)
Solids: 15 m (49 ft)
FDU 84
Solids: 25 m (82 ft)
FDU 85
Solids: 45 m (147 ft)
FDU 86
Solids: 70 m (230 ft)

Features and Benefits


Complete sensor programme for
non-contact, continuous measurement
of level and flow
For use in flumes, weirs, tanks and
silos
Insensitive to dirt and build-up
Optional integrated heating to protect
against a build up of ice on the sensor
Wide range of mountings using flange
or thread
(with slip-on flange for flush mounting
of the sensor)
Weather resistant and safe against
submersion (IP 68)
Integrated temperature sensor

The material to be measured can be


aggressive liquids such as alkali or
acid, or powdery and clumpy solids
such as grain, coal, ore and gravel.

Endress + Hauser
The Power of Know How

Measuring System

Measuring System
The complete measuring system
consists of
the Prosonic FDU 80, 80 F, 81, 81 F,
82, 83, 84, 85 or 86 ultrasonic sensor
the transmitter
Prosonic FMU 860: 1-channel version
for level measurement or
Prosonic FMU 861: 1-channel version
for flow measurement or level
measurement or
Prosonic FMU 862:
2-channel version.
Sensor FDU 86 can be selected and
operated by FMU 86x transmitters with
software version 2.2 upwards.

Sensor Accessories
The accessories (see pages 9 and 10)
ensure that the sensors can be adapted
to special process conditions:
Alignment unit FAU 40 for the sensor
All-weather protective cover
Mounting frame
Wall bracket
Sensor flanges (e.g. FAU 80)
External temperature sensor FMT 131
A separate power supply unit is
available for heated sensors.

FMU
FMU
FMU
FDU 80F with
flange FAU 80

FDU with
alignment unit
FAU 40

FDU

Max.
FDU

The Prosonic transmitters have an input for the


connection of a separate limit switch.

Blocking Distance
Due to the ringing time of the sensor,
there is a zone immediately below the
sensor in which returning echoes cannot
be detected. This so-called blocking
distance BD determines the minimum
distance between the sensor diaphragm
and the maximum level in the silo. If the
minimum distance is not maintained, the
level will not be measured correctly.

FMU

Operating principle of
FDU ultrasonic
sensors
BD Blocking distance
D Distance from sensor
to surface of material
L Height in silo
(Level)
F Maximum level
(100%, Full)
E Zero point of
measurement
(0%, Empty)

D =c t
2

BD

The emitter in the sensor is excited


electrically and sends an ultrasonic
pulse in the direction of the surface of
the product which partially reflects the
pulse. This echo is detected by the
same sensor, now acting as a
directional microphone, and then
converted back into an electrical signal.
The time between transmission and
reception of the pulse (the sonic run
time) is directly proportional to the
distance between the sensor and the
product surface. This distance is
determined by the velocity of sound c
and the run time t using the formula:

Function

Maximum Measuring Range


The correct sensor for your particular
application depends on the process
and ambient conditions. When selecting
the sensor, take into account that the
maximum measuring range of the
individual sensor is determined by the
attenuation of the ultrasonic pulse by the
air as well as by the reflecting
characteristics of the product surface.
Both the level of background noise (e.g.
when filling) and the mounting point also
can affect measurement.

Planning
Recommendations

Calculating the Range


The diagram shows ideal attenuation
curves for the FDU 8086 sensors:
Check the factors affecting your
measurement in the table right.
Add up their attenuation values.
Take this sum and find the point where
it intersects with the range limit line of
the sensor you are using

Application Requirements
Optimum conditions in tanks or silos
are achieved if
the lower edge of the sensor is below
the silo roof
the detection zone does not include
any internal fixtures or the filling curtain
the surface of the solid is hard and
coarse-grained
the surface of the liquid is calm and no
vapour is formed
operation is under normal atmospheric
pressure
the vessel is not being filled during
measurement.
Less than optimum conditions reduce
the measuring range of the sensors.
Factors

Attenuation
(dB)

Temperature layering air


temperature difference between
sensor and surface of material
up to 20C (68F)
up to 40C (104F)
up to 80C (176F)
up to 150C (302F)

0
510
1020
2030

Filling curtain
outside detection zone
small amounts in detection zone
large amounts in detection zone

0
510
1040

Dust
none
low amounts
high amounts

0
5
520

Surface of solid
hard, coarse (e.g. grit)
soft
(e.g. peat, dust-covered clinker)

40
4060

Surface of liquid
calm
ripples
strong turbulence
(e.g. agitator blades)

0
510
1020

Foam
please contact Endress+Hauser

Measuring
range 70
m

Example for calculating range:


Silo with grit
approx. 40 dB
Little content
approx. 5 dB
Little dust
approx. 5 dB

FDU 86

Sensor installation
lower edge free in silo
on collar, lower edge slanted
depending on diameter/length ratio
on collar, lower edge horizontal
depending on diameter/length ratio

Gives an attenuation of 50 dB.

40

The FDU 82 sensor measures up to 8 m


under these conditions.

Dimensions
1 m = 3.28 ft
1 ft = 0.305 m

FDU 85
30

FDU 84
FDU 83

20

FDU 82

10

FDU 81, 81 F
FDU 80, 80 F

0
0

20

40

60

80

100

110
Attenuation dB

Echo attenuation as a
function of range for
various sensors (ideal
reflection and
atmospheric conditions)

0
1020
2040

Detection Limits and Interference


Signals
If internal fixtures are present in the
tank, then careful alignment of the
sensor is critical in order to keep the
interference echeos as low as possible.
The ultrasonic pulse should travel
unimpeded to the surface of the
material. The signal leaves the sensor
as a narrow beamwhich widens as the
distance increases. Every objekt within
this beam gives rise to an echo which is
then received by the sensor.
The radius of the beam can be easily
estimated by using the 3 dB beam
angle.

Installation

Accuracy
A constant temperature and sound
velocity within the measuring path
enable a high degree of accuracy to
be achieved. The effects of large
temperature variations within the
measuring path and changing gas
mixtures must be calculated and the
Prosonic programmed accordingly.
With liquids having a high partial
pressure, the gas composition must
be determined to see if it remains
constant.

Operating Limits
The sensors may not be used to
measure aliphatic hydrocarbons
(not applicable to FDU 80 F / FDU 81 F).

Estimation of the Detection Limits of


the Detector
Please note:
Edges, internal fixtures, etc. within the
sound cone are of greatest
importance in the first third of the
range as the energy of the beam is
highly concentrated.
The energy in the last third of the
range is distributed over a larger area,
so that internal structures and edges
are not as critical.

r= tan

3 dB beam angle
L length of beam
(calculated from max.
measuring range of
sensor)
r radius of beam

FDU 80, 80 F

Liquids

FDU 81, 81 F

FDU 82

FDU 83

FDU 80

Solids
8

FDU 81

FDU 82

FDU 83

FDU 84

FDU 85

FDU 86

L
5m
(16 ft)
10 m
(32 ft)
20 m
65 ft)
25 m
(82 ft)

r
0.35 m
(1.1 ft)
0.69 m
(2.3 ft)
1.4 m
(4.6 ft)
0.87 m
(2.8 ft)

2m
(6.6 ft)
5m
(16 ft)
10 m
(32 ft)
15 m
(49 ft)
25 m
(82 ft)
45 m
(147 ft)
70 m
(230 ft)

0.14 m
(0.46 ft)
0.35 m
(1.1 ft)
0.7 m
(2.3 ft)
0,52 m
(1.7 ft)
1.1 m
(3.6 ft)
1.9 m
(6.2 ft)
3.6 m
(11.8 ft)

Guidelines when Mounting


Check that the maximum level height
does not come within the blocking
distance of the sensor
(see page 11, Technical Data).
If possible, the face of the sensor
should lie parallel to the surface of the
product.
The PE or PTFE coating on the
diaphragm of the FDU 84, 85 and 86
is an integral part of the measuring
system and must not be damaged
during installation.
Do not damage the funnel of the FDU
86 when mounting.
The connecting cable of the FDU
sensor is not designed as a
supporting cable. Do not use it as a
suspension wire.
For dust explosion areas: The
connecting cable of the FDU must be
laid in piping. Local regulations for
explosive athmospheres caused by
dust must be observed.
All national guidelines applicable must
be observed in explosion hazardous
areas.

a)

b)

a) Correct installation
As far as possible from the silo wall, the material
inflow and internal fixtures.
The centre of the outflow funnel reflects an echo
which is received by the sensor even when the silo
is empty.
b) Incorrect installation
The detection zone includes the filling curtain.
The echo is reflected to one side when the silo is
empty.

Mounting in Vessels
Install the sensor so that its lower
edge projects into the vessel.
Position the sensor so that neither the
filling curtain nor any internal fittings,
e.g. an additional limit switch, are
within the detection zone.
The sensor must be positioned at the
centre of the outflow funnel so that an
echo is received when the silo is
empty.
Accurate positioning of the sensor
can be simplified using the FAU 40
alignment unit.
The cable of the prosonic sensor is
not designed as a supporting cable.
Do not use it as a suspension wire.
If the sensor is to be installed in tanks
containing very aggressive media,
check that the chemical and corrosion
resistance of the sensor materials
meet these requirements.
Mounting:
above: FDU 84 on girder or angle bracket
centre: FDU 84 with alignment unit FAU 40 near to
a service access
below: FDU 84 with a 1" sleeve welded to a grating

hazardous area

non-hazardous area

1" pipe
conduit seal

conduit seal

1" threaded
sleeve

Sensor on a 1" pipe in


combustible dust area
(for FM, Class II)

Flush Mounting with Slip-on Flange


FAU 80
The FDU 80 F and FDU 81 F sensors
can be flush mounted using an FAU 80
slip-on flange.

Flanges in polypropylene (PPs) should


only be used with pressures up to
1.5 barabs, flanges in 1.4435 also above.
D
k

81

d2

0,5 A

Order No.

d2

No. d2

Standard for

FAU 80 - CAP

20

200

18

160

DN 80 PN 16
(DIN 2527)

23.9

190.5

19.1

152.4

ANSI 3" 150 psi


(ANSI B 16.5)

18

185

19

150

JIS 10 K 80
(JIS B 2210)

FAU 80 - CAJ
FAU 80 - AAP
FAU 80 - AAJ
FAU 80 - KAP
FAU 80 - KAJ

15

130
81

76

d2
D

Order No.

d2

No. d2

Standard for

FAU 80 - CHP

20

220

18

180

DN 100 PN 16
(DIN 2527)

23.9

228.6

19.1

190.5

ANSI 4" 150 psi


(ANSI B 16.5)

18

210

19

175

JIS 10 K 100
(JIS B 2210)

FAU 80 - CHJ
FAU 80 - AHP
FAU 80 - AHJ
FAU 80 - KHP
FAU 80 - KHJ

Dimensions
1 mm = 0.039 in
1 in = 25.4 mm

FDU 8086

Heat
isolation

Mounting on a Mounting Pipe


The sensor should be mounted on a
pipe only when the maximum level
comes within the blocking distance.
Please note:
No build-up of material should form in
the pipe.
Select a pipe with a diameter as large
as possible (see figures and table).
If there is a possibility of build-up in
the pipe the diameter should be
significantly larger.
The inner surface of the pipe should
be as smooth as possible (no edges
or welding seams). When mounting in
the open, the pipe should be insulated
as the temperature within the pipe can
differ significantly from that in the
vessel.
For other nozzles, fixed target
suppression must be used.

Inner edge
45 x 2 mm

Dimensions
1 mm = 0.039 in
1 in = 25.4 mm

97.5

Sensor
FDU 80, 81
FDU 80 F, 81 F
FDU 80 F, 81 F
FDU 82,
FDU 83,
FDU 84, 85
FDU 86

FDU 80 F,
FDU 81 F
Mounting with
FAU 80
flange DN 80
or DN 100

D / mm
80
80
100
150
200
250
300

L / mm
<250
<250
<300
<300
<400
<500
<600

Mounting above Flumes


To achieve the highest accuracy, the
sensor should be situated immediately
above the high water level (100%) plus
the blocking distance BD (see page 11,
Technical Data).
The sensor must always be mounted
perpendicular to the surface of the
water and be above the centre of the
flume.

The appropriate mounting distances


with respect to the flume are to be
maintained (see operating manual
Prosonic, BA 100F/00/en).
When mounted in the open, the sensor
must be protected against the sun by a
protective cover, so that temperature
compensation works correctly. We
recommend an all weather protection
cover (see page 9, Accessories).

Dimensions
1 mm = 0.039 in
1 in = 25.4 mm
Blocking distance BD
FDU 80:
min. 300 mm

1 x b0

Hmax.

Example:
Flow measurement with
Khafagi-Venturi flumes

Typ

b0 mm

be mm

QV 308

800

320

b0

Mounting unit with wall


bracket and cantilever
(see page 9,
Accessories)

Mounting unit with


mounting frame and
cantilever
(see page 9,
Accessories)

The mounting unit can


be swivelled so that the
sensor can be
positioned over the
centre of the flume.

Electrical Connection

Connecting the FDU


The sensors are supplied with a fixed
cable of 5 m (16.35 ft) in length as
standard (30 m (98.1 ft) if required, cross
section 0.75 mm2 (AWG 18)).
They can be connected:
directly in the FMU connection
compartment; the connecting
terminals are designed for cross
sections up to 2.5 mm2 (AWG 13).
via a terminal box;
an additional cable is then required
which may be up to 300 m (981 ft) in
length, up to 6 per core, maximum
60 nF (terminal box and cable not
included in delivery). A two-wire,
screened cable must be used
(screening: metal braiding max. 6 ).
The screening serves as a return
cable. Do not ground the screening
and lay to the transmitter without any
electrical break.
If the terminal box is to be installed in
explosion hazardous areas, then all
national guidelines applicable must be
observed.

Wire coding
BK
RD
YE
GNYE
BN
BU

Connecting
the sensors
above left :
FDU 80, 80F, 81, 81F,
82
above right:
FDU 80, 81 with
heating system
below right:
FDU 83, 84, 85
(ground via the
terminal box)
below left:
FDU 83, 84, 85, 86
(ground to FMU)
Screening
The screening acts as
feedback and must be
exhibit electrical
continuity between
sensor and transmitter.

Ultrasonic Sensor with Heating


The sensors FDU 80 and FDU 81 can
be supplied with heating units. For
heated sensors:
The connecting terminals for the heating
unit are delivered with the sensor. They
are to be mounted in the connection
compartment of the transmitter.
Technical data for an external power
supply for heating the sensor
24 VDC ( 10%)
for each heated sensor, 250 mA, 8 W
mm2

0.5
(AWG 20)

0.75
(AWG 18)

1
(AWG 17)

max. length
m (ft)

150
(490.5)

250
(817.5)

300
(981)

FDU 80, 80F,


81, 81F, 82,

black
red
yellow
green/yellow
brown
blue

Sensor extension
cable:
FDU 80, 80F, 81, 81F,
82:
Ord. No. 938278-0120
FDU 83, 84, 85
Ord. No. 938278-1021
FDU 86
Ord. No. 52000261

These measures ensure that the sensors


correspond to industrial (NAMUR) and
European EMC Standards EN 50 081-1
for interference emission and
EN 50 082-2 for interference immunity.
For general information on EMC
(test methods, installation hints) see
TI 241F/00/en.

BK

YE

FDU 80/81
with heating

Screening

RD

BN BU BK YE RD

Use terminal
box for cables
up to 300 m
(981 ft)

Use terminal
box for cables
up to 300 m
(981 ft)

Screening

80

81 82

FMU
860/861/862
Channel 1

90

91 92

FMU 862
Channel 2

FDU 83, 84, 85, 86

power
supply unit

80

81 82

FMU
860/861/862
Channel 1

90

91 92

FMU 862
Channel 2

FDU 83, 84, 85, 86

GNYE BK YE RD

GNYE BK YE RD

Use terminal
box for cables
up to 300 m
(981 ft)

Use terminal
box for cables
up to 300 m
(981 ft)

Screening

Screening

80

81 82

FMU
860/861/862
Channel 1

80

81 82

FMU
860/861/862
Channel 1

90

91 92

FMU 862
Channel 2

90

91 92

FMU 862
Channel 2

13

Order number:
919791-0000
919791-0001
919791-0002

25

100

Mounting Frame
Material:
700 mm, galvanised steel
700 mm, 1.4301 (AISI 304)
1400 mm, galv. steel
1400 mm,
1.4301 (AISI 304)

Accessories

55

919791-0003

3.2
33.7

60
4

76
100
200

45
6.5

700/1400

20

Mounting frame with


1" pipe for cantilever
and Prosonic FMU

100
150

130

Cantilever for Mounting Frame


For mounting Prosonic sensors FDU 80
and 81 over open channels
Material/version:
500 mm, galv. steel
500 mm, 1.4301 (AISI 304)
1000 mm, galv. steel
1000 mm,
1.4301 (AISI 304)

919790-0003

A
25 50
100

20

20
C

Dimensions
1 mm = 0.039 in
1 in = 25.4 mm

Order number:
919790-0000
919790-0001
919790-0002

35
For separate
temperature sensor

M8

35
L

1000 1085 750

300

500

200

15

6.5

105

100
22

75
35

75

585

250

Cantilever for mounting


frame

3.2
5

33.7

6.5

213
13

25

Wall bracket for


cantilever

88

110
150

150

110

galvanised steel
919792-0000
1.4301 (AISI 304)
919792-0001

180

Wall Bracket
Material:
Order number:
Material:
Order number:

34

100

All-Weather Protective Cover


For Prosonic sensors FDU 80 and 81
Material:
PP-GF
Order number: 919793-0000
The measurement point designation is
fixed to the protective cover.
Break off the fixing eyes on the sensor
at the preformed positions beforehand.

Accessories

All-weather protective
cover for FDU 80 and
FDU 81

98

Flanges
Version, similar to:
Order number:
DN 80 PN 16 in PPs
919789-0000
DN 100 PN 16 in PPs
919789-0002
DN 150 PN 16 in PPs
919789-0004
DN 200 PN 16 in PPs
919789-0006
The maximum operating pressure of the
sensor applies.
Other flanges on request.
Power Supply Unit for Sensor
Heating of FDU 80 and FDU 81
Power unit (24 V DC) for sensor heating
with IP 66 protective housing.
Material:
PT/ABS
Order No.:
215095-0002

External Temperature Sensor


FMT 131
Application: for heated sensor and
when temperature is not to be measured
in the sensor.
Housing: POM, IP 65
Sensor (NTC): 1.4571 stainless steel
Thread: G 1/2 A
Two-core screened cabling, max. 25
per core.
Order code:
Standard version:
FMT 131-R7:
not certified,
always without cable
Dimensions
1 mm = 0.039 in
1 in = 25.4 mm

Dimensions
1 m = 3.28 ft
1 ft = 0.305 m
Certificates
J
Cenelec EEx m II T5
Q FM Class I Div.1 Groups AD
R Standard
Cable Length
1
*
8

5m
other on request
m variable length
(630 m)

FMT 131 -

67

FMU 860 /
861 / 862 / 867

Pg 16

70

110

G 1/2 A
ISO 228

YEGN

EX

120

right:
electrical connection of
standard temperature
sensor FMT 131-R7
(FMT 131-J is delivered
with cable connected)

SW 27
25

left:
dimensions of
temperature sensor
FMT 131

71

BK YE

EX

BK YE YEGN

10

10

FMT 131

G 1/2
SW 27
12

Dimensions
1 mm = 0.039 in
1 in = 25.4 mm

21.8

110

Protective Sleeve for Temperature


Sensor FMT 131
Material: 1.4571 stainless steel
(AISI 316 Ti)
Order No.: 942046-0000

Alignment Unit FAU 40


For easy mounting and positioning of
the FDU sensor (see Technical
Information TI 179F/00/en).

Dimension of protective
sleeve for temperature
sensor

NPT
Pg 11

Hexagonal screw
AF 13 for lateral
adjustment

Two grub
screws for
height
adjustment
(4 mm
Allen key)

Seal here

Dimensions of
alignment unit FAU 40

O ring

G1A

St Ex Zone 10

Spare Parts for Sensor FDU 86


The following spare parts are available
for the FDU 86 (Type FDU 86-R # #):
Funnel with accessories
Order number: 52002963
Seals with accessories
Order number: 52002964
Cable with accessories
Length
Order number:
5 m (16 ft)
52002957
10 m (32 ft)
52002958
15 m (49 ft)
52002959
20 m (65 ft)
52002960
25 m (82 ft)
52002961
30 m (98 ft)
52002962

11

left:
with G 1 thread and
Pg 11 cable gland
right:
with 1 NPT thread and
3
/4" cable gland for pipe
connection

~70

grounding
screw

Total lenght 500 mm


Height adjustment max. 360 mm

Swivel
through 15

10

Accessories

1 NPT

* for use in Dust-Ex:


Insert the seal which is
supplied with the sensor
here

Technical Data
General Information

Manufacturer

Endress+Hauser GmbH+Co.

Instrument

Ultrasonic sensor

Designation

Prosonic FDU 80, 80F, 81, 81F, 82, 83, 84, 85, 86

Technical documentation
Version
Technical data

TI 189F/00/en
06.99
according to DIN 19259

Application

Non-contact continuous level measurement in liquids and solids

Operation and System Design

Measuring principle

Ultrasonic echo level measurement, time-of-flight

Modularity

Ultrasonic sensor for various measuring ranges for


connecting to the transmitters 860...862, as standard with
integrated temperature sensor and mounting accessories,
FDU 80/81 with optional heating.
Sensor FDU 86 can be selected and operated by FMX 86x
transmitters with software version 2.2 upwards.

Construction

FDU 8086: Sensors with connecting cable, mounting via


threaded boss on collar,
FDU 80F/81F: Flush-mounted sensor with connecting cable,
mounting via slip-on flange

Signal transmission

Analogue voltages

Measured variables

Level or flow, determined by the distance from the ultrasonic


sensor (membrane) to the surface of the product

Input

Measuring ranges
FDU 80
FDU 80F
FDU 81
FDU 81F
FDU 82
FDU 83
FDU 84
FDU 85
FDU 86
FDU 80, 80F
FDU 81, 81F
FDU 82
FDU 83
FDU 84, 85
FDU 86

0.3 m (1.0 ft)


0.5 m (1.6 ft)
0.8 m (2.6 ft)
1.0 m (3.3 ft)
0.8 m (2.6 ft)
1.6 m (5.2 ft)

Operating frequency
(at 23C)

FDU 80, 80F


FDU 81, 81F
FDU 82
FDU 83
FDU 84
FDU 85
FDU 86

58 kHz
44 kHz
29 kHz
30 kHz
21 kHz
17 kHz
11 kHz

Pulse frequency

Dependent on measuring range 1 Hz10 Hz

Attenuation due to conditions

Determining the detection limits with a 3 dB beam angle

r= tan

FDU 80, 80F


FDU 81, 81F
FDU 82
FDU 83

FDU 80
FDU 81
FDU 82
FDU 83
FDU 84
FDU 85
FDU 86

For feet see page 4

Output

in solids
2 m (6.5 ft)

5 m (16 ft)

10 m (32 ft)
15 m (49 ft)
25 m (82 ft)
45 m (147 ft)
70 m (230 ft)

Blocking distance

=3 dB beam angle
L = length of beam (calculated from
max. measuring range of sensor)
r = radius of beam

in liquids
5 m (16 ft)
5 m (16 ft)
10 m (32 ft)
10 m (32 ft)
20 m (65 ft)
25 m (82 ft)

Transmitters

Liquids

8
8
8
4
Solids
8
8
8
4
5
5
6

L
L
5m
10 m
20 m
25 m

r
0.35 m
0.69 m
1.4 m
0.87 m

2m
5m
10 m
15 m
25 m
45 m
70 m

0.14 m
0.35 m
0.7 m
0.52 m
1.1 m
1.9 m
3.6 m

FMU 860: 1-channel instrument for level measurement


FMU 861: 1-channel instrument for flow measurement
FMU 862: 2-channel instrument for flow or level measurement

12

Process Conditions

Mounting conditions
Mounting position

Vertical to the surface of the material

Ambient conditions

Conversion factors
1 mm = 0.039 in
1 in = 25.4 mm
1 bar = 14.5 psi
1 psi = 0.068 bar
1 kg = 2.2 lbs
1 lb = 0.45 kg
x C = (1.8 x + 32) F

Ambient temperature

FDU 80:
FDU 80F
FDU 81:
FDU 81F:
FDU 82, 83, 84, 85:
FDU 86:

40+60C (40+140F)
40+95C (40+203F)
40+80C (40+176F)
40+95C (40+203F)
40+80C (40+176F)
40+150C (40+302F)

Relative humidity

FDU 80, 80F, 81, 81F, 82, 83, 85, 86:


100%
FDU 84: 100% (max. 60C/140F), 95% (max. 80C/176F)

Protection

IP 68 (tested by immersing to 1 m for 24 h)

Electromagnetic compatibility

Emitted interference to EN 61326, Class B equipment;


immunity to interference resistance to EN 61326; Annex A
(industry sector)

General operating conditions


Temperature at sensor
* May be used at high temperatures but only after first
contacting Endress+Hauser
** Limits apply as stated in Certificates E, J (see page 15)
*** Limits apply as stated in Certificates P, Q, S, T
(see page 15)

FDU 80
FDU 80F*****
FDU 81****
FDU 81F*****
FDU 82
FDU 83
FDU 84
FDU 85
FDU 86

20+60C*
40+95C
20+80C
40+95C
20+80C
20+80C
20+80C
20+80C
40150C

**** with heating 20+60C

with limited data


40+60C
40+95C
40+80C
40+95C
40+80C
40+80C
40+80C
40+80C
35+140C**
40+140C***

***** CIP cleaning at 95C


Sterilisation 30 min at 135C
FDU 80
FDU 80F
FDU 81
FDU 81F
FDU 82
FDU 83
FDU 84
FDU 85
FDU 86

Process pressure Pabs


* May be used at high pressures but only after first
contacting Endress+Hauser

Housings

122

132

20
119
3

80

FDU 82
Weight: 1.2 kg (2.6 lbs)

29.5

FDU 80, FDU 81


Weight:
FDU 80: 0.55 kg (1.2 lbs)
FDU 81: 0.6 kg (1.3 lbs)

29.5

FDU 80F, FDU 81F (flush-mounted)


Weight:
FDU 80F: 0.5 kg (1.1 lbs)
FDU 81F: 0.55 kg (1.2 lbs)

98

70

136 (153)

~ 139 (156)
189 (196)

FDU 85
Weight: 5.0 kg (10.9 lbs)

239 (244)

Values in brackets apply to dust-Ex. A 1.4301/SS 304 stainless steel cover


around the PA housing enables it to be used in Zone 10

13

155

FDU 84
Weight: 4.7 kg (10.3 lbs)

30

FDU 83
Weight: 3.1 kg (6.8 lbs)

26.5

97

30

Mechanical Construction

2 bar (29 psi)


4 bar (58 psi)
2 bar (29 psi)
4 bar (58 psi)
2 bar (29 psi)
1.5 bar (22 psi)
1.5 bar (22 psi)
1.5 bar (22 psi)
3 bar (44 psi)

244

ca. 450

30

FDU 86
Weight: 5.0 kg

198

Materials
Conversion factors
1 mm = 0.039 in
1 in = 25.4 mm
1 bar = 14.5 psi
1 psi = 0.068 bar
1 kg = 2.2 lbs
1 lb = 0.45 kg

Housing

FDU 80, 81, 82:


FDU 80F, 81F:
FDU 83
FDU 84
FDU 85
FDU 86

PP-GF
ETFE
PA*
PA*
UP
UP

Thread

FDU 80, 81, 82:


FDU 80F, 81F:
FDU 83
FDU 84
FDU 85
FDU 86

PP-GF
ETFE
1.4301 (AISI 304) or aluminium
1.4301 (AISI 304) or aluminium
UP
UP or 1.4301

Diaphragm
* 0.5 mm stainless steel 1.4571/SS 316Ti with a 4 mm
closed-pore PE cover facing the material

FDU 83
FDU 84
FDU 85
FDU 86

1.4571 (AISI 316 Ti)


1.4571 (AISI 316 Ti)/PE*
AI/PE**
Al/PTFE***

Diaphragm seal

FDU 80...85:
FDU 86:

EPDM
silicone

Connecting cable

FDU 80, 80F, 81, 81F, 82:


FDU 83, 84, 85:
PUR
FDU 86:
silicone

Mounting accessories

Alignment unit: flange 1.4301 (AISI 304), pipe galvanised steel


Slip-on flange: PP (max. 1.5 bar) or 1.4435 (AISI 304) (>1.5 bar)

Power Supply

Power supply

Via transmitters FMU 860862

Certificates and Approvals

Ignition protection

see section Product Structure

CE mark

By attaching the CE mark, Endress+Hauser confirms that


the instrument fulfils all the requirements of the relevant EC
directives.

* A 1.4301/SS 304 stainless steel cover around the PA


housing enables it to be used in Zone 10.

** 1 mm aluminium with a 5 mm closed-pore PE cover


facing the material
*** aluminium diaphragm coated with PTFE

Order Code

see section Produkt Structure

Supplementary Documentation

Technical Information TI 190F/00/en Prosonic FMU 860862


Operating Instructions BA 100F/00/en Prosonic FMU 860862

14

PVC

Product Structure

FDU 80, 80F, 81, 81F, 82 Prosonic Sensors


Certificates
R
J
U
Q
S

Standard (not certified)


ATEX II 2 G EEx m II T5 (T6 for FDU 80)
CSA General Purpose
FM Class I, Div. 1, Groups AD, FM Class II / III, Div. 2, Groups F and G
CSA Class I, Div. 1, Groups A, B, C, D
Process Connection / Material
G
N
F

Thread G 1 A / PP-GF for FDU 80F/81F: ETFE


Thread 1 NPT / PP-GF for FDU 80F/81F: ETFE
Thread 1 NPT / PP-GF (3A certification) for FDU 80F/81F: ETFE
Cable Length
1
2
3
4
5
6
8

Conversion factors
1 m = 3.28 ft
1 ft = 0.305 m

with 5 m (16 ft) connecting cable


with 10 m (32 ft) connecting cable
with 15 m (49 ft) connecting cable
with 20 m (65 ft) connecting cable
with 25 m (82 ft) connecting cable
with 30 m (98 ft) connecting cable
m variable length (630 m)
Heating (FDU 80 and 81 only)
A
B

FDU

none
with heating, 24 V DC

Product designation

FDU 83, 84, 85 Prosonic Sensors


Certificates
R
E
U
P
T

Standard (not certified)


BVS/DMT (Dust-Ex) Zone 10/ATEX II 1/2 D
CSA General Purpose
FM Class II, Div. 1, Groups E, F, G
CSA Class II, Div. 1, Groups E, F, G
Process Connection / Material
G
N
S
V

Thread G 1 A / Aluminium; for FDU 85: plastic


Thread 1 NPT / Aluminium; for FDU 85: plastic
Thread G 1 A / 1.4301 (AISI 304) (FDU 83, FDU 84 only)
Thread 1 NPT / 1.4301 (AISI 304) (FDU 83, FDU 84 only)
Cable Length
1
2
3
4
5
6
8

FDU

with 5 m (16 ft) connecting cable


with 10 m (32 ft) connecting cable
with 15 m (49 ft) connecting cable
with 20 m (65 ft) connecting cable
with 25 m (82 ft) connecting cable
with 30 m (98 ft) connecting cable
m variable length (630 m)

Product designation

15

Product Structure

FDU 86 Prosonic Sensor


Certificates
R
E
F
J
K
L
P
T
U

Conversion factors
1 m = 3.28 ft
1 ft = 0.305 m
x C = (1.8 x + 32) F

Version for non-hazardous area


DMT Dust-Ex ATEX II 1/2 D (40140C)
DMT Dust-Ex ATEX II 1/2 D (4080C)
DMT Gas-Ex ATEX II 2 G (35140C)
FM Class I/II/III, Div. 1/2 Groups A..G, LT (4080C)
CSA Class II/III, Div. 1 Groups E...G, NT (4080C)
FM Class I/II/III, Div. 1/2, Groups AG, HT (40140C)
CSA Class II/III, Div. 1, Groups E-G, HT (40140C)
CSA General Purpose
Process Connection / Material
G
N
S
V

Threaded connection G 1, UP
Threaded connection 1 NPT, UP
Threaded connection G 1, 1.4301 (AISI 304)
Threaded connection 1 NPT, 1.4301 (AISI 304)
Cable Length
1
2
3
4
5
6
8

FDU

86

with 5 m (16 ft) connecting cable


with 10 m (32 ft) connecting cable
with 15 m (49 ft) connecting cable
with 20 m (65 ft) connecting cable
with 25 m (82 ft) connecting cable
with 30 m (98 ft) connecting cable
m variable length (630 m)

Product designation

Endress+Hauser
GmbH+Co.
Instruments International
P.O. Box 2222
D-79574 Weil am Rhein
Germany
Tel. (0 76 21) 9 75-02
Tx 7 73 926
Fax (0 76 21) 9 75-3 45
http://www.endress.com
info@ii.endress.com

Endress + Hauser
The Power of Know How
08.99/MTM

TI 189F/00/en/08.02
015081-1007
HD/CV5

015081- 1007

Technical Information
TI 190F/00/en

Ultrasonic Measurement
Prosonic FMU 860...862
Level and flow measurements with ultrasonics
Simple to start up, easy to use, flexible
Field mounted ultrasonic transmitters

The Prosonic ultrasonic


transmitter in the IP 66
protective housing

Applications
Prosonic FMU 860...862 ultrasonic transmitters are for use with the Prosonic FDU
80...86 family of sensors.
The transmitter determines levels in silos
and tanks and calculates the volume of
solids and liquids they contain.
With the Prosonic 860 ... 862 sensors can
be operated which are mounted in explosion hazardous areas according to FM /
CSA / ATEX.
When used for applications in fresh and
waste-water, Prosonic measures
flow rates in flumes and weirs
water levels
and can control screen cleaning and
pumps.

Features and Benefits


A customised instrument programme for
the specific application.
Choice of transmitters
For the field or control room
Single or two-channel versions with
three or five relays, also with optional
totaliser
With optional HART interface for remote
configuration
With RS-485 or PROFIBUS-DP interface
Intelligent commissioning, ultrasonic
measurement par excellence
Instrument parameters arranged in a
simple matrix
Various linearisation functions, totalisers, and all common Q/h curves on
call
Quick commissioning and stable
measurement thanks to signal pattern
recognition by fuzzy logic and the
application parameter

Prosonic FMU 860...862

Measuring System
Measuring System

The measuring system consists of the Prosonic


transmitter with a Prosonic sensor chosen
according to the application at hand. The twochannel version is for differential measurement
or for controlling two measuring points. The
certified sensor ensures that the measuring
system can be used in explosion hazardous
areas.
Other units can be connected to the Prosonic
transmitter for special applications:
separate temperature sensor, e.g. if the ultrasonic sensor is heated
separate external limit detector.

or

FMU 860

........

or

........

FMU 862

FMU 860

FDU
FDU

EX
ATEX
Zone 20

Ex Zone 1

The Prosonic transmitter can be integrated into


automation systems using the RS-485 or PROFIBUS-DP interface

Overspill protection

Double protection against overfill:


All Prosonic transmitters have an additional
connection for an external limit detector.
Even when the level moves within the blocking distance of the sensor, this is promptly
indicated by the display, the signal output
and relays.

FMU 86

FDU

Max.

Endress+Hauser

Prosonic FMU 860...862

Applications
Prosonic FMU 860

Level
FMU 860

FMU 860
L

FDU
FDU

Continuous level and volumetric measurement of liquids and solids in tanks and silos.
Pump control in up to 5 steps
Alternating pump control
Adjustable switch delay
Prosonic FMU 861

Endress+Hauser

rapid changes in load height are easily dealt


with by the Prosonic FMU 860.

Flow rate measurement in flumes or weirs


Millimeter accuracy for the flow level
The linearisation curves of all common stan

Prosonic FMU 862

Conveyor belts

dard flumes and weirs are preset and can be


called up as required.
For the version with IP 66 housing, the
amount flowing through is summated and
displayed by the totaliser
Low-flow cut-off
Separate display of floodwater on external
counters
Sample control using a quantity or time function

Two channel version


Flow or level measurement in channel 1;
level measurement in channel 2
Differential and average value measurement
(FMU 862 D for distance measurement with
two sensors)
E.g. controlling the screen cleaning process
as a function of clogging (s. fig.)
Superimposed interval timer
Trend indication
Back water alarm (Back water in weirs is
detected, signalled and the flowrate automatically adjusted)

Flow
FMU 861
Q
1 2 3 4 5 6

EX

FDU

Ex Zone 1

Differential
FMU 862
Dh

FDU

FDU

Prosonic FMU 860...862

Operation and Signal Processing


Principle of Operation

An ultrasonic pulse emitted from the sensor is reflected back by the surface of the material or
liquid and is received by the same sensor as an echo signal. The product height or water level is
then calculated from the run time of the ultrasonic signal (echo level determination).

Simple Start-Up

The time required for start-up is minimised by using preset operating parameter values. Selecting
just one parameter automatically sets the measuring line to one of five typical applications:
liquid
vessels with rapid changes of liquid
fine-grained bulk solids
coarse-grained bulk solids
conveyor belts

Intelligent Software with


Fuzzy Logic Elements

The Prosonic transmitter is based on state-of-the-art evaluation methods including fuzzy logic elements for intelligent echo analysis. No other special procedures are required as this method
enables the true level echo to be clearly distinguished from:
sporadic reflections (e.g. from agitator blades),
interference echoes and noise (e.g. from filling) or
multiple reflections (e.g. with closed tanks).
Even with almost unfavorable mounting points, the advantages of continuous, non-contact ultrasonic measurement can be used by activating a special fixed target suppression mode or filtering
factor.

Complete Functionality

For level measurement


The characteristic curve is already programmed for volumetric measurement in a horizontal cylinder. The linearisation curve of any vessel can be easily entered (maximum 32 points).
The Prosonic FMU 862 also has the following modes

Differential measurement:
Value1 Value2

Avarage value measurement:


Value1 + Value
-----------------------------------------2
For flow rate measurement
All common Q/h characteristic curves for measuring flow rates with flumes and weirs are stored
in the Prosonic. Other Q/h curves can be entered (up to a maximum of 32 points).
Three different programmable counting pulses for totalising can be sent to the relay outputs for
controlling external counters. The transmitter itself has a resettable software counter: a nonresettable totaliser is available as an option.

Endress+Hauser

Prosonic FMU 860...862

On-site operation
Keys and display on the
front cover

Full
Application Sensor
Measured Empty
calibration calibration
value
type

Relay
selection

Relay
function

Switch-on Switch-off Pump


point
point
control

Linearisation

Preset
height

Q/h char.
curve

Fixed
target
suppress.

Echo
S/N
attenuation factor

+
-

Only a few input steps are


required for calibrating all
standard applications.

Level

Volume

Warning/
Fault

Output
with
fault

The keypad on the front panel is used to configure the transmitter and call up parameters, which
are shown on a 4 1/2 character display.
The input dialogue is based on the standard Endress+Hauser operating matrix in which every
input field is quickly and easily selected using the "V" (vertical) and "H" (horizontal) keys. Parameters are simply entered using the three keys , +, and are registered and stored once
the "E" key has been pressed.

HART communication protocol


Handheld Terminal
DXR 275

I-- I+
45

DXR 275

Field

Control room
Communication
resistor
min. 250 

DXR 275

4...20 mA

Operation
For devices with HART interface all values can be entered using a handheld terminal. The user
has comprehensive and detailed information on inputs both on-site and in the control room. The
measurement remains totally unaffected during the interactive input.
Electrical Connection
The handheld terminal is connected either
directly to current output 1 of the transmitter or
to a communications resistor.
In general: The handheld terminal can be connected anywhere in the signal circuit as long as
there is a resistance between its terminals which is larger than the minimum communications
resistor (250 ).
Screened cable is recommended, maximum capacitance 100 nF.

Endress+Hauser

Prosonic FMU 860...862

Operation via
Commuwin II

optional
power pack

RS 232 C

4...20 mA
HART

Commubox
FXA 191

VH

minimum total resistance 250

Commuwin II

The Commubox FXA 191 connects HART transmitters to the RS 232 C serial interface of a personal computer. This enables the transmitter to be remotely operated with the Endress+Hauser
Commuwin II operating program.

PROFIBUS-DP interface
System integration
Personal Computer with
Profiboard or Proficard
and Commuwin II or ToF-Tool

PLC

PROFIBUS-DP

VH

other
field devices

Prosonic

The version with PROFIBUS-DP interface can be integrated as a slave into a PROFIBUS-DP segment. In order to connect a Personal Computer to the bus, PROFIBOARD or PROFICARD can be
used.
Operation

The following operation programs are available:


Commuwin II
ToF Tool (limited functionality)

Endress+Hauser

Prosonic FMU 860...862

RS-485 Interface
Connecting a
Personal Computer

Instruments with RS-485 interface can be connected to a Personal Computer in one of the following ways.
RS 485 card for PC (for the Fieldmanager and Commugraph programs)
Adapter RS 232 C/RS 485 (for the Fieldmanager and Commugraph programs)
Commubox FXA 192 (for the graphical program Commuwin II)
FXA 675 with a Gateway ZA 67x with serial interface

Connecting to Process
Control Systems

Personal computer
with display and
operating software
programmable
logic controller

Field transmitter with RS-485 interface

Rackbus
VH

FXA 675

FXA 675

ZA 673

RACKBUS
PROFIBUS

max. 1200 m

Rackbus RS 485

Gateway:
ZA 673
PROFIBUS
ZA 674
FIP ZA 672
MODBUS

The Prosonic FMU 86... can be easily linked to existing process control systems via the RS-485
interface.
The FXA 675 interface card (or the Monorack II RS-485) connects two individual Rackbus RS-485
networks with up to 25 transmitters via the Rackbus. A second card (Gateway) serves as the bus
connection for standard networks such as PROFIBUS, FIP or MODBUS.
The Prosonic P level measurement system also enables a number of widely distributed ultrasonic
measuring points to be controlled by a personal computer.
Operating programs

Operating program "Fieldmanager" (MS-DOS)


Visualisation program "Commugraph" (MS-DOS)
Graphical operating program "Commuwin II" (Windows 3.1/3.11, Windows 95, Windows 98,
Windows NT)

Endress+Hauser

Prosonic FMU 860...862

Housing Versions
Field housing
(Operation in the field)

In this version the transmitter electronics are


built into an IP 66 housing. The transmitter is
parametrised via an operating unit with a keyboard and display or - by using an additional
serial interface - with a handheld terminal.
An external totaliser can also be connected to
the Prosonic FMU 861.

for rack (IP 10)

for control panel (IP 40)


3 HE

Seperate transmitter
electronics
(Control room operation)

144

IP 40 plastic housing

21 TE

IP 10 mounting plate

With this version, the operating unit is separated from the transmitter electronics.The operating
unit is available for mounting in a control cabinet (144 mm x144 mm) or for mounting in an assembly rack (21 HP). The transmitter electronics are mounted in an IP 40 housing or else are on an
IP 10 mounting panel in the control cabinet.

Note!
The versions with separate electronics are not available together with the digital interfaces RS485 or PROFIBUS-DP.

Explosion hazardous areas


For certified systems, the sensor only may be installed in the explosion hazardous area. The transmitter must always be installed in a safe area. All local regulations concerning installation must be
observed.

Endress+Hauser

Prosonic FMU 860...862

Dimensions
IP 66 field housing resp.
IP 40 plastic housing

292

10

min. 52

253

4,5

< 69

275,5

IP 10 mounting plate
255
200
170
9x20

10

90

280

6.4x19

6.4x38

10.5
25.5

9x40

230

Seprate operating unit


operating unit
for control panel
138 +1

operating unit
for rack

min .18

3 HE

63

144

21 TE

max. 105

max. 23

Endress+Hauser

Prosonic FMU 860...862

Accessories
All-Weather Cover
Material: aluminium, blue lacquered
Order No. 919567-0000
Material: stainless steel 1.4301;
Order No. 919567-0001
Weight: approx. 1 kg
Mounting screws supplied

343

17

187,5

Accessories for the field


housing

Post mounting
Material: galvanised steel, Order No.:
for 2"-Post: 919566-0000
for 1"-Post: 919566-1000
Material: stainless steel 1.4301; Order No:
for 2"-Post: 919566-0001
for 1"-Post: 919566-1001
Weight: approx. 1 kg
Mounting screws and nuts supplied

Order No.

RS 485 PC Interface Card

for 230 V: 016398-0000


for 115 V: 016398-0050
Connector for PC: 25pin Min-D-plug
for bus:9-pin Min-D-plug, plug supplied with
screw terminals
Baud rate: 19 200 Bits/s
RS 485-output electrically isolated,
Power supply:15 V DC; power unit 230 V or
115 V, to order
RS 232C interface, can be configured as
DCE/DTE

94

DCE DTE

54

Converter:RS 232C/RS 485


Interface

RS-232C

RS-485

15 V DC

Order No. 016399-0000


Connector: 25 pin Min-D-plug, plug supplied

154

with screw terminals

COM 3, address 3E8H, with protective


ground at Pin 1 or connector, Slot: 8 or 16 bit
RS 485 output electrically isolated

BR 2
J5

100

Baud rate: 19 200 Bits/s


Configuration: supplied configured for

BR 1
J1

J9
I

J2

HART-Communicator
DXR 275

Handheld for instruments with HART interface (siehe Operating Instructions 139F/00/en).

PC Interfaces
for PROFIBUS-DP

PROFICARD (PCMCIA card); Order No. 016570-5200


PROFIBOARD (PCI-Board); Order No. 52005721

10

Endress+Hauser

Prosonic FMU 860...862

Temperature sensor

An external temperature sensor FMT 131 can be connected.

Spare Sensor Cable

Connection from the Prosonic FMU 86 transmitters to the sensors


FDU 80, FDU 80 F, FDU 81, FDU 81 F, FDU 82; Order-No. 938278-0120
FDU 83, FDU 84, FDU 85; Order No. 938278-1021
FDU 86 Order No. 52000261

Overvoltage protection in
IP 66 protective housing

Overvoltage protection unit for power supply


Order No. 215095-0001
Dimensions: s. page 9 (IP 66 housing)

Overvoltage protection
and power supply Unit for
Sensor heating in IP 66 Protective Cover

Power supply unit (24V DC)for sensor heating of up to 2 sensors with integrated overvoltage protection for power supply
Order No. 215095-0000
Power supply: 230 V (+15%/20%)
Dimensions: s. page 9 (IP 66 housing)

Power supply unit for Sensor Heating in IP 66 Protective Housing

Power supply unit (24 VDC) for Sensor Heating of up to 2 sensors


Order No. 215095-0002
Power supply 230 V (+15%/20%)
Dimensions: s. page 9 (IP 66 housing)

Endress+Hauser

11

Prosonic FMU 860...862

Electrical Connection
Terminal Strip
L+ LL1 N

5
YE RD YE RD

24 VAC; 48VAC;
115 VAC; 230VAC

Sensor 2

RS-485 version
5

RS-485

11 12 13

31 32 33 41 42 43 51 52 53

DP

RS-485

RxD/TxD-N
GND
RxD/TxD-P

31 32 33 41 42 43 51 52 53

RxD/TxD-N
GND
RxD/TxD-P

11 12 13

Sensor 1

for FMU 862


only

Profibus-DP version
DP

Temp.

0/4 20 mA

0/4 20 mA

L+
20 30 VDC LL1
N
PE

terminals fitted to
the version with
5 relays only

for FMU 862


only

70 71 80 81 82 90 91 92

Sync. FMU

6 7 11 12 13 21 22 23 31 32 33 41 42 43 51 52 53 60 61 62 63 64

4 5

Liquiphant
Soliphant

1 2 3

The terminal strip for cable diameters up to 2.5 mm2 is in a separate connection chamber. The
cable entries are prestamped for easy removal.
underside 5 x Pg 16 und 4 x Pg 13.5 (M20x1,5)
rear 5 x Pg 16
The electrically isolated areas are separated by thick lines in the figure above.
Sensor Cable

Electrical Isolation

12

Connection is with the cable supplied or by using an extension via a terminal box with commercial, two-core screened cabling (also available from E+H). Maximum values: up to 6 per core,
maximum 60 nF.
mm2

0,5

0,75

max. length in m

150

250

300

Current output, relay outputs, power connection and sensor input are all electrically isolated from
one another.
With the FMU 862, the two current outputs are electrically connected to one another, as are the
two sensor inputs.

Endress+Hauser

Prosonic FMU 860...862

Power Supply

Alternating voltage
180253 V

+10% / 15%

50/60 Hz

90132 V

+15% / 22%

50/60 Hz

3855 V

+15% / 20%

50/60 Hz

1928 V

+15% / 20%

50/60 Hz

Power consumption: maximum 15 VA


Current consumption: maximum 65 mA at 230 VAC
Direct voltage
20...30 V (residual ripple within tolerance), integrated reverse connection protection.
Power consumption: maximum 12 W (typically 8 W), maximum 500 mA at 24 VDC
Synchronisation line
FMU 86
63

64

FMU 86
63

64

FMU 86
63

max. 20units

64

In order to avoid cross-talk between parallel routed sensor lines connect the transmitters (max.
20) to a synchronisation line. The sensors are then scanned in sequence. If more devices are present, groups of 20 transmitters should be used. The cables within one group can be in parallel.
The cables of different groups must be separated. Common screened cable can be used.

Endress+Hauser

13

Prosonic FMU 860...862

Technical Data
General Information

Manufacturer

Endress+Hauser GmbH+Co. KG

Instrument

Ultrasonic transmitter

Designation

Prosonic FMU 860, 861, 862

Technical Documentation
Version
Technical Data

TI 190F/00/en
08.02
to DIN 19259

Application

Non contact, continuous level measurement in liquids and solids,


for determining flowrates in open channels and weirs, water levels or for controlling screens and pumps

Function and
System Design

Measuring principle
Modularity

FMU 860: One signal input for level measurement


FMU 861: One signal input for flow measurement
FMU 862: Two signal inputs for differential level measurement

Operation and system


design

Transmitter

IP 66 field housing for post and wall mounting


Separate operating unit (keyboard and display) for control
panel mounting or for rack mounting; 3 m connecting cable
supplied
IP 40 plastic housing with electronics for connecting a
separate operating unit
IP 10 mounting plate for connecting a separate operating
unit

Input

Measured variable

Time of flight measurement of the ultrasonic pulse using


ultrasonic sensors

Measuring range

270 m depending on the ultrasonic sensor, s. TI 189F

Ultrasonic sensors

FDU 80, 80F, 81, 81F, 82, 83, 84, 85, 86

Separate switch input

external passive limit switch (NO contact or NC contact) or PNP


switch, 24 V, maximum short circuit current 20 mA

Separate temperature sensor

to compensate for temperature errects on time of flight in open


channels, NTC version

Analogue output

Output signal

4 ... 20 mA, switchable to 0 ... 20 mA (can be inverted),


superposed digital communications signal HART
FMU 862: same values for second signal output, simultaneous switchover of Channel 1 to 0 ... 20 mA
with plug-in module and also serial interface
4mA level for coupling

Output on error

020 mA:
10 % (2 mA), +110 % (22 mA), HOLD (last current value
is held)
420 mA:
10 % (2,4 mA, +110 % (21,6 mA), HOLD (last current
value is held)

Current limit

14

Ultrasonic echo, time of flight measurement

24 mA

Integration time

0300 s

Load

max. 600

Effect of load

negligible

Endress+Hauser

Prosonic FMU 860...862

Relay output

Version

Functions

Accuracy

Ambient conditions

Materials/Weight

Accessories

Endress+Hauser

optional three or five independent relays each with one potentialfree change-contact
always three relays only with RS-485- or PROFIBUS-DP interface

limit value
alarm relay
trend
time pulses(FMU 861 and FMU 862 only)
max. counting frequency 2 Hz, pulse width200 ms
time pulses (FMU 861 only)
back-up (FMU 862 only)

switching power

AC: 4 A, 250 V, 1000 VA at cos = 0,7,


DC: 4 A, 35 V and 100 W

Measured error
(sum of linearity, hysteresis and
reproducibility)

typical 0,2 % for maximum measurement span with smooth


surface

Max. resolution

1 mm for FDU 80

Effect of load

negligible within permissible range

Ambient temperature

20+60 C

Storage temperature

40+80 C

Shock resistance

2 g (1055 Hz) and 15 g for 11 ms (DIN 40040, Typ W)

Climatic class

DIN 40040 Type R


Relative air humidity 95% in yearly average, condensation
permissible

Ingress protection

DIN 40050:
Field housing: IP 66 with closed housing and cable entry of
identical protection
IP 40: plastic housing with cable entry of identical protection
IP 10: plate for mounting in control cabinet
IP 40: separate operating unit for control panel
IP 10: separate operating unit for rack

Electromagnetic compatibility (EMC)

AC power supply:
Interference emmission to EN 61326 ; Electrical equipment
class B
Interference immunity to EN 61326 ; Annex A (Industrial)
DC power supply:
Interference emmission to EN 61326 ; Electrical equipment
class A
Interference immunity to EN 61326 ; Annex A (Industrial)
for PROFIBUS-DP instruments
Interference emmission to EN 61326, Electrical equipment
class A
Interference immunity to EN 61326

IP 66 / NEMA 4x field housing

IP 40 plastic housing

PC/ABS
Weight: 1,0 kg

IP 10 mounting plate

Al/PS
Weight: 0,8 kg

IP 40 separate operating unit

PC/ABS
Weight: 0,3 kg

Protective cover for field housing

Materials: Aluminium blue lacquered or SS 304 (1.4301)


Weight: approx. 1,0 kg
Mounting screws supplied

Post mounting

Material: galvanised steel or SS 304 (1.4301)


Weight: approx. 1,0 kg
Mounting screws and nuts supplied

Housing body: PC/ABS


Transport cover: PC (polycarbonate)
Front plate with tag area
Weight: 2,6 kg

15

Prosonic FMU 860...862

Display and Operating


Interface

Communication Interfaces

Power supply

Certificates and approvals

Supplementary
documentation

16

Display (LCD)

4 -character display, optional lighting


with segment display of the current in 10 % steps
Display elements: error, signal overflow or underflow, communication

LEDs

one yellow LED each for indicating the switching status of


the relay (lit: relay energised)
one yellow LED error indication (lit = error-free operation)
one green LED indicates error free indication
(lit = error-free operation, flashing = warning)

Counter

FMU 861 standard only, FMU 862 optional


Version: six-character, cannot be reset

Software counter

FMU 861 standard only, FMU 862 optional

HART

On-site operation via HART handheld DXR 275


Connection to PC via Commubox FXA 191
Remote operation via Commuwin II software

RS 485

via interface card FXA 675 connection to


Rackbus-RS 485 networks; Operation via Fieldmanager,
visualisation via Commugraph
via Commubox FXA 192 connection to serial interface
RS 232C of a PC; operation via Commuwin II

PROFIBUS-DP

Profile Version 3.0


supported Baudrates:
19.2 kBaud
45.45 kBaud
93.75 kBaud
187.5 kBaud
500 kBaud
1.5 MBaud
via PROFIBOARD or PROFICARD connection to PC
Operation via Commuwin II or ToF Tool

Synchronizing connection

Parallel link for up to 20 instruments if several sensor cables are


laid together over long distances.

AC

180253 V (50/60 Hz), 90132 V (50/60 Hz),


3855 V (50/60 Hz), 1928 V (50/60 Hz)

DC
Power consumption

2030 V (residual ripple within tolerances)


max. 12 W (typical 8 W), max. 500 mA at 24 V DC

Ripple with Smart transmitters

HART max. Ripple (measured to 500 ) 47125 Hz:


USS=200 mV
max. noise (measured to 500 ) 500 Hz10kHz:
Ueff=2,2 mV

Reliable galvanic isolation

between current output, relay outputs, interfaces, power supply


and sensor inputs

Power supply cable

common two wired screened cable


Maximum values: to 6 per wire, max 60 nF

Ignition protection

CSA General Purpose

CE Mark

By attaching the CE Mark, Endress+Hauser confirms that the


instrument fulfils all the requirements of the relevant EC
directives.

Technical Information TI 189F/00/en Prosonic Ultrasonic Sensors FDU 8086


Operating Instructions BA 100F/00/en Prosonic FMU 860862

Endress+Hauser

Prosonic FMU 860...862

Ordering Information
Product Structure

Prosonic Transmitter FMU 86


Instrument Version
0
One channel for level measurement
1
One channel for flow measurement
2
Two channel for flow and/or level measurement, differential measurement
Certificates *
R Standard (non-certified transmitter, also for all certified sensors)
U CSA General Purpose
Housing for electronics
1 IP 66 protective housing for field mounting and operation
2 Plastic housing IP 40 for remote operation
7 Mounting plate IP 10 for control panel mounting and remote operation
Versions for operation/display/totaliser for flow measurement
A Keypad in protective housing / with display / without totaliser, not for FMU 861
B Keypad in protective housing / with display / with totaliser, not for FMU 860
E Keypad in protective housing / with illuminated display / without totaliser,
not for FMU 861
F Keypad in protective housing / with illuminated display / with totaliser,
not for FMU 860
D Separate keypad for control panel / with display / without counter / without RS 485/
without DP
H Separate keypad for control panel / with illuminated display / without counter / without
RS 485/ without DP
C Separate keypad for rack / with display / without counter / without RS 485/ without DP
G Separate keypad for rack / with illuminated display / without counter / without RS 485/
without DP
K Without keypad / without display / without counter,
operation via HART, RS 485 or PROFIBUS-DP
Relays
1 Three potential-free change-over contacts
2 Five potential-free change-over contacts, not for versions with RS-485 or
PROFIBUS-DP
Power supply
A AC
180253 V
50/60 Hz
B AC
90132 V
50/60 Hz
C AC
3855 V
50/60 Hz
D AC
1928 V
50/60 Hz
E DC
2030 V
Interface/protocol
1 Wtihout interface
3 Serial interface with HART protocol
4 Separate serial Rackbus RS 485 interface
5 Separate serial PROFIBUS-DP interface

FMU 86

Product designation

* Shipbuilding approvals:
GL; DNV, LR, ABS, BV, RINA on request
Scope of delivery

Endress+Hauser

Instrument in the ordered version


Operating manual BA 100F

17

Prosonic FMU 860...862

18

Endress+Hauser

Prosonic FMU 860...862

Endress+Hauser

19

Prosonic FMU 860...862

Endress+Hauser GmbH+Co.
Instruments International
P.O. Box 2222
D-79574 Weil am Rhein
Germany
Tel. (07621) 975-02
Tx 773926
Fax (07621) 975 345
e-mail: info@ii.endress.com

Internet:
http://www.endress.com

11.01

TI 190F/00/en/02.03
FM+SGML 6.0

Prosonic
FMU 860

KA 017F/00/a6/05.00
016085-0000
Software 2.3

d Kurzanleitung Fllstandmessung

VH

FMU 860

e Quick Reference Guide Level Measurement

Mise en service condense niveaumtrie

FDU

es Manual breve de instalacin para la medicin de nivel

Manuale breve di installazine per la misura di livello

nl Verkorte handleiding niveaumeting

Endress + Hauser
The Power of Know How

d Sicherheitshinweise

Qualifikation
Montage, elektrische Installation, Inbetriebnahme, Wartung und Bedienung des Gertes darf
nur durch ausgebildetes Fachpersonal erfolgen, das vom Anlagenbetreiber dazu
autorisiert wurde. Das Fachpersonal mu diese Kurzanleitung und die Betriebsanleitung
BA 100F gelesen und verstanden haben und die Anweisungen befolgen.

e Safety Instructions

Note
Mounting, electrical installation, start-up, maintenance and operation of the instrument are
only to be carried out by trained personnel authorised by the operator of the plant.
The personnel must read, understand and follow the instructions given in this quick reference
guide and the operating manual BA 100F.

Qualification
Le montage, linstallation lectrique, la mise en service, la maintenance et lutilisation de
lappareil ne doivent tre confis qu un personnel spcialis autoris par lutilisateur de
linstallation. Ce personnel devra lire les instructions contenues dans la prsente mise en
service condense ainsi que dans le manuel complet BA 100F et les appliquer
rigoureusement.

Conseils de scurit

d Gerte-Identifikation
ENDRESS+HAUSER
PROSONIC FMU 860
FMU860R1A1 1
U: XX V AC+XX / XX/XX HZ
P: 15 VA
IP 66

Typenschild
Nameplate
Plaque
signaltique

NEMA 4X

Ser.No.: XXXXXXXXXXX
Pat.

Diese Kurzanleitung beschreibt die wesentlichen und erfahrungsgem am hufigsten


benutzten Einstellungen zur Fllstandmessung mit dem FMU 860. Sie gilt fr alle
Gerte, auf deren Typenschild der Code
FMU860-R1A1 1 angegeben ist.
Eine vollstndige bersicht ber alle
Funktionen der Gerte Prosonic
FMU 860862 gibt Betriebsanleitung
BA 100F.

e Instrument Identification

FMU860-R1A1

Standardausfhrung / Standard version / Standard version


Gehuse / Housing / Boitier
Tastatur und Display auf der Frontplatte /
Keypad and display on front panel /
Clavier et affichage en face frontale

This quick reference guide describes the


most important settings for level
measurement with the FMU 860 which are
commonly met in practice. This applies to
all instruments which have nameplates with
the markings FMU860-R1A1 1.
A complete summary of all functions for the
Prosonic FMU 860...862 is given in the
operating manual BA 100F.

Drei Relais / Three relays / Trois relais


Spannungsversorgung / Power supply / Tension dalimentation
A: 180253 V, 50/60 Hz
B: 90132 V, 50/60 Hz
C: 3855 V, 50/60 Hz
D: 1928 V, 50/60 Hz
E: 2030 V (DC)

Ohne Kommunikationsprotokoll /
No communication protocol /
Sans protocole de communication

Identification de lappareil

Cette mise en service condense dcrit les


principaux rglages ou ceux le plus
frquemment utiliss pour la mesure de
niveau avec le FMU 860. Elle est valable
pour tous les appareils portant le code
FMU860-R1A1 1 sur la plaque
signaltique.
Toutes les fonctions des appareils Prosonic
860...862 sont dcrites dans la mise en
service BA 100F.

d Elektrischer Anschlu

Vor allen Arbeiten an der Anschluleiste Spannungsversorgung ausschalten.


berprfen, ob Versorgungsspannung mit der am Typenschild angegebenen bereinstimmt
Bei der Installation des Sensorkabels beachten:
Bei Leitungslngen bis 300 m Klemmenkasten verwenden
Abschirmung nicht erden
Abschirmung ohne elektrische Unterbrechung vom Sensor bis zum Auswertegert fhren
FDU 83, 84, 85, 86: Leitung fr Potentialabgleich nicht innerhalb der Abschirmung mitfhren
Abschirmung: Metallgeflecht max. 6 ,
Kabelspezifikation (pro Ader): max. 6 , max. 60 nF Gesamtkapazitt
Bei der Verdrahtung von mehreren Prosonic-Gerten mssen die Synchronisationsanschlsse verdrahtet werden (siehe BA 100F).

e Electrical Connection

Switch off the power supply to the connecting strip before carrying out any work on the
instrument
Check that the power supply agrees with that stated on the nameplate
When installing the sensor cable ensure that:
Terminal boxes are used for cables up to 300 m
The screening is not grounded
The screening is continuous without any electrical breakage between the sensor and the
transmitter
FDU 83, 84, 85, 86: the potential compensation cable is not laid within the screening
Screening: metal strands max. 6
Cable specifications (per wire): max. 6 , max. 60 nF as total capacitance
When several Prosonics are connected together, the synchronisation connections must also
be made (see BA 100F).

Les travaux de raccordement doivent tre raliss hors tension


Vrifier que la tension dalimentation correspond aux valeurs indiques sur la plaque
signaltique
Lors de la pose du cble de sonde:
en cas de longueurs jusqu 300 m, utiliser une boite de jonction
ne pas mettre le blindage la terre
prvoir un blindage ininterrompu depuis le capteur jusquau transmetteur
FDU 83, 84, 85, 86: ne pas prvoir le conducteur de mise la masse lintrieur du blindage
blindage: tresse mtallique max. 6
spcifications de cble (par conducteur): max. 6 , max. 60 nF de capacit totale
Lorsque plusiers cbles de liaison FMU/FDU doivent tre pos cte cte, il est conseill de
relier les Prosonic FMU entre eux via les bornes de synchronisation (voir BA 100F).

Raccordement lectrique

L+ L-

l1+

L1 N

l2+

YE RD

1 2 3 4 5 6 7 11 12 13 2122 23 31 32 33 4142 43 515253 60 6162 63 64


Strom
current
sortie analogique

Sensor
sensor
sonde

Relais
relays
relais

erden
grounding
barrette de terre

80 81 82

80 8182

70 71 80 81 82

Speisegert
power supply unit
alimentation

80 8182

80 8182

Abschirmung
screening
blindage

BK YE RD

FDU 80/80F/81/81F/82

GNYE BK YE RD

GNYE BK YE RD

FDU 83/84/85/86

FDU 83/84/85/86

Erdung am Klemmenkasten
grounding at the terminal box
mise la terre dans la boite de
jonction

Erdung am FMU
grounding at the FMU
mise la terre au FMU

BN BU BK YE RD

FDU 80/81
mit Heizung
with heating
avec chauffage

d Display

VH

e Display

Affichage

Kommunikationssignal
(nur bei Version mit
Kommunikationsprotokoll)

Communication signal
(only with versions having a
communications protokoll)

Parameter des
gewhlten Matrixfeldes
(blinkt bei der Bedienung)

Parameter of the matrix


field (flashes during
operation)

Matrixfeld

Matrix field

Signalberlauf
Strom grer als 20 mA

Signal overrun
Current greater than 20 mA

Segmentanzeige des
Stroms

Bar display of current

Signalunterlauf
Strom kleiner als 0/4 mA

Signal underrun
Current smaller than
0/4 mA

Symbol zur Fehlermeldung


leuchtet: Strung
blinkt: Warnung, das Gert
versucht weiterzumessen

Symbol for error indication


Lit: Fault
Flashing: Warning,
the instrument tries to
continue measuring

Symbole de
communication
(Seulement pour version
avec protocole de
communication)

Paramtre de la case
matricielle slectionne
(clignote lors de la
programmation)

Coordonnes matriciel
les slectionnes

Dpassement de signal
Courant suprieur 20 mA

Affichage bargraph
reprsentatif du signal
analogique

Dpassement de signal
Courant infrieur 0/4 mA

Symbole de dfaut
allum: dfaut
clignote: avertissement,
lappareil essaye de
poursuivre la mesure

Matrixfeld whlen mit V und H


der Parameter im angewhlten Matrixfeld
blinkt und kann verndert werden
Hinweis: Bei gleichzeitigem Drcken von V
und H springt die Anzeige auf V0H0

d Bedienung

Der FMU wird ber eine 10x10-Felder


Matrix bedient (siehe Seite 18/19)
Jedem Feld der Matrix ist eine Funktion
zugeordnet.

VH

Parameter ndern mit + , ,


Hinweis: Bei gleichzeitigem Drcken von V
und springt der Dezimalpunkt eine Stelle
nach rechts.

Eingabe besttigen mit Enter


Select matrix field with V and H keys
The parameter in the selected field flashes
and can be changed
Note: The display jumps to V0H0 when V
and H are pressed simultaneously
Change the parameter using the keys +,

e Operation
The FMU is operated using a 10x10-field
matrix (see page 18/19)
A function is assigned to every field of the
matrix.

,
Note: The decimal point moves one
position to the right when V and are
pressed simultaneously.
Confirm input with E

VH

Slectionner la case matricielle avec


V et H
le paramtre slectionn dans la case
clignote et peut tre modifi
remarque : en activant simultanment V
et H laffichage passe V0H0
Modifier les paramtres avec +, ,
remarque: en activant simultanment V et
la dcimale se dplace dun rang vers la
droite
Valider lentre avec Enter

Commande

Le FMU est programmable par le biais


dune matrice 10x10 (voir page 18/19)
A chaque case de la matrice est attribue
une fonction.

E
7

d Parametrierung
Nach jedem Parametrierungsschritt knnen
die aktuellen Mewerte abgefragt werden.
Fr Funktionen, die nicht parametriert
werden, gelten die Werkseinstellungen.

Grundeinstellungen
Basic settings
Rglage de base

10

Mewertanzeige
Display of measured value
Affichage de la mesure

Abgleich
Calibration
Etalonnage

11

Eingabe Kundeneinheit
Entering technical units
Linarisation pour
afficage en unit technique

12

e Calibration
The actual measured values can be called
up after each calibration step.
Factory settings are used for those
functions not calibrated.

Analogausgang
Analogue output
Sortie analogique

13

Relais
Relay
Relais

15

Programmation

Aprs chaque pas de programmation il est


possible dinterroger les valeurs de mesure
actuelles.
Pour les fonctions non programmes ce
sont les rglages par dfaut qui sont
valables.

Verhalten bei Strung


Response on fault
Comportement en cas
de dfaut

Fehlerdiagnose
Trouble-shooting
Recherche de dfauts

16

17

d Mewertanzeige

V0H0: % oder beliebige Maeinheit


V0H8: Distanz D (m/ft)
V0H9: Fllhhe h (m/ft)
BD
Blockdistanz
Blocking Distance
Distance de blocage
FDU 80/80F

0.3 m

FDU 81/81F

0.5 m

FDU 82

0.8 m

FDU 83

1.0 m

FDU 84

0.8 m

FDU 85

0.8 m

FDU 86

1.6 m

BD

d Matrix verriegeln

100%
V0H8

V0H0
V0H9

Nach Eingabe aller Parameter Matrix


verriegeln!
In der verriegelten Matrix knnen die
Eingaben gelesen aber nicht gendert
werden.

e Display of Measured Value

V0H0: % or units selected


V0H8: Distance D (m/ft)
V0H9: Height h (m/ft)

0%

e Locking the Matrix

V0H0

Anzeige
Mewert (% oder
beliebiger Maeinheit)

Display
Meas. value (% or in
units selected)

Affichage
Valeur mesure
(% ou unit technique)

V0H8

Distanz D (m/ft)

Distance D (m/ft)

Distance D (m/ft)

V0H9

Fllhhe h (m/ft)

Height h (m/ft)

V9H6

Matrix verriegeln
Eingabe einer
beliebigen dreistelligen
Zahl

Locking the matrix


Enter any 3-figure
number

Hauteur de niveau H
(m/ft)
Verrouiller la matrice
Entre dun nombre
quelconque trois
chiffres

V9H6

Verriegelung aufheben
Unlocking the matrix
Eingabe von 519
Enter the number 519

Dverrouiller la matrice
Entre de 519

Lock the matrix after entering all the


parameters!
Entries can be read but not changed when
the matrix is locked.

Affichage de la mesure

Verrouillage de la matrice

V0H0 : % ou unit technique quelconque


V0H8 : distance D (m/ft)
V0H9 : hauteur de niveau h (m/ft)
Aprs programmation de tous les
paramtres, verrouiller la matrice!
Dans la matrice verrouille il est possible
de lire les paramtres programms mais
non de les modifier.

d Grundeinstellungen

Leuchtet oder blinkt whrend der Grundeinstellungen


Lights up or flashes when entering basic settings
S allume ou clignote pendant les rglage de base

Diese Einstellungen bei Inbetriebnahme


oder Austausch des Sensors vornehmen.
Aus der Tabelle Matrixfelder in der richtigen
Reihenfolge entnehmen und
Eingabeparameter (fett gedruckt z.B. 333
fr Grundreset) auswhlen.
Eingabe mit E besttigen.
Achtung: Lngeneinheit darf nur unmittelbar nach einem Reset gendert werden.

VH

1
VH

VH

+
E

e Basic Settings
Carry out these settings on start-up or when
replacing the sensor.
Call up the matrix fields from the table in
the correct sequence and select the
parameter to be entered (bold type, e.g.
333 for general reset).
Register entry with E.
Note: Units of length should only be
changed immediately after a reset.

1.

V9H5

Eingabe
333: Grundreset

Entry
333: Reset

BUSY erscheint in der Anzeige shown in display

Rglages de base

Ces rglages doivent tre effectus la


mise en service ou lors du remplacement
de la sonde.
Slectionner les cases matricielles dans
lordre indiqu ci-dessous et programmer
les paramtres imprims en gras
(par ex. 333 pour reset de base).
Activer E pour valider l entre.
Attention: lunit de longueur ne doit tre
modifie quimmdiatement aprs un reset.

10

2.

V8H3

3.

V8H0

4.

V0H4

Lngeneinheit whlen
0: m
1: ft
Betriebsart whlen
0: Fllstand Kanal 1
Sensortyp
80: FDU 80, 81: FDU 81
80F: FDU 80F
81F: FDU 81F
82: FDU 82, 83: FDU 83
84: FDU 84, 85: FDU 85
86: FDU 86

Technical units
0: m
1: ft
Operating mode
0: level channel 1
Sensor type
80: FDU 80, 81: FDU 81
80F: FDU 80F
81F: FDU 81F
82: FDU 82, 83: FDU 83
84: FDU 84, 85: FDU 85
86: FDU 86

Entre
333: Reset
apparait dans laffichage
Unit de longueur
0: m
1: ft
Mode de fonctionnement
0: Niveau voie 1
Type sonde
80: FDU 80, 81: FDU 81
80F: FDU 80F
81F: FDU 81F
82: FDU 82, 83: FDU 83
84: FDU 84, 85: FDU 85
86: FDU 86

BD

Fllstandanwendungen
Applications of level measurement
Types dapplications
V0H3

100%

0%

1.

V0H1

2.

V0H2

3.

V0H3

Eingabe
Leer E: Distanz
Sensormembran
0%-Punkt
Voll F: Distanz 0%Punkt 100 %-Punkt
Fllstandanwendung:
0: Flssigkeit
1: Schnelle Fllstandnderung
2: feine Feststoffe
3: Grobe Feststoffe
4: Bandbelegung
Fr das 0/420 mA
Signal gilt die
Werkseinstellung:
0 %: 0, 100 %: 100

Entry
Empty E: Distance
sensor diaphragm
0% point
Full F: Distance
0% point - 100% point

Entre
Vide E: distance entre la
sonde et le niveau 0%

Plein F: distance entre


le niveau 0% et le
niveau 100%
Types dapplications
Level application
0: liquides
0: Liquids
1: changement rapide
1: Rapid level change
du niveau
2: Fine grain solids
2: solides faible granul.
3: Coarse grain solids
3: solides grosse granul.
4: Conveyor belt
4: convoyeur bande
Le rglage par dfaut
The factory setting for
the 0/4...20 mA signal is: (0% : 0, 100% : 100) est
0 %: 0, 100 %: 100
valable pour le signal
0/4...20 mA

d Abgleich
Grundlage fr alle Messungen sind die
Eingaben Leer und Voll
Leer E: Distanz Sensormembran0%-Punkt
Voll F: Distanz 0%-Punkt100%-Punkt
Angaben fr E und F nur in der
Lngeneinheit, die beim Grundabgleich
gewhlt wurde
Zuweisung 0/420 mA: Analogausgang
(S. 13) und Beispiel und (S.14)

e Adjustment
The basis for all measurements are the
entries Empty and Full
Empty E: Distance of the sensor
diaphragm...0% point
Full F: Distance of 0% point...100% point
Values for E and F are only given in the
units selected during the basic calibration
Allocating 0/4...20 mA: Analogue output
(Page 13) and Examples and
(Page 14)

Etalonnage

Etalonnage de base: talonnage vide/plein


Vide E: distance entre la membrane et
le niveau 0%
Plein F: distance entre le niveau 0% et
le niveau 100%
Valeurs E et F dans lunit de longueur
slectionne lors de ltalonnage de base
Attribution 0/4...20 mA: sortie analogique
(p. 13) et exemples et (p. 14)

11

Diese Eingaben ermglichen es, den


Mewert (V0H0) fr einen linearen Behlter
nicht in %, sondern in einer beliebigen
Maeinheit abzulesen.
Dem 100%-Punkt wird der entsprechende
Wert in der gewnschten Einheit
zugewiesen.
Diese Eingaben nur dann, wenn keine
Linearisierung erfolgen soll.

BD

100%

e Selecting the Units


These entries enable the measured value
(V0H0) for a linear vessel to be read off in
any units, not in %.
The appropriate value is allocated to the
100% point in the units required.
These values are only entered if no
linearisation is to be carried out.

Choix dune unit technique


quelconque

Si la valeur mesure ne doit pas tre


indique en % en V0H0 mais dans une autre
unit, quelques paramtres supplmentaires
devront tre ajouts ceux de ltalonnage
de base.
Aux point 100% on attribue la valeur
correspondante dans lunit souhaite.
Cette programmation nest valable que si
aucune linarisation na t effectue.

12

0%

5.

V2H7

6.

V2H0

Fllhhe / height / hauteur de niveau

d Auswahl einer beliebigen


Maeinheit

Eingabe
(siehe auch Beispiel 1
Seite 14)
Volumen am 100%Punkt in Kundeneinheit
Linearisierungsart
0: linear

nur fr lineare Behlter


only linear vessel
uniquement pour
rservoirs linaires

(m3, hl, )

Volumen / volume / volume

Entry
(see also Example 1,
page 14)
Volume at 100% point in
technical units
Linearisation mode
0: linear

Entre
(Voir aussi exemple 1
page 14)
Volume V1 (100%)
en unit technique
Type de linarisation
0: linaire

d Analogausgang einstellen

20 mA

4 mA
0%

100 %
Mewert /
measured value /
valeur de mesure

Die Einstellungen zum Analogausgang


ordnen dem Mewert ein Stromsignal zu
dem Wert am 0 %-Punkt 0 oder 4 mA
dem Wert am 100 %-Punkt 20 mA
Der Stromausgang kann so eingestellt
werden, da der Mewert (V0H0) bei
Strungen einen bestimmten Wert einnimmt.
Bei Strungen leuchtet das Symbol zur
Fehlermeldung.

110 %

Verhalten bei Strung / Display on error /


Affichage en cas de derreur
V8H1 0: 020 mA 1: 420 mA

20 mA

e Setting the Analogue Output

hold

V3H4

0: 10 %
1: +110 %

-2 mA
22 mA

-2,4 mA
21,6 mA

4 mA

V8H1

Eingabe
Entry
(siehe auch Beispiel 1
(see also Example 1
und 2, S.14)
and 2, Page 14)
Stromausgang whlen
Select current output

2.

V0H5

0: 020 mA
1: 420 mA
4 mA-Wert

0: 020 mA
1: 420 mA
4 mA value

3.

V0H6

4.

V3H4

20 mA-Wert
Anzeige bei Strung
0: -10 %
des Mebereichs
1: 110 %
des Mebereichs
2: letzten Mewert halten

20 mA value
Display on error
0: -10%
of measuring range
1: 110%
of measuring range
2: Hold last measured
value

1.

- 10 %

Zeit / time / temps

Entre
(voir ausi exemples 1
et 2, p. 14)
Slectionner sortie
courant
0: 0...20 mA
1: 4...20 mA
Valeur 4 mA
Valeur 20 mA
Affichage en cas de
derreur
0: -10% de la gamme
de mesure
1: 110% de la gamme
de mesure
2: maintenir la dernire
valeur

The settings for the analogue output


allocate a current signal to the measured
value
0 or 4 mA at 0% point
20 mA at 100% point
The current output can be set so that the
measured value (V0H0) assumes a specific
value on error.
The error symbol lights up on error.

Rglage de la sortie analogique

Les rglages de la sortie courant attribuent


une valeur de dbut dchelle la valeur
initiale de la sortie courant (0 mA ou 4 mA)
une valeur de fin dchelle (20 mA)
La sortie courant peut tre rgle de
manire ce quelle prenne une certaine
valeur en cas de dfauts.
En prsence dun dfaut un symbole
clignote pour le signaler.

13

d Beispiel

Fr einen stehenden zylindrischen Tank

soll der Mewert (V0H0) in hl


ausgegeben werden.
100 %: 350 hl
Als Analogausgang wird 420 mA
gewhlt.
15 hl: 4 mA
350 hl: 20 mA
Bei Strungen soll der Stromausgang
110 % des Mebereichs einnehmen.

e Example

100 %

350 hl

0%

15 hl

100 %

350 hl

1.
2.

Eingabe
350
0

V2H7
V2H0

Entry
350
0

V2H7

Entre
350
0

The measured value (V0H0) should be

given in hl for a vertical cylindrical tank


100%: 350 hl
A 4...20 mA signal is selected for the
analogue output.
15 hl: 4 mA
350 hl: 20 mA
On error, the current output should
assume 110% of the measuring range.

Exemple

Pour un rservoir cylindique vertical, la

14

mesure (V0H0) doit tre donne en hl


100%: 350 hl
Comme sortie analogique on choisit
4...20 mA
15 hl: 4 mA
350 hl: 20 mA
En cas de dfaut la sortie courant doit
tre gale 110 % de la gamme de
mesure.

350 hl

21,6 mA
20 mA

15 hl

4 mA

110 %

Zeit / time / temps

1.
2.
3.
4.

V8H1
V0H5
V0H6
V3H4

Eingabe
1
15
350
1

Entry
1
15
350
1

Entre
1
15
350
1

Relaisbezeichnungen / Relay symbols / Etat des relais


Ruhezustand: abgefallen
Arbeitszustand: angezogen
Operating mode: energised
Standby mode: de-energised
Travail: attir
Repos: retomb
Relais
Relais
relay
relay
LED
relais
relais
r u a

d Relaisfunktion Grenzwert

LED

r u a

LED

V1H3
r u a

LED

V1H3

fallend / falling /
descendant

zieht an / energises / attir

V1H2

steigend / rising /
montant
fllt ab / de-energises /
retombe

BD

Relais / relay / relais

r u a

V1H2
Fllstand / level / niveau

Eingabe
Relais whlen
1: Relais 1
2: Relais 2
Relaisfunktion whlen
0: Grenzwert

Entry
Select relay
1: relay 1
2: relay 2
Select relay function
0: limit value

Entre
Choix relais
1: relais 1
2: relais 2
Fonction relais choisir
0: fonction seuil

V1H2

Einschaltpunkt
in Kundeneinheit

Switch on point
in customer units

Point denclenchement
unit technique

V1H3

Ausschaltpunkt
in Kundeneinheit

Switch off point


in customer units

Point de
dclenchement
unit technique

1.

V1H0

2.

V1H1

3.

4.

FMU 860 hat 3 (1, 2, 5) wahlweise 5


Relais. Relais 5 ist die Funktion Strrelais
zugeordnet.
Diese Einstellungen weisen einem Relais
Schaltpunkte zu, die Grenzwerte bei der
Befllung des Behlters sind.
Das Grenzwertrelais schaltet in
Abhngigkeit des vorgegebenen Einschaltund Ausschaltpunktes und bezieht sich auf
den Mewert in V0H0.

e Relay Function Limit Value


FMU 860 has 3 (1, 2, 5) or 5 relays.
Relay 5 is allocated the error relay.
These settings assign switchpoints to a
relay, which are the limit values when filling
the tank.
The limit value relay responds to the
preset switch on and switch off points and
refers to the measured value in V0H0.

Fonction relais seuil

Le FMU 860 possde 3 (1, 2, 5) ou 5 relais.


Au relais 5 est attribue la fonction relais
dfaut.
Ces rglages attribuent un relais des
points de commutation qui font office de
seuils lors du remplissage du rservoir.
Le relais de seuil commute en fonction des
points denclenchement et de
dclenchement.

15

d Verhalten bei Strung


Das Relais zur Strungsmeldung fllt ab
Das Symbol zur Strungsmeldung leuchtet
oder blinkt
Der Analogausgang reagiert entsprechend
den Einstellungen in V3H4
ber den Fehlercode wird der Fehler
identifiziert

e Response on Error

The relay for error indication de-energises


The symbol for error indication lights up or
flashes
The analogue output responds according
to the settings in V3H4
The error is identified by its error code

Comportement en cas de dfaut

Le relais de dfaut retombe


Le symbole de signalisation de dfaut
sallume ou clignote
La sortie analogique reagit en fonction des
rglages en V3H4
Le dfaut est identifi laide du code
erreur

16

blinkt
flashes
clignote

Anzeige des aktuellen Fehlercodes z.B. E501


Display of the actual error code, e.g. E501
Affichage du code erreur actuel par ex. E501

Relais zur Strungsmeldung fllt ab


die gelbe LED blinkt
Relay for error indication
de-energises, the yellow LED flashes
Relais de dfaut retombe,
la DEL jaune clignote

normal
normal
normal

Segmentanzeige des Stroms zeigt


Signalber- oder Unterlauf
Bar graph of current shows signal
outside range
Affichage du symbole de
dpassement de signal

Strung
error
dfaut

1.

V9H0

Anzeige
Aktueller Fehlercode

Display
Current error code

Affichage
Code erreur actuel

2.

V9H1

Letzter Fehlercode

Last error code

Dernier code erreur

3.

V9H2

Vorletzter Fehlercode

Last but one error code

Avant dernier code


erreur

E501

E613

E231

Diagnose / Manahme
Kein Sensortyp gewhlt
In V0H4 Sensortyp
eingeben
Gert in Betriebsart
Simulation;
in V8H0 Betriebsart 0
whlen
Kurzschlu interner
Temperaturfhler;
Sensoranschlu berprfen oder
E+H-Service rufen

E641

Ultraschallecho kann
nicht ausgewertet
werden; Fehler durch zu
hohe Dmpfung (Staub
oder Schaum);
bleibt Fehler lnger
bestehen
Sensoranschlu
berprfen oder
E+H-Service rufen

E661

Temperatur am Sensor
zu hoch;
Mestelle berprfen

E111
E112
E113
E114
E115

Elektronischer
Gertefehler.
E+H-Service rufen

Error and remedy


No sensor type selected
Enter sensor type in
V0H4
Instrument in simulation
mode
Select mode 0 in V8H0
Short circuit of the
internal temperature
sensor;
Check sensor
connection or call E+H
Service Centre
Ultrasonic echo cannot
be evaluated. Error tue
to excessive damping
(dust or foam);
The error remains check
sensor connection or
call E+H Service Centre

Erreurs et remdes
Aucun type de sonde
slectionn en V0H4.
Entrer le type de sonde.
Appareil en mode
simulation. Choisir en
V8H0 un autre mode de
fonction.
Court-circuit de la sonde
de temprature interne.
Vrifier le raccordement
de sonde ou contacter
SAT E+H.
Echos ne peuvent tre
exploits. Error due un
amortissement trop
important (poussires
ou mousse); si lerreur
subsiste, vrifier le
raccordement de sonde
ou contacter le SAT E+H.
Vrifier le raccordement
de sonde ou contacter
SAT E+H.
Temprature la sonde
trop leve; vrifier le
point de mesure

Temperature at the
sensor too high.
Check measurement
point
Electronic instrument
Dfaut dlectronique;
error.
appeler le SAT E+H
Call E+H Service Centre

d Fehlerdiagnose und Manahme


Treten auer den genannten
Fehlermeldungen noch weitere auf oder lt
sich der Fehler nicht beheben, Angaben in
der Betriebsanleitung BA100F beachten oder
E+H-Kundendienst informieren.

e Error and Remedy


If other error messages occur besides those
given or if the error cannot be remedied, then
refer to information given in BA100F and
contact your E+H Service Centre.

Erreurs et remdes

Si en plus du message erreur signal il se


produit encore dautres dfauts ou si lerreur
en question ne peut tre supprime suivre
les conseils donns dans BA100F et en
informer le SAT E+H.

17

FMU 860

V0

d
e
f

Grundabgleich Mekanal 1
Calibration Channel 1
Etalonnage de base voie 1

H0
Mewert
Measured value
Valeur de mesure

H1
Abgleich Leer
Empty calibration
Etalonnage vide

H2
Abgleich Voll
Full calibration
Etalonnage plein

H3
Fllstandanwendung
Level application
Type dapplication

Relais

Auswahl Relais

Relaisfunktion

Einschaltpunkt

Ausschaltpunkt

e
f

Relays
Relais

Relay selection
Slection relais

Relay function
Fonction relais

Switch-On point
Point dencl.

Switch-Off point
Point de dcl.

d
e
f

Linearisierung Mekanal 1
Linearisation Channel 1
Linarisation voie 1

Linearisierung
Linearisation
Linarisation

d
e

Echoparameter Mekanal 1
Echo parameters Channel 1

Ist-Fllhhe
Actual level
Hauteur de remplissage relle
Echodmpfung
Echo attenuation

V1

V2

V3

Eingabe Fllhhe
Input level
Entre hauteur de
niveau relle
Wenn Echo fehlt
If no echo

Festzielausblendung
S/N-Verhltnis
Range for automatic
Signal/noise ratio
suppression
Paramtres chos voie 1
Suppression des
Attnuation de lcho Rapport signal/bruit
Perte dcho
chos fixes
Zeilen 4, 5 und 6 nur bei FMU 862 / Rows 4, 5 and 6 for FMU 862 only / Lignes 4, 5 et 6 uniquement pour FMU 862
Service
Service
Service
Service
Service
Service
Service
Service
Service
Service
Service
Service
Service
Service
Service
Betriebsparameter
Betriebsart
Stromausgnge
4 mA-Schwelle
Lngeneinheit

V7

d
e
f
d

V8

Operating status

Operating mode

Select current

4 mA-threshold

Select distance unit

Paramtres de fonctionnement

Sorties courant

Seuil 4 mA

Unit de longueur

Service und Simulation

Mode de
fonctionnement
Aktueller Fehlercode

Letzter Fehlercode

Vorletzter Fehlercode

Service and simulation

Diagnostic code

Last diagnostic code

Service et simulation

Code erreur actuel

Dernier code erreur

Last but one diagn.


code
Avant-dernier code
erreur

Gerte und
Softwareversion
Instrument and
software version
Version appareil et
logiciel

V9

f
Anzeigefeld / Output fields / Zone daffichage

18

H4
Sensortyp
Type of sensor
Type sonde

H5
Wert fr 0/4 mA
Value for 0/4 mA
Valeur pour 0/4 mA

Alternierende
Pumpensteuerung
pump control
Commande de
pompe alterne
Eingabe Volumen
Input volume
Entre volume

Zeilennummer
Line number
Numro ligne

Verhalten bei Strung


Safety alarm

Hllkurvenstatistik
Envelope statistics

H6
Wert fr 20 mA
Value for 20 mA
Valeur pour 20 mA

H7
Integrationszeit
Output damping
Temps dintgration

H8
Distanz
Measured distance
Distance

H9
Fllhhe
Measured level
Hauteur de
niveau
Schaltverzgerung

Switch delay
Temporisation
Durchmesser Behlter
Diameter of vessel
Diamtre cuve cyl.
horiz.

Volumen Behlter
Volume of vessel
Volume cuve cyl.
horiz.

En cas dalarme

Service
Service
Service

Statistique de la
courbe enveloppe
Zeilen 4, 5 und 6 nur bei FMU 862 / Rows 4, 5 and 6 for FMU 862 only / Lignes 4, 5 et 6 uniquement pour FMU 862
Service
Service
Service
Service
Service
Service
Service
Service
Service
Service
Service
Service
Service
Service
Service
Externer
Grenzwertschalter
Temperaturfhler
Limit switch
External temperature
sensor
Dtecteurs externes
Sonde de temp.
externe
Verriegelung
Simulation Fllstand
Simulation Volumen
Simulation Strom
General Reset 333

General reset 333

Security locking

Simulation level

Simulation volume

Simulation current

Reset gnral 333

Verrouillage

Simulation niveau

Simulation volume

Simulation courant

Eingabefeld / Entry fields / Zone dentre

19

20

Prosonic
FMU 860

KA 017F/00/a6/05.00
016085-0000
Software 2.3

es Manual breve de instalacin para la medicin de nivel

VH

FMU 860

Manuale breve di installazine per la misura di livello

nl Verkorte handleiding niveaumeting


FDU

Endress + Hauser
The Power of Know How

es Nota sobre seguridad

Atencin
El montaje, la instalacin elctrica, la puesta en marcha, el mantenimiento y la utilizacin del
instrumento debe realizarse nica y exclusivamente por personal cualificado, autorizado por
el operario de la planta. El personal deber leer y seguir atentamente las instrucciones
indicadas en el presente manual breve de instalacin, as como el manual de servicio
BA 100F.

Nota
Linstallazione, i collegamenti elettrici, la messa in esercizio, la manutenzione e lutilizzo
di questo strumento deve essere effettuata esclusivamente da personale qualificato.
Il personale dovr leggere attentamente, capire e seguire le istruzioni fornite da questo
manuale breve e dal manuale operativo BA 100F.

Note sulla sicurezza

nl Veiligheidsinstructies

Kwalificatie
De montage, elektrische installatie, inbedrijfname, onderhoud en bediening van het
instrument alleen door gekwalificeerd personeel laten uitvoeren. Laat het personeel deze
verkorte handleiding en de inbedrijfnamevoorschriften BA 100F lezen en begrijpen en volg
alle instructies hierin vermeld.

es Identificacin del instrumento

ENDRESS+HAUSER
PROSONIC FMU 860
FMU860R1A1 1
U: XX V AC+XX / XX/XX HZ
P: 15 VA
IP 66

Placa de
identificacin
etichetta
typeplaatje

NEMA 4X

Ser.No.: XXXXXXXXXXX
Pat.

El presente manual breve de instalacin


describe los ajustes ms comunmente
empleados para la medicin de nivel. Esto
tambin es aplicable a todos los
instrumentos que lleven la indicacin
FMU 860-R1A1 1.
Para informacinms detallada sobre todas
las posibilidades e ajuste del Prosonic
FMU 860862 consultar el manual de
puesta en servicio BA 100F.

FMU860-R1A1

versin estndar / versione standard / standaarduitvoering


caja / custodia / behuizing
teclado e indicador en parte frontal /
tastiera e display sul frontalino /
toetsen en display op het front

Identificazione dello strumento

Questo manuale breve descrive le pi


importanti impostazioni per la misura di
livello con lFMU 860.
E riferito a tutti quegli strumenti che
sulletichetta di indentificazione riportano il
numero di codice FMU860-R1A1 1.
La descrizione di tutte le funzioni del
Prosonic FMU 860...862 disponibile nel
Manuale Operativo BA100F.

tres rels / tre rel / drie relais


Tensin de alimentacin / alimentazione / voedingsspanning
A: 180253 V, 50/60 Hz
B: 90132 V, 50/60 Hz
C: 3855 V, 50/60 Hz
D: 1928 V, 50/60 Hz
E: 2030 V (DC)

sin protocolo de comunicacin /


nessun protocollo di comunicazione /
zonder communicatieprotocol

nl Identificatie instrument

Deze verkorte handleiding beschrijft de


wezenlijke en meest voorkomende
instellingen voor niveaumeting met de
FMU 860. Deze geldt voor alle instrumenten
waarbij op het typeplaatje de code
FMU860-R1A1 1 is vermeld.
Een volledig overzicht van alle functies van
de instrumenten Prosonic FMU860...862 is
opgenomen in de inbedrijfnamevoorschriften
BA100F.

es Conexin elctrica

Antes de manipular el instrumento asegrese de que est desconectado de la fuente de


alimentacin.
Verificar que la tensin de alimentacin se corresponde con los valores indicados en la
placa de identificacin.
Al instalar el cable del sensor debe asegurarse que:
Las cajas de terminales intermedias pueden ser utilizadas con 300 mts de cable como mx.
La pantalla no debe estar conectada a tierra
La pantalla no debe sufrir ninguna rotura entre el sensor y el transmisor
FDU 83, 84, 85, 86: el cable de compensacin de potencial no se encuentra en la pantalla.
Pantalla: filamentos de metal mx. 6
Especificaciones del cable (por hilo): mx. 6 , mx 60 nF de capacidad total
Si varios equipos Prosonic se encuentran instalados unos cerca de otros, debern ser
sincronizados (ver BA 100F).

Scollegare lalimentazione prima di ogni intervento sullo strumento.


Accertarsi che la tensione di alimentazione equivalga a quella indicata sulla targhetta.
Installando il cavo del sensore assicurarsi che:
per cavi di lunghezza fino a 300 m vengano utilizzate scatole di giunzione
le schermature non siano collegate a terra
a schermatura non presenti interruzione fra il sensore e il trasmettitore
FDU 83, 84, 85, 86: il cavo di compensazione di potenziale non deve essere allinterno
della schermatura
schermatura: rete metallica max. 6
specifiche del cavo: max. 6 per anima. max 60 nF come capacit totale
Nel caso di utilizzo di pi centraline Prosonic, queste vanno sincronizzante con lopportuno
collegamento (vds. BA 100F).

Collegamenti elettrici

nl Elektrische aansluiting

Schakel altijd eerst de voedingsspanning uit voordat met werkzaamheden wordt begonnen.
Controleer of de voedingsspanning overeenkomt met die welke staat vermeld op het
typeplaatje.
Let bij het installeren van de sensorkabel op het volgende:
Gebruik bij kabellengten tot 300 m een klemmenkast
Aard de afscherming niet
Trek de afscherming zonder elektrische onderbreking van de sensor naar de meetversterker
FDU 83, 84, 85, 86: kabel voor potentiaalvereffening niet binnen de afscherming leggen
Afscherming: gevlochten metaal max. 6
Kabelspecificatie (per ader): max. 6 , max. 60 nF totale capaciteit
Bij de aansluiting van meerdere Prosonic-instrumenten moeten de synchronisatieaansluitingen verbonden worden (zie BA 100F).

L+ LL1 N

l1+

l2+

YE RD

1 2 3 4 5 6 7 11 12 13 2122 23 31 32 33 4142 43 515253 60 6162 63 64

salida analgica
corrente
stroom
toma de tierra
messa a terra
aarde

80 81 82

80 8182

70 71 80 81 82
sensor
sensore
sensor

rels
rel
relais

alimentacin
alimentatore
voedingseenheid

80 8182

80 8182

pantalla
schermatura
afscherming

BK YE RD

FDU 80/80F/81/81F/82

GNYE BK YE RD

GNYE BK YE RD

FDU 83/84/85/86

FDU 83/84/85/86

toma de tierra dentro de la caja


de terminales
messa a terra alla scatola di
giunzione
aarde aan klemmenkast

toma de tierra en el FMU


messa a terra allFMU
aarde aan FMU

BN BU BK YE RD

FDU 80/81
con calefactor
con riscaldatore
met verwarming

es Indicador

VH

Seal de comunicacin
(slo en versiones con
protocolo de
comunicacin)

Segnale di comunicazione
(solo per versioni con
protocollo di
comunicazione)

Parmetro del campo en


la matriz (parpadea
durante la programacin)

Campo de matriz

Parametro della matrice


operativa (lampeggia
durante
il funzionamento)

Campo di matrice

Superacin de la seal
Corriente superior a 20 mA

Superamento del segnale.


Corrente superiore a
20 mA

Grfico de barras
representando la seal
analgica

Superacin de la seal
Corriente inferior a 0/4 mA

Indicazione a barre del


segnale

Smbolo de indicacin de
error
iluminado: fallo
intermitencia: advertencia,
el instrumento intenta
continuar la medicin

Superamento del segnale.


Corrente inferiore a 0/4 mA

Simbolo dellindicazione
derrore.
acceso: errore
lampeggiante:
avvertimento,
lo strumento prova a
continuare il
funzionamento

nl Display

Display

Communicatiesignaal
(alleen bij uitvoering met
communicatieprotocol)

Parameter van het


geselecteerde matrixveld
(knippert tijdens het
programmeren)

Matrixveld

Balkdisplay stroomuitgang

Symbool voor storing


brandt: storing
knippert: waarschuwing,
het instrument probeert
verder te meten

Signaaloverschrijding
stroom groter dan 20 mA
Signaalonderschrijding
stroom kleiner dan 0/4 mA

Seleccionar el campo matriz con las


teclas V y H
El parmetro del campo seleccionado,
parpadea y puede ser cambiado
Nota: El indicador cambia a V0H0 cuando
se presionan simultneamente las teclas V
yH
Utilizar las teclas +, , para modificar
los parmetros
Nota: El punto decimal se desplaza una
posicin a la derecha cuando V y se
presionan simultneamente.

es Funcionamiento

El FMU se programa mediante una matriz


10x10 campos (ver pg. 18/19)
A cada campo de matriz se le asigna una
funcin.

VH

Confirmar la programacin presionando E

Funzionamento

Il Prosonic FMU funziona attraverso una


matrice operativa di 10x10 campi
(vds. pag. 18 e 19).
Ad ogni campo di matrice assegnata una
funzione.

Selezionare il campo di matrice tramite i


tasti V e H
Il parametro nel campo selezionato
lampeggia e pu essere modificato
Nota: Il display torna a V0H0 quando i tasti
V e H vengono premuti simultaneamente
Modificare il parametro usando
i tasti +, ,
Nota: Il punto decimale si sposta di una
posizione verso destra quando V e
vengono premuti simultaneamente
Confermare la modifica premendo E

VH

+
nl Bediening

Matrixveld kiezen met V en H


de parameter in het gekozen matrixveld
knippert en kan worden gewijzigd
opmerking: bij tegelijkertijd indrukken van V
en H verspringt het display naar V0H0
Parameter wijzigen met +, ,

Opmerking: bij tegelijkertijd indrukken van


V en verspringt de decimale punt een
positie naar rechts.

De FMU wordt met behulp van een 10x10


matrix bediend (zie blz. 18/19).
Aan ieder veld in de matrix is een bepaalde
functie toegekend.

Invoer bevestigen met Enter


7

es Programacin

Los valores de medida se pueden


recuperar despus de cada programacin.
Los ajustes de fbrica se emplean para
aquellas funciones no programadas.

Ajuste bsico
Impostazioni di base
Basisinstelligen

10

Indicazione del valore medido


Misurato
Meetwaarde-aanwijzing

Calibracin
Taratura
Inregeling

11

Introduccin de valores
en unidades seleccionadas
Ingegneristiche
Invoer klanteenheid

12

Taratura

I valori misurati attuali possono essere


richiamati dopo ogni passo di taratura.
Per le funzioni per cui non si fatta alcuna
taratura vengono utilizzate le impostazioni
di fabbrica.

Salida analgica
Uscita analogica
Analoge uitgang

13

Rels
Rel
Relais

15

nl Parameters instellen

Na iedere instelling van een parameter


kunnen de momentele meetwaarden worden
opgevraagd.
Voor functies die niet worden ingesteld
gelden de default-instellingen.

Respuesta en caso de fallo


Riposta in caso di guasto
Gedrag bij storing

16

Deteccin da fallo
Ricerca guastia
Foutdiagnose

17

es Indicacin del valor medido

V0H0: % o unidades seleccionadas


V0H8: Distancia D (m/ft)
V0H9: Altura H (m/ft)
BD
distancia de bloqueo
distanza di blocco
blokafstand
FDU 80/80F

0.3 m

FDU 81/81F

0.5 m

FDU 82

0.8 m

FDU 83

1.0 m

FDU 84

0.8 m

FDU 85

0.8 m

FDU 86

1.6 m

BD

es Bloqueo de la matriz

100%
V0H8

V0H0
V0H9

0%

Bloquear la matriz despus de introducir


todos los parmetros.
Los parmetros pueden visualizarse pero
no cambiarse cuando la matriz est
bloqueada.

V0H0: % o unit selezionate


V0H8: Distanza D (m/ft)
V0H9: Altezza h (m/ft)

V0H0

Indicacin
Visualizzatore
Valor medido (% o en
Valore misurato (% o
unidades seleccionadas) nelle unit selezionate)

Display
Meetwaarde (% of
willekeurige eenheid)

V0H8

Distancia D (m/ft)

Distanza D (m/ft)

Afstand D (m/ft)

V0H9

Altura H (m/ft)

Altezza h (m/ft)

Niveauhoogte h (m/ft)

V9H6

Bloqueo de la matriz
Teclear cualquier
nmero de 3 cifras

Blocco della matrice


Immettere un qualsiasi
numero di 3 cifre

Matrix vergrendelen
Invoer van een
willekeurig getal van
3 cijfers

V9H6

Desbloqueo de la
matriz
Teclear el nmero 519

Sblocco della matrice


Immettere il numero 519

Visualizzazione del valore


misurato

Matrix vrijgeven
Invoer van 519

Blocco della matrice

Bloccare la matrice dopo aver immesso


tutti i parametri!
Le immissioni possono essere lette ma non
modificate se la matrice bloccata.

nl Meetwaarde-aanwijzing

V0H0 meetwaarde: % of willekeurige


eenheid
V0H8 meetwaarde: afstand D (m/ft)
V0H9 meetwaarde: niveauhoogte h (m/ft)

nl Matrix vergrendelen

Na invoer van alle parameters de matrix


vergrendelen.
In de vergrendelde matrix kunnen de
waarden wel worden uitgelezen maar niet
worden gewijzigd.

es Ajustes bsicos

Se ilumina o parpadea cuando realizan los ajustes bsicos


Si illumina o lampeggia durante le impostazioni di base
Brandt of knippert tijdens invoer basisinstellingen

Realizar los ajustes durante la puesta en


marcha o bien cuando se reemplaza el
sensor.
Seleccionar los campos de matriz en el
orden indicado a continuacin, y programar
los parmetros en negrita
(por ej. 333 para reset general).
Activar E para validar la programacin.
Nota: Las unidades de longitud slo
debern cambiarse inmediatamente
despus de un reset.

VH

VH

Impostazioni di base

Registrare limmissione con E


Nota: Le unit di lunghezza (m, ft) possono
essere modificate solo immediatamente
dopo il reset.

10

1.

2.

nl Basisinstellingen

Deze instellingen altijd uitvoeren bij de


inbedrijfname of bij het vervangen van de
sensor.
Uit de tabel de juiste volgorde van de
matrixvelden aflezen en de invoerparameter
(vet afgedrukt bijv. 333 voor basisreset)
kiezen.
Invoer met E bevestigen.
Opgelet: lengte-eenheid alleen onmiddellijk
na een reset wijzigen.

VH

Effettuare queste impostazioni alla messa in


funzione o dopo aver sostituito il sensore.
Richiamare i campi di matrice dalla tabella
nellesatta sequenza e scegliere i parametri
da immettere (in grassetto per esempio 333
per il reset generale).

3.
4.

Entrada
333: Reset

Immissione
333: Reset

Invoer
333: Basisreset

BUSY Visualizado en el
indicador
V8H3 Unidades de altura
0: m
1: ft
V8H0 Modo de operacin
0: nivel del canal 1
V0H4 Tipo de sensor
80: FDU 80, 81: FDU 81
80F: FDU 80F
81F: FDU 81F
82: FDU 82, 83: FDU 83
84: FDU 84, 85: FDU 85
86: FDU 86

Mostrato sul display

Verschijnt op het display

Unit ingegneristiche:
0: m
1: ft
Modalit operativa
0: livello, canale 1
Tipo di sensore
80: FDU 80, 81: FDU 81
80F: FDU 80F
81F: FDU 81F
82: FDU 82, 83: FDU 83
84: FDU 84, 85: FDU 85
86: FDU 86

Lengte-eenheid kiezen
0: m
1: ft
Bedrijfstype kiezen
0: niveau kanaal 1
Type sensor
80: FDU 80, 81: FDU 81
80F: FDU 80F
81F: FDU 81F
82: FDU 82, 83: FDU 83
84: FDU 84, 85: FDU 85
86: FDU 86

V9H5

BD

aplicaciones de nivel
applicazioni per la misura di livello
niveautoepassingen
V0H3
0
1

100%

es Ajuste
La base de toda medicin son las entradas
Vaco y Lleno
Vaco E: Distancia entre la membrana y el
nivel 0%
Lleno F: Distancia entre el nivel 0% y el
nivel 100%
Valores E y F dentro de las unidades de
altura seleccionadas durante el ajuste
bsico
Seleccin: 0/4...20 mA: salida analgica
(pg. 13) y ejemplos 1 y 2 (pg. 14)

0%

1.

V0H1

2.

V0H2

3.

V0H3

Programacin
Vaco E (m, ft):
Distancia entre la
membrana y el nivel 0%
Lleno F (m, ft):
Distancia entre el nivel
0% y el nivel 100%
Aplicaciones de nivel )
0: Liquidos
1: Cambios rpidos de
nivel
2: Slidos de grano fino
3: Slidos de grano
grueso
4: Cinta ransportadora

Immissione
Vuoto E: Distanza tra la
membrana del sensore
e il punto 0%
Pieno F: Distanza tra il
punto 0% e il punto
100%
Misura di livello
0: Liquidi
1: Liquidi con rapide
variazioni di livello
2: Solidi a granulometria
fine
3: Solidi a granulometria
grossa
4: Nastro trasportatore
El ajuste de fbrica para
Le impostazioni di
la senal 0/420 mA es de fabbrica per luscita
0 %: 0, 100 %: 100
0/4...20 mA sono: 0%:0,
100%: 100

invoer
Leeg E: afstand
sensormembraan 0%-punt
Vol F: afstand 0%-punt 100%-punt
Niveautoepassing:
0: vloeistof
1: snelle
niveauverandering
2: fijnkorrelige vaste stof
3: grofkorrelige vaste stof
4: belading
transportband
Voor het 0/4...20 mA
signaal geldt de
default-instelling 0%: 0,
100%: 100.

Regolazione

Basilari per tutte le misure sono le


immissioni Vuoto e Pieno
Vuoto E : distanza fra la membrana del
sensore e il punto di 0%
Pieno F: Distanza tra il punto di 0% e il
punto di 100%
I valori relativi a E e F devono essere
espressi nellunit di lunghezza selezionata
durante la taratura di base
Attribuzione delluscita 0/4...20 mA: Uscita
analogica (pag. 13) e Esempi 1 e 2
(pag. 14)

nl Inregeling

Uitgangspunten voor alle metingen zijn de


parameters vol en leeg
Leeg E: afstand sensormembraan...0%-punt
Vol F: afstand 0%-punt...100%-punt
Invoer voor E en F alleen in lengte-eenheid
die bij de basisinregeling is gekozen.
Toekennen 0/4..20mA: analoge uitgang
(blz. 13) en voorbeeld (1) en (2) (blz. 14)

11

BD

Scelta delle unit ingegneristiche

0%

Queste immissioni permettono al valore


misurato (V0H0) di essere letto in diverse
unit ingegneristiche tranne la %..
Impostare il valore appropriato a 100%
nellunit ingegneristica desiderata.
Questi valori non sono attivi se non si
effettua la linearizzazione.

nl Keuze van een willekeurige


maateenheid
Hier is het mogelijk om voor een lineaire tank
de meetwaarde niet in %, maar in een
willekeurig eenheid uit te lezen.
Het 0% en 100% punt worden toegekend
aan de overeenkomstige waarde in de
betreffende eenheid.
Deze invoer alleen uitvoeren wanneer geen
linearisatie nodig is.

12

100%

altezza / niveau / altura del nivel

es Seleccin de las unidades


Si el valor medido no se desea indicar en %
en V0H0, sino en otra unidad, dichos
parmetros suplementarios debern fijarse
en los ajustes bsicos.
A los punto 100% se les atribuye el valor
correspondiente dentro de la unidad
deseada.
Solamente se introducirn los valores
cuando no se realice una linealizacion.

slo para depsitos


lineales
solo serbatoi lineari
alleen lineaire tanks

(m3, hl, )

volume / volume / volumen

1.

V2H7

2.

V2H0

Entrada
(Ver tambin Ej. 1,
pg. 14)
Volumen V1 (100%) en
unidad seleccionada
Modo de linealizacin
0: lineal

Immissione
(Vds. anche Esempio 1
a pag. 14)
Altezza al punto di
100% nell unit di
lunghezza
Modalit di
linearizzazione
0: lineare

Invoer
(zie ook voorbeeld 1,
blz. 14)
Volume op 100%-punt in
klanteenheid
Type linearisatie
0: lineair

e Ajuste de la salida analgica

20 mA

4 mA
0%

100 %
Valor medido/
valore misurato /
meetwaarde

Los ajustes para la salida analgica


asignan una seal de corriente al valor
medido
0 4 mA a 0%
20 mA a 100%
La corriente de salida puede fijarse de
modo que el valor medido (V0H0) asuma
un valor especfico en caso de fallo.
El smbolo de error se ilumina en caso de
fallo.

110 %

Uscita in caso di errore / gedrag bij storing /


Indicacin en caso de fallo
V8H1 0: 020 mA 1: 420 mA

20 mA

V3H4

0: 10 %
1: +110 %

1.

V8H1

2.

V0H5

3.

V0H6

4.

V3H4

-2 mA
22 mA

-2,4 mA
21,6 mA

i
hold

4 mA

- 10 %
tiempo / tempo / tijd

Programacin
(Ver tambin ej.1 y 2,
pg. 14
Seleccin de la
corriente de salida
0: 0...20 mA
1: 4...20 mA
Valor 4 mA

Immissione
(Vds. anche Esempio 1
e 2 a pag. 14)
Scelta delluscita in
corrente
0: 0...20 mA
1: 4...20 mA
Valore 4 mA

Invoer
(zie ook voorbeeld 1 en
2 blz. 14)
Stroomuitgang kiezen

Valor 20 mA
Indicador con
interferencias
0: -10 % del rango de
medida
1: 110% del rango de
medida
2: Mantiene el ltimo
valor medido

Valore 20 mA
Uscita in caso di errore
0: -10% del campo di
misura
1: 110% del campo
misurato
2: Mantiene lultimo
valore misurato

20 mA-waarde
Aanwijzing bij storing
0: -10% van het
meetbereik
1: 110% van het
meetbereik
2: laatste meetwaarde
vasthouden

0: 0...20 mA
1: 4...20 mA
4 mA-waarde

Impostazione delluscita
analogica

Limpostazione delluscita analogica


assegna un segnale in corrente al valore
misurato
0 o 4 mA al punto di 0%
20 mA al punto di 100%
Luscita in corrente pu essere impostata
cos che il valore misurato (V0H0) assuma
un valore specifico in caso di errore.
Il simbolo dellerrore si accende in caso di
errore.

nl Analoge uitgang instellen

De instellingen voor de analoge uitgang


kennen de meetwaarde toe aan een
stroomsignaal
de waarde 0/4 mA aan het 0%-punt
de waarde 20 mA aan het 100%-punt
De stroomuitgang kan zo worden ingesteld
dat de meetwaarde (V0H0) bij storingen
een bepaalde waarde aanneemt.
Bij storingen brandt het symbool voor
foutmelding.

13

es Ejemplo

En el caso de un depsito cilndrico

vertical, el valor medido (V0H0) deber


darse en hl.
100%: 350 hl
Como salida analgica se selecciona
una seal 4..20 mA
15 hl: 4 mA
350 hl: 20 mA
En caso de fallo, la corriente de salida
deber asumir el 110% del rango de
medicin.

Esempio

100 %

350 hl

0%

15 hl

100 %

350 hl

1.
2.

Entrada
350
0

V2H7
V2H0

Immissione
350
0

V2H7

Invoer
350
0

Il valore misurato (V0H0) pu essere

espresso in hl per un serbatoio a cilindro


verticale.
100%: 350 hl
Un segnale 4...20 mA impostato per
luscita analogica
15 hl: 4 mA;
350 hl: 20 mA
In caso derrore, luscita in corrente
dovrebbe assumere il 110% del campo
di misura.

nl Voorbeeld

350 hl

21,6 mA
20 mA

15 hl

4 mA

Voor een verticale cilindrische tank moet

14

de meetwaarde (V0H0) worden gegeven


in hl.
100%: 350 hl
Als analoge uitgang wordt 4...20 mA
gekozen.
15 hl: 4 mA;
350 hl: 20 mA
Bij storingen moet de stroomuitgang
een waarde 110% van het meetbereik
aannemen.

110 %

Tiempo / tempo / tijd

1.
2.
3.
4.

V8H1
V0H5
V0H6
V3H4

Entrada
1
15
350
1

Immissione
1
15
350
1

Invoer
1
15
350
1

es Funcin del rel como valor


lmite

Estado de rel / simboli dei rel / relaissymbolen


Reposo: desconectado
Modo de trabajo: conectado
modalit operativa: energizzato
modalit stand-by
arbeidstoestand: aangetrokken
rusttoestand: afgevallen
rel
rel
rel
rel
LED
relais
relais
r u a

LED

r u a

LED

V1H3
r u a

LED

descenso /
decrescente / dalend

V1H3

conexin /
energizzato / komt op

V1H2

incremento / crescente /
toenemend
desconexin /
de-energizzato / valt af

BD

rel / rel / relais

r u a

V1H2
nivel / livello / niveau

1.

V1H0

2.

V1H1

3.

V1H2

4.

V1H3

Entrada
Seleccinar rel
1: rel 1
2: rel 2
Seleccinar funcin rel

Invoer
relais kiezen
1: relais 1
2: relais 2
relaisfunctie kiezen

0: valor lmite
Punto de conexin
en unidades del cliente

Immissione
Scegliere rel
1: rel 1
2: rel 2
Scegliere la funzione del
rel
0: valore di soglia
Punto di attacco
nellunit ingegneristica

Punto de desconexin
en unidades del cliente

Punto di stacco
nellunit ingegneristica

Uitschakelpunt
in klanteenheid

0: grenswaarde
Inschakelpunt
in klanteenheid

El FMU 860 tiene 3 (1, 2, 5) o 5 rels


Al rel 5 se le atribuye la funcin de rel de
alarma.
Estos parmetros asignan los puntos de
conmutacin al rel, los cuales sern los
valores lmites fijados para el llenado del
tanque.
El rel de valor lmite responde a los puntos
prefijados de conexin y desconexin y se
refiere al valor medido en V0H0.

Valore di soglia della funzione


del rel

Il prosonic FMU 860 dispone di 3 (1, 2, 5) o


5 rel. Il rel 5 assegnato alla funzione di
segnalazione di errore.
Queste impostazioni assegnano i punti di
commutazione ai rel, che corrispondono ai
valori di soglia durante il riempimento del
serbatoio.
Il rel del valore di soglia corrisponde ai
punto di attacco e di stacco impostati e si
riferisce al valore misurato in V0H0.

nl Relaisfunctie grenswaarde

De FMU 860 heeft 3 (1, 2, 5) of indien


gewenst 5 relais. Aan relais 5 is de functie
storingsrelais toegekend.
Deze instellingen kennen een schakelpunt
aan een relais toe, welke grenswaarden zijn
bij het vullen van een tank.
Het grenswaarderelais schakelt
afhankelijk van het vooringestelde in- en
uitschakelpunt en is gerelateerd aan de
meetwaarde in V0H0.
15

es Respuesta en caso de fallo

El rel de indicacin de fallo se desconecta.


El smbolo de indicacin de fallo se ilumina
o parpadea.
La salida analgica responde de acuerdo
con los ajustes en V3H4.
El fallo se identifica por el cdigo de fallo.

Risposta in caso di errore

Il rel per lindicazione derrore viene


de-energizzato.
Il simbolo per lindicazione derrore si
accende o inizia a lampeggiare.
Luscita analogica si comporta secondo
quanto impostato in V3H4.
Lerrore viene identificato mediante un
codice derrore.

nl Gedrag bij storing

Het relais voor storingsmelding valt af.


Het symbool voor storingsmelding knippert
of brandt.
De analoge uitgang reageert
overeenkomstig de instellingen in V3H4.
Door middel van de foutcode wordt de
storing gedentificeerd.

16

parpadea
lampeggia
knippert

el rel de fallo se desconecta, el LED


amarillo se ilumina
il rel per lindicazione derrore viene
de-energizzato, il LED giallo lampeggia
relais voor storingsmelding valt af, de
gele LED knippert

normal
normale
normaal

indicacin del cdigo de error


display dellattuale codice derrore, es. E501
anwijzing momentele foutcode bijv. E501

el grfico de barras de la corriente


muestra la senal fuera de rango
lindicazione a barre della corrente va
fuori campo
balkaanwijzing stroom toont
signaalover- of onderschrijding

fallo
errore
storing

1.

V9H0

Indicacin
Cdigo de fallo actual

Display
Codice derrore attuale

Display
momentele foutcode

2.

V9H1

ltimo cdigo de fallo

Ultimo codice derrore

laatste foutcode

3.

V9H2

Penltimo cdigo de fallo Penultimo codice derrore voorlaatste foutcode

E501

E613

E231

E641

E661

E111
E112
E113
E114
E115

Cdigos de error y su
correccin
No se ha especificado
el tipo de sensor;
entrar tipo de sensor en
V0H4
Instrumento en modo de
simulacin; seleccione
otra modalidad
operativa en V8H0
Cortocircuito en el
sensor de temperatura
interno; compruebe la
conexin del sensor o
bien contacte con el
servicio tcnico de E+H
El eco ultrasnico no
puede ser evaluado;
compruebe la conexin
del sensor o bien
contacte con el servicio
tcnico de E+H

Temperatura en el
sensor demasiado alta;
compruebe el punto de
medicin
Error electrnico en la
unidad; contacte con el
servicio tcnico de E+H

Errore e rimedio

Diagnose/maatregel

Nessun tipo di sensore


selezionato;
immettere il tipo di
sensore in V0H4.
Strumento in modalit di
simulazione;
selezionare la modalit
0 in V8H0.
Corto circuito del sensore
di temperatura integrato;.
verificare il collegamento
del sensore o chiamare il
Servizio Assistenza E+H

Geen sensortype
gekozen;
in V0H4 sensortype
invoeren.
Instrument in
simulatiefunctie;
in V8H0 functie 0 kiezen.

Leco ultrasonoro non


viene valutato. Errore
dovuto ad un eccessivo
smorzamento (polvere o
schiuma);
se lerrore permane
verificare il
collegamento del
sensore o chiamare il
Servizio Assistenza E+H
Temperatura al sensore
troppo elevata;
verificare il punto di
misura
Errore nellelettronica
dello strumento;
chiamare il Servizio
Assistenza E+H

Kortsluiting interne
temperatuursensor;
sensoraansluiting
controleren of contact
opnemen met E+H
service-afdeling
Ultrasone echo kan niet
worden verwerkt; fout
door te hoge demping
(stof of schuim); blijft de
storing langer bestaan
controleer dan de
sensoraansluiting of
neem contact op met
E+H service-afdeling
Temperatuur aan de
sensor te hoog;
controleer de meting
Elektronische instrument
fout; contact opnemen
met E+H serviceafdeling

es Cdigos de error y su correccin


En caso de requerir ms amplia informacin
sobre la deteccin de averas, consulte el
manual de instrucciones BA 100F o bien
contacte con nuestro servicio tcnico.

Errori e rimedi

Se si verificano errori con codice diverso da


quelli forniti, oppure se permangono, fare
riferimento al Manuale Operativo BA 100F e
contattare il Servizio Assistenza E+H.

nl Foutdiagnose en maatregelen
Wanneer een foutmelding optreedt die niet
is genoemd of kan de fout niet worden
opgeheven zie dan de
inbedrijfstellingsvoorschriften BA 100F of
neem contact op met de E+H serviceafdeling.

17

FMU 860

V0

Campos de lectura / Campi di lettura / Aanwijzing-veld

es
i
nl
es

Calibracin del canal 1


Taratura del canale 1
Basisinregeling kanaal 1
Rel

H0
Valor medido
Valore misurato
Meetwaarde
Seleccin de rel

H1
Calibrado en vaco
Taratura di vuoto
Inregeling leeg
Funcin de rel

H2
Calibrado en lleno
Taratura di pieno
Inregeling vol
Punto de conexin

H3
Aplicacin de nivel
Tipo di applicazione
Niveautoepassing
Punto de desconexin

Rel

Scelta del rel

Funzione del rel

Punto di attacco

Punto di stacco

nl
es

Relais
Linealizacin del Canal 1

Relaiskeuze
Linealizacin

Relaisfunctie
Nivel actual

Inschakelpunt

i
nl
es

Linearizzazione canale 1
Linearisatie kanaal 1
Parmetro de eco canal 1

Uitschakelpunt
Programacin de
volumen de llenado
Immissione livello
Invoer niveau
Si no hay eco

V1

V2

nl

Tipo di linearizzazione Valore attuale


Linearisatie
Momenteel niveau
Rango para supresin Atenuacin del eco
Relacin seal/ruido
automtica
Nessun eco
Parametri eco canale 1
Campo per la
Attenuazione delleco Rapporto Segnale/
disturbo
soppressione
automatica
Gedrag indien echo
Echoparameter kanaal 1
SignaalStoorechoEchodemping
ontbreekt
ruisverhouding
onderdrukking
Filas 4,5 y 6 nicamente para FMU 862 / Righe 4, 5 e 6 solo per FMU 862 / Regels 4, 5 en 6 alleen bij FMU 862
Servicio
Servicio
Servicio
Servicio
Servicio
Service
Service
Service
Service
Service
Service
Service
Service
Service
Service
Modo operativo
Estatus operativo
Seleccin de corriente Umbral 4 mA
Seleccionar unidad
distancia
Modalit operativa
Scelta corrente
Soglia 4 mA
Scelta unit di
Stato operativo
lunghezza
Bedrijfsparameter
Bedrijfsfunctie
Analoge uitgangen
4mA drempel
Lengte-eenheid

es

Servicio y simulacin

Servizio e simulazione

nl

Service en simulatie

V3

nl

V7

es
i
nl
es

V8

V9

18

Cdigo de diagnstico ltimo cdigo de


diagnstico
Codice di diagnosi
Ultimo codice di
diagnosi
Momentele foutcode
Laatste foutcode

Penltimo cdigo de
diagnstico
Penultimo codice di
diagnosi
Voorlaatste foutcode

Equipo y versin de
software
Strumento e versione
software
Instrument en
software-versie

Programacin de campos / Campi di immissione / Programmeerveld

H4
Tipo de sensor
Tipo di sensore
Sensortype
Control alternativo de
bomba
Controllo delle pompe
Alternerende
pompsturing
Entrar volumen

H5
Valor para 0/4 mA
Valore per 0/4 mA
Waarde voor 0/4 mA

H6
Valor para 20 mA
Valore per 20 mA
Waarde voor 20 mA

H7
H8
Tiempo de integracin Distancia
Smorzamento uscita
Distanza misurata
Integratietijd
Afstand

Immissione volume
Invoer volume
Alarma seguridad

Numero della linea


Diametro del serbatoio Volume del serbatoio
Steunpuntnummer
Tankdiamter
Tankvolume
Estadstica envolvente

Allarme di sicurezza

Statistica della curva


di inviluppo

H9
Nivel medido
Livello misurato
Niveau
Retraso conexin

Ritardi di intervento
Schakelvertraging
N lnea

Dimetro depsito

Volumen depsito

Gedrag bij storing

Servicio
Service
Service

Stoorechofilter
Filas 4,5 y 6 nicamente para FMU 862 / Righe 4, 5 e 6 solo per FMU 862 / Regels 4, 5 en 6 alleen bij FMU 862
Servicio
Servicio
Servicio
Servicio
Servicio
Service
Service
Service
Service
Service
Service
Service
Service
Service
Service
Sensor de
Interruptor lmite
temperatura externo
Contatto di soglia
Sensore esterno di
temperatura
GrenswaardeExterne
schakelaar
temperatuursensor
Reposcin general
Bloqueo de seguridad Simulacin nivel
Simulacin volumen
Simulacin corriente
333
Reset generale 333
Blocco di sicurezza
Simulazione di livello Simulazione del
Simulazione della
volume
corrente
Algemene reset 333
Vergrendeling
Simulatie niveau
Simulatie volume
Simulatie stroom

19

Austria
Endress+Hauser Ges.m.b.H.
Wien
Tel. (01) 8 80 56-0, Fax (01) 8 80 56-35

Hong Kong
Endress+Hauser (H.K.) Ltd.
Hong Kong
Tel. 25 28 31 20, Fax 28 65 41 71

Spain
Endress+Hauser S.A.
Sant Just Desvern
Tel. (93) 4 80 33 66, Fax (93) 4 73 38 39

Belgium / Luxembourg
Endress+Hauser N.V.
Brussels
Tel. (02) 2 48 06 00, Fax (02) 2 48 05 53

Italy
Endress+Hauser Italia S.p.A.
Cernusco s/N Milano
Tel. (02) 9 21 92 19 21, Fax (02) 92 10 71 53

Sweden
Endress+Hauser AB
Sollentuna
Tel. (08) 55 51 16 00, Fax (08) 55 51 16 55

Canada
Endress+Hauser Ltd.
Burlington, Ontario
Tel. (9 05) 6 81 92 92, Fax (9 05) 6 81 94 44

Japan
Sakura Endress Co., Ltd.
Tokyo
Tel. (04 22) 54 06 13, Fax (04 22) 55 02 75

Switzerland
Endress+Hauser AG
Reinach/BL 1
Tel. (0 61) 7 15 75 75, Fax (0 61) 7 11 16 50

Denmark
Endress+Hauser A/S
S@248borg
Tel. (70) 13 11 32, Fax (70) 13 21 33

Malaysia
Endress+Hauser (M) Sdn. Bhd.
Petaling Jaya, Selangor Darul Ehsan
Tel. (03) 7 33 48 48, Fax (03) 7 33 88 00

Thailand
Endress+Hauser Ltd.
Bangkok
Tel. (2) 9 96 78 11-20, Fax (2) 9 96 78 10

Finland
Endress+Hauser Oy
Espoo
Tel. (09) 8 67 67 40, Fax (09) 86 76 74 40

Netherland
Endress+Hauser B.V.
Naarden
Tel. (0 35) 6 95 86 11, Fax (0 35) 6 95 88 25

USA
Endress+Hauser Inc.
Greenwood, Indiana
Tel. (3 17) 5 35-71 38, Fax (3 17) 5 35-84 98

France
Endress+Hauser
Huningue
Tel. (3 89) 69 67 68, Fax (3 89) 69 48 02

Norway
Endress+Hauser A/S
Tranby
Tel. (0 32) 85 98 50, Fax (0 32) 85 98 51

Germany
Endress+Hauser Messtechnik GmbH+Co.
Weil am Rhein
Tel. (0 76 21) 9 75 01, Fax (0 76 21) 97 55 55

Singapore
Endress+Hauser (S.E.A.) Pte., Ltd.
Singapore
Tel. 5 66 82 22, Fax 5 66 68 48

International
Endress+Hauser GmbH+Co.
Instruments International
Weil am Rhein
Tel. (0 76 21) 9 75 02, Fax (0 76 21) 97 53 45

Great Britain
Endress+Hauser Ltd.
Manchester
Tel. (01 61) 2 86 50 00, Fax (01 61) 9 98 18 41

South Africa
Endress+Hauser Pty. Ltd.
Sandton
Tel. (0 11) 4 44 13 86, Fax (0 11) 4 44 19 77

KA 017F/00/a6/05.00, 016085-0000, R/CV4.2

http://www.endress.com
04.00/PTS-D

016085- 0000

Operating instructions for automatic gap


adjustment system

6.1

Introduction
The automatic gap adjustment system is a unit that is capable of working
independent of the environment.
The system consists of the hydraulic power pack controlled by an on-board
control cabinet. The hydraulic cylinders, the measuring equipment and the
mechanical equipment are attached to the crusher. The control cabinet
accommodates the power supply equipment for the consumers (hydraulic
pump, valves) and their control systems. The control system is based on a
Mitsubishi microcontroller M16C.
The control system can be operated locally by pressing the appropriate
buttons on the front door of the control cabinet or from an external central
control room through remote control cables. The operation of the gap
adjustment system requires signals to be exchanged with the control system
of the crusher plant. The crushing gap can only be adjusted when the crusher
is at standstill or idling.
Caution!

6.2

The crushing gap may not be adjusted when the crusher is


in operation.

Crushing gap adjustment procedure


The front panel of the control cabinet has various buttons by which the gap
adjustment system can be operated. The door of the control cabinet also
features a selector switch allowing the control mode of the plant to be
changed over from local control to remote control or vice versa. For activating
the local control buttons, set the selector switch to local. This releases the
buttons open and close needed to increase or reduce the crushing gap.
The actual position of the crushing jaws (not the wear of the crusher jaws and
thus CSS) is continuously shown on a display. A 4..20 mA power signal can
be connected to the central control room / the higher-ranking control system,
too.

11/2002

The front door also has two telltale lamps indicating the actual condition of
the system.
The telltale lamp ready shows that the system is ready for adjusting the
crushing gap (lamp is on continuously) and/or that the control system is
operating correctly and that the gap adjustment release from the higherranking control system is missing (lamp is flashing).
The telltale lamp fault indicates the collective message fault message
(lamp is on continuously) and/or the message warning (lamp is flashing).

2-443-20351-01e

6-1

The fault message can be reset locally as well as in the central control room
by pushing the reset button. The control cabinet has 5 coupling relays
optically indicating the exact assignment of the fault coded with a binary code
(in accordance with a list) and/or transmitting the message to the central
control room via potential-free contacts.

6.3

Notes relating to wiring


The wiring of the gap adjustment system is limited to a few cables that need
to be installed and connected. The entire electrical equipment of the
hydraulic power pack has already been connected during fabrication.
Since displacement pick-up units monitoring the end positions of the wedge
cylinders are attached to the crusher, they can only be connected on site.
Other external connections to be carried out on site include power supply
cables and signal exchange cables to be connected to the higher-ranking
control system.
The control cabinet is supplied with three-phase current (due to the hydraulic
pump; the cable cross section must be adapted to the pump delivery as this
pump is the principal consumer). It is recommended to use shielded cables
for the signal exchange and measuring cables.

11/2002

Coupling relays are used for the potential-free exchange of signals in both
directions. A remote display of the gap width is possible through a signal
amplifier with potential isolation.

6-2

2-443-20351-01e

Manual de instrucciones para la regulacin automtica de la rendija.

6.1

Introduccin
El regulador automtico de la rendija es una unidad que est en la condicin
de trabajar independientemente de las condiciones externas.
El dispositivo est compuesto de la unidad hidrulica, que est alimentada
elctricamente y tcnicamente controlada por un armario de distribucin incorporado. En el chancador se encuentran montados los cilindros hidrulicos con tcnicas de medicin as como con dispositivos mecnicos. El
armario de distribucin es responsable de la alimentacin de energa, por
ejemplo: bomba hidrulica, vlvulas, as como el control de las mismas. El
control se basa en un microcontrolador M16C de Mitsubishi.
La operacin del control se realiza in situ al presionar la tecla de la puerta
frontal del armario de distribucin as como desde una estacin de control
externa mediante una lnea piloto. Para el trabajo del dispositivo de regulacin es tambin necesario un intercambio de la seal con el control del sistema de chancado. La regulacin de la rendija slo es posible cuando el
chancador est parado y/o en marcha sin carga.
Atencin!

6.2

Durante el funcionamiento del chancador no est permitido realizar la regulacin del ancho de la rendija.

Procedimiento para la regulacin de la rendija


En la parte frontal del armario de distribucin se encuentran varias teclas
que posibilitan la regulacin de la rendija. Adicionalmente de encuentra en
la puerta del armario de distribucin un selector, que permite la realizacin
del ajuste in situ o remoto. Para activar la tecla que permite la regulacin
in situ se debe colocar el selector en la posicin local Recin despus se
pueden presionar las teclas Abrir y/o. Cerrar La posicin actual de la
mandbula ( no el desgaste de la mandbula de trituracin y con ello el CSS)
se indica permanentemente en el aparato de visualizacin, una seal de corriente de 4.20 mA se puede tambin conectar en la estacin de mando/ control superior

11/2002

En la puerta frontal se encuentran tambin dos avisadores luminosos, que


sealan el estado actual del dispositivo.
La lmpara Listo indica que todo esta listo para la regulacin del ancho de
la rendija (luz permanente) y/o el funcionamiento correcto del control y la
falta de la seal permisiva para la regulacin de la rendija por parte del control superior.

2-443-20351-01sp

6-1

La lmpara Error indica el mensaje de error(luz permanente) y/o el


mensaje advertencia (luz intermitente).
La aparicin del mensaje de error puede ser confirmada tanto en el lugar as
como desde la estacin de mando con la tecla Reset En el armario de distribucin se encuentran 5 relees acoplados que transfiere al nivel de mando
una asignacin exacta del error codificado en cdigo binario mediante una
lista ptica y/o mediante contactos libres de potencial.

6.2.1

Indicaciones para el cableado


El cableado del dispositivo de regulacin de la rendija se limita a pocos cables que deben ser colocados y conectados. La conexin de todos los dispositivos elctricos de la unidad hidrulica ya fue realizada durante el
proceso de fabricacin.
Los dispositivos como por ejemplo el transductor de desplazamiento del cilindro de la cua, slo pueden ser colocadas en el lugar de montaje.
Como conexin externa deben ser mencionadas la alimentacin y el intercambio de seales con el control superior, esto tambin tienen que ser realizados en el lugar de montaje.
El armario de distribucin debe ser alimentado con corriente trifsica (debido a la bomba hidrulica, la seccin eficaz del cable debe estar adaptada a
la potencia de la bomba, ya que sta es la principal consumidora). Para la
colocacin de los cables de seales y de medicin recomendamos el uso de
cables blindados.

11/2002

El intercambio de seales se realiza en ambas direcciones libre de potencial


mediante relees acoplados. La indicacin a distancia del ancho de la rendija
se realiza mediante un amplificador de seales con separacin de potencial.

6-2

2-443-20351-01sp

DALOG - Software
Manual
DALOG Diagnosesysteme GmbH
Augsburg
Version 2.47x, 2002

Index

Index
I

Indroduction

Structure of the Reference Manual

General Introduction

II

Putting into Operation

Hard- and Software Requirements

Configuring the System

2.1

Installation of the DALOG-Software

III

Working with the DALOG - Software

Symbols and Statements

1.1

The Keyboard

1.2

How to use the mouse

1.3

Mouse Pointer und Mouse Techniques

1.3.1

Pointer forms

1.3.2

Basic Mouse Techniques

1.3.3

Mark

Start-up of the Dalog Software

File

10

3.1

New

10

3.2

Open

10

3.3.

Print

11

3.4

Printer set-up

11

Index

II

3.5

Base settings

12

3.6

Exit

14

Dalog

15

4.1

Open

15

4.1.1

DALOG data box - direct arrangement of a connection to DALOG

15

4.1.2.

Modem

17

4.1.3

Settings-storing modem connections

18

4.1.4

Dial getting a connection

19

4.1.5

PCMCIA drive - uploading and configuring memory cards

21

4.1.5.1

Configuring a memory card

23

4.1.5.2

Uploading the memory card and offline data analysis

24

Templates

24

Window

25

Help

26

File

27

8.1

New...

27

8.2

Open...

27

8.3

Close

27

8.4

Save

27

8.5

Save as...

27

8.6

Save all

27

8.7

Print

27

8.8

Printer set up...

27

8.9

Base setting

27

8.10

Exit

27

Index

III

Edit

28

9.1

Undo

28

9.2

Redo

28

9.3

Cut

28

9.4

Copy

28

9.5

Paste

28

9.6

Delete

29

9.7

Mark all

29

9.8

Zoom

29

9.9

Monochrome

9.10

Event data interactice

29

9.11

Set up

29

9.11.1

Memory card...

30

9.11.2

Base menus...

30

9.11.3

Passwords

30

9.11.4

Monitored plant...

30

9.12

New elements

31

9.12.1

Standard

32

9.12.2

Logic

32

9.12.3

Timers

33

9.12.4

Signal conditioning

34

9.12.5

Display

35

9.12.6

Analysis

35

10

Dalog

36

10.1

Open...

36

10.2

Connect...

36

10.2.1

Reinitialization of the transissio

37

10.3

Disconnect

37

10.4

Info on data box

38

29

Index

IV

10.5

About monitored plant

38

10.6

Load config. From box

38

10.7

Configure box

38

10.8

Load all buffers

39

10.9

Load complete card...

40

10.10

auto transfer

41

11

Window

41

12

Help

41

13

Explanation of the function blocks

42

13.1

Top icon bar

42

13.2

Bottom icon bar

44

13.2.1

New data channel

47

13.2.1.1

Configuring the analog inputs

48

13.2.1.2

Configure digital inputs

53

13.2.2

Sample rate

56

13.2.3

Recursive data filter

58

13.2.4

Violation of limit value / Limit above

59

13.2.5

Violation of limit value /Limit below

60

13.2.6

Data buffer

61

13.2.6.1

Explanation how the data buffers work

63

13.2.7

Logical AND

63

13.2.8

Logical OR

64

13.2.9

Logical NOT

64

13.2.10

JK flipflop

64

13.2.11

Pulse generator

64

13.2.12

Phone message

65

13.2.13

Digital monitoring output

66

Index

13.2.13.1 Configure digital output

67

13.2.14

Timer

67

13.2.15

Delay timer

68

13.2.16

Stop watch

70

13.2.16.1 Uploading the data of the stop watch symbol

71

13.2.17

Data vector

72

13.2.18

Formula interpreter - Calculation of measured variables

73

13.2.18.1 Arithmetic

76

13.2.18.2 Boolean logic

77

13.2.18.3 Conditional terms

78

13.2.18.4 Statistics

78

13.2.19

Derivation

80

13.2.20

Fatigue Load Rainflow Classification

82

13.2.21

Fast Fourier Transformation

85

13.2.22

Sum

86

13.2.23

Minimum

87

13.2.24

Maximum

88

13.2.25

Event

89

13.2.26

Offline data evaluation

90

13.2.27

Online data evaluation

90

14

Setting up a configuration and explanation

91

14.1

Setting up a configuration

91

14.2

Meaning of the connecting lines

93

14.2.1

Thin and thick black connecting lines

93

14.2.2

Black and white connecting lines

94

14.2.3

Non-interrupted crossing lines

94

14.2.4

Interrupted crossing lines

94

14.2.5

Crossing lines with branches

94

Index

VI

15

Data analysis

95

15.1

Graphical representation of the offline signals

95

15.2

Representation of the offline event data in tabular form

102

15.3

Representation of the online event data in tabular form

105

15.4

Rainflow Classification Analysis

107

15.4.1

2d Presentation of the Classification Data

107

15.4.2

2d/t Presentation of the Classification Data

110

15.4.3

5/2d Presentation of the Classification Data

112

16

Data-Upload

114

17

Online representation

116

17.1

Graphical representation of the online signals

116

17.2

Online representation of the bar graphic

119

17.3

Online representation of the frequency curves

121

18

Printing the event tables

125

18.1

Exporting data

125

18.2

Print Editor

125

19

Printing the signal and frequency curves as well as the


classifications

126

IV

Converting the binary files to ASCII or DIA PC format

127

Converting the binary files to ASCII format

127

Converting the binary files in DIA PC format

130

Index

VII

Binary data format

132

Data format of the binary files

132

1.1

Structure of the global header

132

1.2

Structure of the data files (*.UPT)

133

1.2.1

Structure of the header of individual data blocks

133

1.2.2

Structure of the data ranges

133

1.3

Structure of the event data files (*.UPE)

134

1.3.1

Frame structure of a single event

134

1.4

Structure of the classification data files

135

1.4.1

Structure of the header of single classificatio data blocks

135

1.4.2

Stucture of the classification

135

Chapter I:

Introduction

Introduction

Structure of the Reference Manual

The reference manual helps you to install the DALOG Software on your PC, specifies the
symbols of the DALOG Software and shows you some examples.

Chapter I

describes the structure of the reference manual. You get a general


introduction about DALOG.

Chapter II

contains informations about the PC, the hardware and the software and
instructions for installation the DALOG Software.

Chapter III

deals with how to work with the DALOG - Software. It specifies the several
menu points and symbols and shows how a configuration could be built with
the DALOG - Software.

Chapter IV

shows how the user can convert the binary dates to ASCII dates or
DIA-PC dates.

Chapter V

explaines the binary format.

Chapter VI

gives instructions for replacing the memory card in the DALOG.

Chapter VII

contains general technical specifications and the connection diagram

We wish you much sucess with DALOG.

Chapter I:

Introduction

General Introduction
Increasing demands for the availability and reliability of machines and plants as well as quality
considerations require more and more efficient, user friendly, electronical systems for a safe
storing of measuring data.
These systems have a high economical and precaution significance. Failure and defects of
machines and plants can be prevented with a continuous trend analysis of the actual conditions. With such a system irregularities of the machines can be detected early. The stops of a
plant and time for repair may be reduced and the quality standards will be increased.
The DALOG is an all-purpose, compact and self-supporting system for acquisition and storing of measuring data. It is especially developed for rough and severe operating conditions
(IP65). The DALOG allows an individual, customer specific adaptation of the sensors. Its robust housing, the high sample rates and the individual, customer specific adaptations of the
sensors allow universal applications.
The DALOG can continuously record over days, weeks, months or years. Each analog input
can be monitored with defined limit values and integrated directly into the system monitoring in
case of excess. It has its own real time clock so that the user will always know date and time
when something has happened.
The DALOG - Software is a comfortable, graphical software under Microsoft WINDOWS
and solves virtually any application problem. The enormous flexibility and manifold possibilities
of combinations will give you the best information on your measuring data. The software allows to configure the DALOG, to read the data out, and to represent them on screen in tabular form and graphics. With the DALOG - Software the user has the possibility to set up independently his own channel configuration. The user can create the block diagram of his own
measurement problem by easy-to- understand graphic symbols. You get a clearly arranged
presentation of your measuring problem.
The data can be reduced by efficient free eligible trigger conditions. The trigger conditions are
limit values, pre- and post-trigger, logical connections, timer, counter, stop-timer, events, etc..
The length and the timing of the measurement can be set by timer. The user has the possibility of a continuous data acquisition or an interval data acquisition. The channels can be configured in the specific physical units. Also the limit values can be fed in the physical units. The
storage allocation can be set separately for each channel. Thus you get an optimum of the
storage allocation. With the pretrigger and posttrigger modes, the DALOG can acquire data
before and after a trigger condition occurs. You can acquire a programmed number of samples before and after a trigger condition. Individual events including actual values, date and
time can be stored via event elements. The data and channels can be preprocessed by
mathematical operations. Data processing programs can be developed specifically to suit the
monitored device.The online display capacity of the system allows the user to view all measured data instantly on the screen at all times during the start-up and the operation of the plant.
The number of signal operations on screen can be selected with the DALOG - Software.
The configuration of the DALOG - System and the upload of the measured data can be accessed via RS 232 interface, modem, ethernet lan or by a memory card floppy.
The DALOG - Software can be installed on IBM compatible personal computer 80486 or
higher with 8mbyte memory under Microsoft WINDOWS with VGA graphics card and a colour
screen.

Chapter II:

II

Putting into Operation

Putting into Operation

Hard- and Software Requirements


Hardware

IBM PC/AT or 100% compatible with 80486 or higher CPU


min. 8 MByte extended memory (WINDOWS 3.x
min.32 MByte extended memory (WINDOWS,
WINDOWS 98, WINDOWS NT)
Floppy disk drive 3"
Mouse, Trackball
VGA

Software

MS-DOS 6.x or higher (only for WINDOWS 3.x)


Microsoft WINDOWS 3.x or WINDOWS 95 or
WINDOWS 98 or WINDOWS NT

Configuring the System

2.1

Installation of the DALOG - Software


1. Put the DALOG disk into the floppy drive, e.g. drive A
2. Choose the command execution from the menu start

Chapter II:

Putting into Operation

3. Install the DALOG Software by entering:

Clicking the following menu item appears on the screen.

Clicking the DALOG software will be installed.

4. Clicking for to accept the installation path otherwise you can


put in your own destination path.
5. If there is already a DALOG software version installed then
the following menu item will appear.

Chapter II:

Putting into Operation

6. Clicking the directory and the files will be overwritten.


If you dont want to loose the old version then you should
choose a new path and directory.
The files will be copied in the target directory.

7. After finishing the installation, on the screen appears following menu item:

Working with the DALOG - Software

Chapter III:

III

Working with the DALOG - Software

Symbols and Statements

1.1

The Keyboard
Working with the DALOG software, you can use key
combinations Alt, D means, that you should click and hold
the keys in the indicated sequence.
To select a command from the menu, you can use the
mouse or a key combination. The description which keys
should be used is always given at the end of the
corresponding command or menu.
For example:
Select the command Open from the
menu File (ALT,F,O).
Clicking on the small rectangular area activates the command.
Clicking on the small activated rectangular area the command will be deactivated.
Clicking on the menu item activates the command. An
altered representation will be displayed at the screen.
Clicking on the activated menu, item the menu item will be
deactivated.
Clicking on a menu item which has three dots after the command, one or more menu/menus will appear.

1.2

How to use the mouse


The mouse controls a pointer on the screen. All important techniques can be done by the mouse.
The mouse has two buttons. Most times you will need the left
button of the mouse.
For the following basic tasks you only have to shift the mouse
and press the mouse button show, click and draw.

Show

To move the mouse pointer to the requested element or menu


item.

Click

If the mouse pointer is on the requested menu item or element,


briefly press the mouse button and then release it
to select an element, the selected element will be flashing
to deselect an element
to insert a function symbol in a configuration

Double Click

Point to a function symbol and briefly press the left mouse button twice; an action will be initiated and/or a dialogue box will be
6

Working with the DALOG - Software

Chapter III:

opened.

Draw

Keep the mouse button pressed while you shift the mouse
pointer. This technique can be used to select function symbols
or to get a connection between determined function symbols.

1.3

Mouse Pointer and Mouse Techniques

1.3.1

Pointer Forms

If you are pointing with the mouse on different parts of the


screen, if you click on icons or some symbols, the pointer will
change its form. The form of the pointer will also change with
some commands.
When the pointer does not take the expected form, then press
the ESC-KEY to get the standard form of the pointer.
The normal forms of the pointer are shown below:

Pointer is situated:

Function:

- in menus
- in a window
- on an icon
- select a menu
- click on an icon
- select an icon
in an active configuration window
(selected icons are flashing)

Pointer is situated:

- in a window-frame

Function:

- changing the window size vertically,


horizontally or diagonally deon the form of the

pending
pointer

Pointer appears:

- when selecting the command shifting


or changing the size

Function:

- Shifting the window to another place


or drawing the window frame

Pointer appears:

- DALOG is doing a procedure which


needs a few moments.
e.g. Data-Upload, image editing, etc.

Pointer appears:

- Click on determined icons in an


active window and draw the
within an active window.

mouse
Function:
connections

- "connector symbol"
connect or disconnect the
between the icons.

Pointer appears:

- Click on an icon in the symbol bar or


- choosing an icon from the menu.

Function:

- "insertion pointer
shows where the icon will be

inserted

Working with the DALOG - Software

Chapter III:

Pointer appears:
online or
hand appears.
Function:

to the

1.3.3

- In an active online or offline window,


click with the mouse on an
off-line window, the
- shifting the mouse to the left or right
the signal curve will be moved
right or to the left.

Pointer appears:

- Click on an active configuration


window.

Function:

- Draw the mouse and a rectangular dot


ted line appears. The icons
marked. The marked symbols
flashing.

can be
are

1.3.2

Basic Mouse Techniques


Show

Move the mouse pointer to the requested element or menu


item.

Click

If the mouse pointer is on the requested menu point or element,


briefly press the mouse button and then release it.

Double Click

If the mouse pointer is on the requested element, briefly press


the mouse button twice and release.

Draw

Keep the left mouse button pressed and draw the mouse to the
requested position. Release the mouse button.

Mark
For a lot of commands the icons, parts of the configuration or
the configuration must be marked first
1. Mark single icons:
Click with the mouse pointer on the requested icon.
The icon is flashing and signalizes that it is marked. If several icons are to be marked, then the procedure must be
repeated as often as required.
Click with the mouse pointer on a marked icon, and the
selection will be undone.
2. Mark parts of the configuration or the entire configuration
Point on one corner of the configuration part which is to
be marked.
Push the left mouse button and draw the mouse pointer to
the diagonally opposite corner. All parts of the configuration
which will be touched will be also marked.
The whole marked part of the configuration is flashing.

Working with the DALOG - Software

Chapter III:

Start-up of the DALOG Software


Before you can build a new configuration or make changes to
an existing configuration, you have to open a configuration window. Then you can begin to build a configuration or make
changes to a configuration. You should store the configuration
at regular intervals to avoid losing your data.
Double click on the DALOG symbol. The following blank window will appear.

Topmost line:

Name of the software "DALOG"

Second line:

Main menu options

Third line:

Symbol bar with three active icon blocks


They give access to the most important commands:
Building a new configuration
Erecting a connection to an active DALOG
Opening an existing configuration

Working with the DALOG - Software

Chapter III:

10

File
Click on the menu item File and the opposite pull-down menu
will be displayed.

3.1

New...

opens the following window on the screen

3.2

Open

opens the following window to call up already built configurations that are stored on the hard disk/floppy disk load configuration.

10

Working with the DALOG - Software

Chapter III:

Call-up of a configuration

11

1. Click on one of the configuration files shown


configuration files always have the extension .CFG
2. Confirm the choice by clicking on the OK button. On the
screen the chosen configuration, will be displayed, e.g.:

3.3

Print...

will print the configuration displayed at the screen.


Click on the menu, the following window will be displayed.
In this window you can do the set-up for the printer.

3.4

Printer set-up...

The printer can be adjusted by the user. Click on the menu item
printer set-up... and the following window will open.

11

Working with the DALOG - Software

Chapter III:

3.5

12

Base settings...

opens the following window to set user-defined basic settings.

Password:

The user can enter his password here.


There are different password levels for assigning rights for operating and/or using the DALOG Software.
The top level is the **master** level. On this level, the password will be assigned customer-specific by DALOG GmbH.

Rights:

Click and the following window New password will appear. In


this menu the user can select different password levels.

Password:

The user can enter his own password here.

Rights:

Upon clicking the following pull-down menu appears. For each


level the user can define separate passwords.

12

Working with the DALOG - Software

Chapter III:

data analysis

13

The user can only have an online or offline look at the data,
which have been released for viewing by the master user.
The user can not configure.
He cannot add or erase online and offline windows.
He can only do an up-load of such buffers, which have been
released for inspection.
The user can only open Templates.
The user cannot see the configuration. He only can see a
blank background or a user-defined graphic background.

build templates

The user cannot configure.


He can see the configuration.
He can add or erase offline and online windows in the configuration at his own.
He can define online and offline window groups of his own
which are released for inspection by the user who has the
right for data analysis.
He can do a data up-load of all buffers and can view all data.

configure

He can configure, can view the data on-line and off-line and
can do data analysis.
He can assign rights to build templates or for to do data
analysis.

**master**

The user has all rights.


He can assign rights for configuring, building templates and
analysing the data.

Rights::

Choose the requested password level from the pull-down menu


and enter a user-defined password in the Password field.
The password will be saved.
The password will be deleted.
You will return to the previous menu.
Click on the square, the entered password will be kept and be
used when the program starts the next time. The user can di

13

Working with the DALOG - Software

Chapter III:

14

rectly work with the DALOG software the next time.


The program caption title is default DALOG. You can change
the caption title and replace it by your own name.
You can display your own background bitmap, e.g. a logo of the
company, a machine or a picture of a plant on the screen. The
picture will appear on the screen, when the password rights
data analysis are chosen. In all other cases the normal configuration will be shown on the screen.
Click on the square, the DALOG box will be automatically reconnected when the DALOG software will start the next time
and the DALOG box is connected to the PC via RS 232 interface.
Print in colour: The graphics will be printed in colour, if you
use a colour printer or in various shades of grey if you use a
monochrome printer.
Print in black/white: The graphics will be printed in black and
white (without grey shades).

3.6

Modem

Click on the Modem button, the following window will appear on


the screen. In the menu settings for the modem, the telephone
number (Connections) and the modem specific AT strings
(Initialization) can be entered (also see chapter 3.1.3 modem
set-up).

Advice:

All the inputs in the menu option base settings... will be stored
by so-called templates. When you start the DALOG program
the next time and call the file name of a template, all inputs will
be re-established. This means all inputs have to be made only
once.

Exit

With the menu option Exit you leave the DALOG program.

14

Working with the DALOG Software

Chapter III:

15

Dalog
Click, the opposite pull-down menu appears.

4.1

4.1.1

Open...

Direct arrangement of a connection:

on-line connection between DALOG and PC via RS


232 interface

modem connection between DALOG and PC via RS


232 interface

connection to a memory card via PCMCIA drive

connection to a card image file

Open...

The following window will appear.

Data source:

default setting is DALOG data box.

DALOG data box

Click on the menu option DALOG data box, the following pulldown menu will appear.

Dalog data box direct arrangement of a connection to DALOG


Direct arrangement of a connection to DALOG:
1. Click on the menu option Open....
The following menu will appear at the screen.

15

Chapter III:

Working with the DALOG Software

16

2. In the next step you select the required interface:


Click on not connected, and the following menu will be
shown. If the selection you have made is incorrect, the OK
Button will not be active.

3. Click on the menu Interface:


Make a selection by clicking on the interface, e.g. COM1.
The following will be shown.

4. Getting a Connection
Click on the OK button, the connection to DALOG will be
done. If there is an incorrect connection between PC and
DALOG, the following failure report will appear at the
screen.

When there is a correct connection, the configuration currently

16

Working with the DALOG Software

Chapter III:

17

running at DALOG will appear at the screen, e.g.

4.1.2

Modem

Getting a connection via modem between PC and DALOG


1. Click on Modem at the menu option Data source. The
following will be shown in the window Connect.

2. Click on not connected in the menu option Interface.


The following menu will be shown at the screen.

3. Click on the menu Interface:


Make a selection by clicking on the interface, e.g. COM1.
The following will be shown.

17

Working with the DALOG Software

Chapter III:

18

4. Click on the button Dial....


If there is a connection between PC and modem, then the
modem will be automatically initialized. The following will be shown on the screen.

4.1.3

Settings storing modem connections


Settings

Click on the button Settings, the following window will appear.


Here you can enter the telephone numbers of the modems
which are connected to the individual DALOGs. You can store
up to 10 different telephone numbers.

Connections:

Here you enter:

Station:

the name of the company


the name of the plant
or an identification for a DALOG assigned by you.

Number:

Here you enter:


the telephone number of the modem which is connected to
the DALOG
The telephone number must be entered with trunk code and
extension number, if any.

18

Working with the DALOG Software

Chapter III:

Initialization:

19

Here you can enter the initialization strings for the connection
between:
DALOG and modem Modem at box and
modem and PC Modem at PC
Click here to store the inputs.
When you click here the inputs will not be stored, you leave the
window without any changes.

4.1.4

Dial getting a connection


Close the menu window Settings by clicking on the OK button,
and the following window will appear.

1. Click on <no station>in the field Station. The selectable


19

Chapter III:

Working with the DALOG Software

20

stations will appear.

2. Click on the requested connection, e.g. DALOG GmbH.


In the field Station appears the name of the modem connection.

3. Click on the button Dial.


If there is a correct connection between PC and modem as
well as between modem and DALOG, then a connection will
be effected automatically. The following will appear on the
screen.

4. The field Status indicates the transmission rate.


5. Click on the button Hang up, the modem connection will be
cancelled and the telephone line will be free again.
6. Click on the button OK, the online window will appear. The
DALOG configuration will be shown on the screen.

20

Working with the DALOG Software

Chapter III:

21

You can see the status of the connection in the graphic at the
right bottom. In this case you have a PC modem modem DALOG E connection.
7. If there is no modem or an incorrect connection between
modem and PC, the following will be shown on the screen.

Note:

4.1.5

You can still click on Settings and enter the station name and
the telephone number of a modem connection to a DALOG.

PCMCIA drive uploading and configuring memory cards


This function is very interesting, if there is no possibility for a
connection between PC and DALOG via interface cable or a
modem connection, etc.. The data upload or a new configuration of a DALOG is done by replacing the memory card. The
memory card will be taken out of the card drive and a new one
will be inserted. The memory cards are buffered by a battery
(3V silicon battery). The data of a 2MByte memory card will be
stored for a minimum of 12 months without an external power
supply.
Advice:

Make sure to put the memory card correctly into the memory
card drive (see chapter VII 1).

Attention:

If you intend to transfer a new configuration via a memory


card to DALOG, the power supply must be off without
fail!!!
21

Chapter III:

Working with the DALOG Software

22

Configuration and data upload are via the PCMCIA drive integrated in the PC.
1. Put the memory card into the internal PCMCIA drive.
2. Click on the menu option PCMCIA drive in the window
Connect.
The following will be shown on the screen.

Most PCMCIA drives have two slots, therefore one slot must be
selected.
3. Click on Slot0 in the field Interface, the following pull-down
menu will be shown.

4. Click on the required slot, in the field Interface.

5. Click on the OK button. If there is a configured memory


card in the PCMCIA memory card drive, then the configuration will be shown on the screen.

22

Chapter III:

Working with the DALOG Software

23

You can see the status of the connection in the bottom right. In
this case you have a PCMCIA - DALOG connection.

4.1.5.1

Configuring a memory card


To configure a memory card, you must either
build a configuration or
load an already built configuration that is stored on a data
carrier.
Setting a connection to a memory card is via the menu item
Dalog and/or the pull-down menu item Connect, see chapter
3.1.2.5.
Configuring the memory Click on the menu item Dalog. The following pull-down-menu
card
will be displayed:

Click on the menu item Configure card. The memory card will
be configured with the configuration connected with the
PCMCIA drive.
On the other hand, a configuration stored on the memory card
may be uploaded from the card via the menu item Load config.
from card.

23

Working with the DALOG Software

Chapter III:

4.1.5.2

24

Uploading the memory card and offline data analysis


Load config. from card Click on the menu item Load config. from card.
For uploading the measurement data stored on the memory
card, a connection must be set up to the memory card via the
menu item Dalog as well as via the pull-down menu item Connect as described in chapter 3.1.2.5.
The procedure for uploading the data measurement data stored
on the memory card as well as for offline data analysis is the
same as described in chapter III 15 Upload and/or chapter III 16
data analysis.

Templates
Template

The following pull-down menu will be displayed.


Templates are used to save online and offline screen settings.
Any user-defined arrangement of windows and window configurations may be saved under a template name. These settings
will always be restored when the corresponding template name
is called. This means that e.g. several online and/or offline windows will be opened automatically and directly by calling the
corresponding template.
The windows have to be configured and placed in the required
arrangement at the screen only once.
First you need a configuration to set up templates. Setting-up
templates for online windows can only be done with an online
connection to a DALOG and for offline windows only in connection with measurement data already stored on a data carrier.
The template names to save the individual templates can be
freely selected.

Save

Changes to the actual template will be stored under the existing


template name.
When you have not chosen a template name, the DALOG
software will ask you automatically to put in a template name.

Save as...

You will always be asked to put in a template name.


When there is an existing template name you will be asked if
you want to overwrite the existing template name.

Delete

Deletes marked templates.

Close

Closes the pull-down menu.

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Window

25

With the menu option Window you can configure the layout of
the configuration windows on the screen as well as fade in or
fade out the symbolbars, the footbar and the quick info.
Click on the menu option Window, and the following pull-down
menu will appear on the screen:

Cascade

The configuration windows are overlaid. The title bar will be


seen.

Tile

The configuration windows are presented side by side.

Arrange

The minimized configuration windows (symbol size) will be arranged at the lower border of the DALOG window.

Symbolbar

The Symbolbar can fade in or fade out. The faded-in Symbolbar is indicated by a check mark ( Symbolbar).

Footbar

The Footbar can fade in or fade out. The faded-in Footbar is


indicated by a check mark ( Footbar).

Quick info

The Quick info can fade in or fade out. The faded-in Quick
info is indicated by a check mark ( Quick info).

File name of the configura- The Quick info indicates the file names of the opened configution
ration windows. When you click on a file name, this configuration window will become the active one.

Note:

The pull-down menu options Cascade and Tile are only active
when one or more configuration windows are open.

Help

With the menu option Help you can activate the WINDOWS
help of the DALOG software. The menu option Help will assist

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26

you when you use the DALOG software and will give you general information on DALOG.
Click on the menu option Help, and the following pull-down
menu will appear.

Content

Calls the general help for the DALOG software.

Search...

Key-word search for working with the DALOG software

Help on Help...

You will get hints on how to use the DALOG help.

About DALOG...

Will indicate the software version number as well as name and


address and the service telephone number. The following window will appear at the screen.

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27

File

When a configuration is opened and you are clicking on the


menu option File, the following pull-down menu will appear on
the screen.

8.1

New...

See chapter III 3.1

8.2

Open...

See chapter III 3.2

8.3

Close

close the actual opened configuration window

8.4

Save

Changes to the actual configuration will be stored under the


existing configuration name.
When you have not chosen a configuration name, the DALOG
software will ask you automatically to put in a configuration
name. All configuration names must have the extension CFG. If
you have not done any changes to the actual configuration this
menu option will not be active.

8.5

Save as...

You will always be asked to put in a configuration name (file


name). All configuration names must have the extension CFG.
When there is an existing configuration name, you will be asked
if you want to overwrite the existing configuration name.

8.6

Save all

You will always be asked to put in a configuration name (file


name) when you have not selected a configuration name already. Otherwise, the existing configuration will be stored under
the current configuration name. All configuration names must
have the extension CFG.

8.7

Print...

See chapter III 3.3

8.8

Printer set up...

See chapter III 3.4

8.9

Base settings...

See chapter III 3.5

8.10

Exit

See chapter III 3.6

Edit

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28

mands will be shown. On the screen appears following pulldown menu.

9.1

9.2

9.3

Undo

All done commands will be Undone, e.g. deletion of a function


icon or parts of the configuration..

Note:

The command Undo must be selected immediately after deletion.

Redo

The previous configuration state will be re-established.

Note:

The command Redo must be selected immediately after the


changes to the configuration.

Cut

Marked function icons or parts of the configuration will be cut


out of the configuration.
When you have cut out the wrong parts of the configuration
choose the command Redo immediately and the preceding
configuration status will be re-established.

9.4

Copy

Marked function icons or configuration parts will be copied.


With the command Copy you can copy recurrent function icons
or configuration parts and can paste (put in) them in at any
place of the configuration with the command Paste.

9.5

Paste

Deleted, copied or cut out configuration icons or configuration


parts can be pasted in at any place of the configuration.

9.6

Delete

Marked function icons or configuration parts will be deleted.


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29

Should you have deleted the wrong parts with the command
Delete by mistake, select the command Undo at once. The
previous state will be re-established.
You can paste in the deleted parts with the command Paste.

9.7

Mark all

The entire configuration will be marked. All parts of the configuration are flashing.
The entire configuration can be deleted, copied or cut out in this
way.

9.8

Zoom

The entire configuration can be reduced or enlarged.


The default presentation of the configuration is enlarged.

9.9

Monochrome

The entire configuration will be presented monochrome.

9.10

Event data interactive

Click on the menu option Event data interactive, and the


event icons will be integrated in the configuration. (For connection of the events by means of a menu, see chapter ????).
When event icons have been connected to the configuration
already, the connecting lines will be indicated when this menu
option is activated.

Attention:

All data connections can be connected via the menu window.


Exception: The connection of pre-processed signals such as
minimum, maximum, filter values, etc. This connection must be
done interactively.

9.11

Set up...

Upon clicking a further pull-down menu will appear.

The menu comprises:


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30

Capacity of the Memory card


Base menus... general text information for systems with
display
Passwords... for an entry to the display reading
General information on the Monitored plant....
The menu options Base Menus... and Passwords... are only
active in connection with DALOG-D (with display reading).

9.11.1

Memory card...

Upon clicking, the following menu window will appear.

Here you can put in:


the memory capacity of the Memory card and/or
the memory card capacity of an existing configuration will be
shown.
Attention:

It is not allowed that the set memory capacity is larger than


the real maximum capacity of the target memory card!

9.11.2

Base menus...

general text information for systems with display (DALOG-D).

9.11.3

Passwords...

for an entry to the display reading (DALOG-D).

9.11.4

Monitored plant...

Here you can put in machine specific data. The data must be
written in text files. The extension of this files is *.TXT. These
text files are stored on the memory card.

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31

Input of the file name with the machine data, e.g. madata.txt

Clicking on Import the file with the machine data will be imported and connected to the configuration.
The imported data will be shown on the screen. The data can
be shown and edited.
Clicking OK the window will be closed.

9.12

New elements...

Click and a further pull-down menu will be shown.

Standard...

function modules for setting-up a configuration

Logic...

function modules for setting-up logical operations

Timer...

function modules for trigger operations and for timing the measuring.

Signal conditioning...

function modules for signal conditioning

Display...

function modules for online and offline presentation at the display (only DALOG-D)

Analysis...

function modules for online and offline presentation of the signals

Note:

All function modules can be called more easily and faster by an


icon function bar. Simply click on the icons, this will be an easy
way to do a configuration.

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9.12.1

Standard...

32

Procedure for items 8.13.1.1 - 8.13.6.2


Click on a menu item, e.g. Channel, and the insertion pointer
will be displayed.
You can decide by a mouse click where the function icon is to
be located.

Standard...

Upon clicking a further pull-down menu will be shown.

Here you can choose the Standard function modules to build a


configuration.
Channel...

Defines the input channels


The menu for selecting the measuring channel will be displayed
at the screen after clicking.

9.12.2

Sample rate

Sample rate icons will be inserted.

Filter

Filter icons will be inserted.

Limit above

Limit above icons will be inserted.

Limit below

Limit below icons will be inserted.

Buffer

Buffers will be inserted.

Logic...

Click and a further pull-down menu will be shown:

Here you can choose logical functions.


AND

The icon

for logical AND will appear.

The AND icon connects two trigger conditions, i.e. only if two
conditions are fulfilled at the same time, a triggering will be
done.
OR

The icon

for logical OR will appear.

The OR icon connects two trigger conditions, i.e. only of one .


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33

or the other trigger condition is fulfilled, a triggering will be done.


Not

The icon

for logical Not will appear.

The NOT symbol terminates a triggering and may also be used


for reversing a statement from true to false or vice versa.
JK flipflop

The symbol

for the JK flipflop will be displayed.

The JK flipflop is used for storing a condition, i.e. triggering will


only be initiated when a second condition is additionally fulfilled.
Impuls-Generator

The symbol

for the Impuls-Generator will be displayed.

The Impuls-Generator is used for initiating a trigger pulse e.g.


as a function of the net operating time of the machine.
Phone message

The symbol

for the phone message will be displayed.

The phone message is used for making a call to the user, initiated by a trigger condition..

9.12.3

Digital output..

The digital output channels can be defined here. Click on the


left mouse button and the menu for the digital outputs will be
displayed at the screen.

Timers...

Click here to display a further pull-down menu.

In the Timer... pull-down menu you will find the function modules for the time control and triggering of the measurement.
Interval timer

The symbol

for the Interval timer will be displayed.

The Interval timer initiates periodical trigger pulses, e.g. for


measurements at periodical intervals.
Delay timer

The symbol

for the Delay timer will be displayed.

With the Delay timer the pre- and/or the post trigger time is set.
Stop watch
The symbol

for the Stop watch will be displayed.

The Stop watch measures the length of a time interval, e.g. the
period of an off-limit condition or the accumulated number of
individual time intervals.

9.12.4

Signal conditioning...

When you click here, a further pull-down menu will be displayed.

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34

In the pull-down menu Processing... you will find the function


modules for pre-processing the measurement signals.
Fatigue load
The symbol
FFT

The symbol
displayed.

for the Fatigue load will be displayed.


for FFT (Fast-Fourier-Transformation) will be

Sum
The symbol

for the Sum will be displayed .

The sum is used to count trigger events, e.g. the number of offlimit conditions.
Minimum

The symbol

for the Minimum will be displayed.

The Minimum determines the lowest value within a fixed time


base.
Maximum

The symbol
for the Maximum will be displayed.
The Maximum determines the highest value within a fixed time
base.

Derivation

for Derivation will be displayed. The derivaThe symbol


tion allows the triggering on the rise change of an analog signal
within a time unit.

Event

The symbol

for the Event will be displayed.

The event determines:


the instant (date and time)
the measurement values and the duration of the trigger
event
as well as the measurement values that have been measured at other channels parallel to the event.
The values are represented in tabular form.
Data vector
The symbol
Calculation formula

The symbol

for the Data vector will be displayed.


for the Calculation formula will be displayed.

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9.12.5

Display...

35

When you click here, a further pull-down menu will be displayed.

Here you will find the function modules for configuring the display functions.
Note:

Functions are only available with DALOG-D (with Display).

Text

The symbol

for the Text will be displayed.

The Text is used to enter the texts at the display.


Key

The symbol

for the Key will be displayed.

The Key is used for configuring the soft keys at the display.
Data
The symbol
for the Data will be displayed.
The symbol Data is used to indicate the online and offline data
at the display.

9.12.6

Analysis...

Online

Note:

Offline

When you click here, a further pull-down menu will be displayed.

The symbol
for the Online Function will be displayed.
Data will be indicated online at the screen.
The online function module is only available in connection with
the function "Connect DALOG.".
The symbol
for the offline function will be displayed.
Data will be indicated offline at the screen.

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36

10

Dalog

when a configuration has already been opened, the pull down


menu below will be displayed.

10.1

Open...

See chapter III 4.1

10.2

Connect...

With this menu item you can set up the following connections
when a configuration has already been opened (e.g. to configure DALOG with the configuration displayed in the active window):

Online connection via the serial interface RS 232


to DALOG
Modem connection to DALOG
Connection to a PCMCIA drive
Connection to a card image file
Important note:

With the menu item Connect... the online screen can be called
without a direct connection to DALOG. With this quasi connection, the individual online windows and online connections can
be configured. The following status indication will be faded in at
the right bottom edge of the screen.
At the bottom right edge the status of the connection, in this
case a modem - ? connection is faded in. The question mark
symbolizes that no active DALOG has been recognized at the
interface.
(Also see chapter III 4.1.1 and the following).

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10.2.1

37

Reinitialization of the interface in the case of an interruption of the online


transmission
Should there be an interruption of an active online connection
between PC and DALOG, the message below will be displayed

Reinitialization of the interface may be done via the menu item


Connect... as follows.
1. Click on the menu item Data box...
2. In the pull-down menu displayed now, call the menu item
Connect....
The window below will be displayed.

3. Click on the Reset COM button. The interface will be reinitialized now.
4. When a proper connection has been set up, the symbol to
the left will be displayed at the bottom right edge of the
screen.
5. When a proper connection has not been set up, the symbol
to the left will be displayed at the bottom right edge of the
screen.
If the latter is the case, check the following:
Serial connection between PC and DALOG
Supply voltage of DALOG

10.3

Disconnect

When you click here, the program will return from the online
mode to the configuration mode.
This menu item is only active when the program is in the online
mode.

10.4

Info on data box

You will get information on the connection state between the


PC and DALOG by clicking here. When the connection has
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Working with the DALOG Software

Chapter III:

38

been set up correctly, the firmware version, the system time,


the configuration name and date, the memory capacity of the
memory card, and the operational status will be indicated..

10.5

About monitored plant After clicking here you will get general information on the moni-

10.6

Load config. from box

When you click here, the configuration stored in the box will be
loaded, provided there is a connection between PC and
DALOG. This menu item is only active when the program is in
the online mode.

10.7

Configure box

When you click here, DALOG will be reconfigured provided


there is a connection between PC and DALOG. The window
below will be displayed.

tored plant, provided corresponding machine-related data have


been stored on the memory card (see chapter III 9.11.4).

Short name of configura- contains the default name of the configuration. This name can
tion
be changed if required.
Note:

The field Short name of configuration must always be filled in


and must not contain any special characters, blank characters,
umlaute, etc.!

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User's name

39

is not filled in as default. The user may enter his name here.
This name will also be indicated in the Info Menu of DALOG.
Filling in this field is not absolutely necessary.
you will exit the window configure box by clicking here The
window system time of the data box below will be displayed.

The window will indicate the following:


Current system time of the data box:
New system time:
Current system time:

will always indicate the current date and the time of the real
time clock of DALOG .

New system time:

The user may alter the real time clock here. Thus the real time
clock may be adapted to the local time. Date and time correspond to the PC-clock.
When you click on the Yes button, the real time clock will be
reinitialized together with the reconfiguration of the box.
When you click on the No button, the time of the real time clock
will not be altered when the box is reconfigured.

10.8

Load all buffers

All measurement data that are stored in the buffers in the


DALOG will be loaded and stored on the hard disk of your PC.
The window below will be displayed at the screen.

The program will automatically upload all buffer directories one


after the other and store them under the configuration name on
the hard disk. The measurement data will be stored in binary
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Working with the DALOG Software

Chapter III:

40

format (see chapter V 1).

10.9

Note:

Even after uploading and storing, the measurement data on the


memory card will not be erased on the hard disk. They will remain there until the disk is overwritten or DALOG is configured.

Load complete card...

The entire contents of the memory card will be copied and


stored on the hard disk.
A so-called card image is generated. A file is stored on the hard
disk that will be given the name of the configuration as default
and that must always have the extension .IMG. The name of
the image file can be changed by the user.
The image file will always be of the same size as the memory
capacity of the memory card in the box, provided it has been
transferred completely. A completely transferred 2MByte memory card will have 2Mbyte on the hard disk, too.
The window below will be displayed after clicking.

File name

contains the configuration name as default.

Directories:

the DALOG directory will be indicated as default.


Other directories or drives than those indicated may also be
selected.
Starts the image upload.
The window below with the following data will be indicated.
y Upload name, e.g. DIS.IMG
y Transfer time, e.g. 4 sec
y Remaining time, e.g. 28 sec
y Percentage of file transmitted, e.g. 25%

OK

10.10

auto transfer

By means of the auto transfer, the measurement data are continuously transferred in the ASCII format via the serial interface
(see chapter III 14.2).
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11

Window

41

With the menu item Window you may:

configure the layout of the configuration windows at the


screen

fade in and out symbol bars, footbar and quick info


Click and the following pull-down menu will be indicated.

12

Help

With the menu item Help you can:


activate the WINDOWS help for the DALOG software. It will
assist you when you handle the DALOG2 software.
get general information on DALOG.
Click and the following pull-down menu will be indicated at the
screen.

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13

42

Explanation of the function blocks


Complete configurations can be set up by clicking on the individual icon blocks.
In the configuration mode of DALOG-Software you will find two
bars with icon blocks.
The top icon bar contains all functions required for operating
the software program. These are functions as opening a file,
copying, inserting etc. corresponding to word processing programs.

The bottom icon bar contains all functions required for setting
up the configuration.

13.1

Top icon bar


New configuration
Click here and a blank configuration window will be displayed..

Open box
Connects DALOG to a PC via the serial interface (RS232),
modem or mains

Open configuration
Opens an already existing configuration on the hard disk or
floppy disk

Store configuration
To store a new and/or changed configuration on the hard disk
or floppy disk
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Chapter III:

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43

Undo
To undo the last change to an existing configuration

Cut
To cut marked icon blocks and connections by the mouse
(marked parts are flashing on the screen)

Copy
To copy marked blocks and connections by the mouse (marked
parts are flashing on the screen)

Insert
To insert previously cut or copied parts of a configuration

Delete
To delete previously marked parts of a configuration

Larger/smaller
To increase or reduce a configuration currently displayed at the
screen

Erect a connection
To connect a DALOG to a PC

Information on data box


Survey of the current system state while there is a connection
to DALOG

Information on monitored plant


Survey of the customer-specific data of the monitored plant

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13.2

44

Bottom icon bar


The bottom icon bar shows the symbols that can be inserted
into the configuration by clicking.
Note:

, the correAfter a double click on the icon concerned, e.g.


sponding menu window will be displayed at the screen.
Or:
With a click of the right mouse button on the icon the opposite
menu will e.g. be displayed. Here you are requested to call the
menu Configure with the left mouse button. The corresponding
menu window will be displayed

New data channel


To insert analog or digital data channels into a configuration

Sample rate
Sample rate elements

Recursive data filter


Recursive digital data filter, e.g. to suppress interfering signals

Exceeding a limit value


When you click on the icon block "exceeding a limit value" any
overrun of a limit value and/or change in the switching state of
an analog or digital input can be registered and recorded.

Remain under a limit value


Registration when a limit value is underrun and/or changes in
the switching state of an analog or digital input

Data buffer
Data buffer to determine the memory size for the channel concerned.

Logical AND
Logical linking of channels by an AND condition

Logical OR
Logical linking of channels by an OR condition

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Chapter III:

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45

Logical NOT
Logical linking of channels by a NOT condition

JK flipflop
Logical linking of channels by storing a logical state by a JK
flipflop

Pulse generator
Triggers an action by an adjustable number of pulses

Message calls
DALOG will report automatically e.g. when a limit is exceeded

Digital monitoring output


Digital monitoring output, e.g. indication of a limit value violation

Timer generator
To initiate trigger conditions at exactly defined times

Delay timer
To determine a defined period for data recording

Stopwatch
To establish the retention time, e.g. the duration of a limit value
violation or operating hours

Data vector
To establish data vectors in order to prepare statistical characteristics, FFTs etc.

Calculations
To calculate channels and physical units and to draw up complex logical conditions

Derivation
To initiate a trigger pulse at rising or falling edge

Classification
Classification of the data as per Rainflow
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Chapter III:

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46

Fast Fourier Transformation (FFT)


The measurement data are subjected to a signal analysis in the
frequency range.

Sum
Counter to form the accumulated number of individual events
e.g. limit value limitations

Minimum
Records the minimum that occurred

Maximum
Records the maximum that occurred

Event
Records an event, e.g. limit value violation

Offline data evaluation


Offline video display of the measurement data of the channel
selected

Online data output


Online-video display of the measurement data of the channel
selected

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13.2.1

47

New data channel


When you click on the function block New data channel and
insert this in a configuration, the following menu window will be
displayed:

Desired channel type

click on analog or digital

Analog

You can choose between the two different resolution levels 12


bit and 10 bit for the analog inputs by clicking on the arrow..

12 bit inputs

Depending on the selected data type analog 12 bit, analog 10


bit or digital, the appropriate total number of the available channels will be indicated, e.g. 12 bit inputs.

Total number

Total number of the analog 12 bit inputs: 24

In use

Number of the channels already in use

Selection

When you do not select the individual channels specifically, the


channels will be indicated at the screen one after the other
each time you click on the OK button. The letter following the
term input, e.g. U, corresponds to the pin assignment of the
plug.
When you click on the arrow in the menu option Selection, you
have a free choice of the analog channels at 12 bit or 10 bit
resolution or the digital channels, e.g. when you select 12 bit
the opposite channels.

The selection will be stored. The symbol below will be displayed


at the screen, example analog input U:

when a digital channel, e.g. digital input E is selected:

The selection will not be stored.


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48

13.2.1.1 Configuring the analog inputs


Double click on the analog input symbol in the configuration.
The following menu will be displayed:

Input pin:

indicates the input that is being configured, e.g. analog input V.

AD converter:

indicates the resolution of the input, e.g. 12 bit.

Measuring point:

blank field for an input name defined by the user

Signal:

Here you can select the type of the sensor connected and the
signal.

Type:

Only analog sensor can be selected as standard. Customerspecific sensor signal pre-analysing may be stored here.

Name.:

When you click on the arrow, a selection menu of user-defined


physical conversion tables will be displayed, provided physical
conversion tables have been prepared already, as e.g.

log. measuring range:

indicates the measuring range and the corresponding physical


unit selected for this input, e.g. -150 - 600 bar.
When you do not select any physical conversion table in the
field name: and/or when you select (unknown), the resolution of
the input will be indicated here, e.g. 0 - 4095

log. resolution:

indicates the logical resolution of the signal.


The logical resolution is equal to the physical resolution, e.g. 12
bit, when the user has not entered any other data in the menu
Define signal in the menu item internal conversion.
For the time being, the logical resolution may be changed with
the models DALOG PS1 and DALOG 32 only. Unlike the
physical resolution, the logical resolution may be increased up
to 14 bit.

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Symbol:

49

In this field a characteristic symbol, depending on the sensor,


will be indicated.
The selection will be stored. The following symbol. will e.g. be
displayed at the screen.
The inputs made in the window Configure measuring input will
be displayed at the screen, e.g.:
Name of the input:

High pressure

Signal:

0-600-bar

When you click here, the following menu Sensor adjustment


will be displayed. Here you can draw up new physical conversion tables or change already existing ones.

Name:

When you click here, a selection menu of user-defined physical


conversion tables will be displayed, provided physical conversion tables have been drawn up already. These can be selected. You may also enter a new user-defined name.

Relevant signal range:

Indicates the measuring range of the defined physical conversion table.

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Logical resolution:

50

Indicates the logical resolution of the signal


The logical resolution is equal to the physical resolution as
standard. For the time being, the logical resolution may be
changed with the models DALOG PS1 and DALOG 32 only.
Deletes individual, selected physical conversion tables
Changes to an existing conversion table are accepted and
stored under the same name.
All inputs and/or changes are stored, and you will leave the
Sensor adjustment.
The inputs and/or changes will not be stored, and you will exit
the menu Sensor adjustment.

Linearisation

A user-defined linearisation of the measuring signal may be


entered here..

Physical
resolution:

Indicates the physical resolution of the selected analog channel

Binary value:

Here you can enter any binary value within the given resolution.

It may be 8 bit, 10 bit or 12 Bit.

Resolution:

Signal

12 bit 0 - 4095
10 bit 0 - 1023
8 bit 0 - 255

Here you enter the physical measured value associated to the


binary value, e.g.:
Binary value: 819 4mA 0bar Enter at Signal
0
Binary value: 4095 20mA 600bar Enter at Signal 600
After you have entered the binary value and the Signal click
on the Set button to store the input.
Deletes individual marked data.
Deletes all input data in the input field..

Sensor adjustment

Below you see a completely filled-in menu window.

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The menu window Defining signal below will be indicated at


the screen. Here you can enter new user-defined physical conversion tables.

Signal

Name:

Indicates the Name for the physical conversion table that has
been entered in the menu window Sensor adjustment, e.g.
vibration.

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Symbol:

52

You can select a suitable symbol for the physical unit via the
arrows.

Physical unit

Unit:

Click on the arrow to select a given physical unit or to enter a


new one..

Definition:

Enter the SI base-units


They refer to the higher-order physical variables entered in the
field Unit, e.g. N kg m / s2.

Internal conversion

Logical resolution

Here you can enter a user-defined Logical resolution of up to


14 bit, deviating from the physical resolution. (For the time being, this applies only to the models DALOG PS1 and DALOG
32)

Sample range:

You can define a physical Sample range that corresponds to


the selected logical resolution.
from: Starting value
to:
Final value
(For the time being, this applies only to the models DALOG
PS1 and DALOG 32)

Defining signal

Below you will find a completed menu window

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53

All the inputs and/or changes will be stored, and you will exit the
menu.
Inputs and/or changes will not be stored, and you will exit the
menu.

13.2.1.2 Configure digital inputs


Double click on the digital input symbol and the menu below will
be displayed at the screen:

Input pin:

Indicates the input that is being configured, e.g. digital input F

Measuring point

blank field for any input name, e.g. Trigger

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54

Signal:

Here you can determine the type of sensor connected.

Type:

Here you can choose between a digital input and a frequency


counter.
(This applies only to the models DALOG PS1 and DALOG
32)
As frequency counters, sensors with TTL level may be connected, as an option other voltage levels, too.

Name:

A selection menu of user-defined frequency tables will be displayed, provided these have been drawn up, and the frequency
counter has been selected.

log. measuring range:

Logical measuring range with a digital input of 0/1


With the frequency meter, the defined frequency range will be
indicated here.

log. resolution:

Logical resolution with a digital input of 1 bit


With the frequency counter, the logical resolution may be max.
14 bit.

Symbol

Indicates the symbol for the digital input


This symbol cannot be changed.

Type:
Frequency counter

Here you can draw up new frequency tables or change existing


ones. The menu Frequency measurement below will be displayed.

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55

Signal

Here you can enter the sensor-specific data.

Name:

A selection menu of user-defined frequency tables will be displayed, provided these have been drawn up. These may be
selected or new Names may be entered.

Maximum frequency:

Here you can enter the maximum frequency measuring range.


Select the required frequency range via the arrow.

Logical resolution:

Here you can enter a user-defined Logical resolution of up to


14 bit.
(For the time being, this applies only to the models DALOG
PS1 and DALOG 32)
Changes to an existing frequency table are taken over and
stored under the same name.
Deletes individual marked frequency tables.
Inputs and/or changes are stored and you will exit the menu
Frequency measurement.
The inputs made in the window Configure digital input will be
indicated on the screen, e.g.:
Name of the input "level"

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13.2.2

56

Sample rate
A double click on the function symbol Sample rate will call the
following menu:

Signal name:

User-defined signal name

Rate

The sample rate can be set as required

Static load of the box:

Percentage of static load as a function of the computer power of


the DALOG processor

Maximum recommended
sample rate:

Maximum permissible sample rate


The value indicated will change as a function of the complexity
of the configuration and the selected sample rates.
Click here, the following menu window will be displayed. You
can enter the signal name in this menu window.

Note:

The signal name is also used as identification of the Y axis in


the online and offline representation. The program generates a
short form of the name for this purpose. For generating the
short form, the capitals are always used first, max. three, or
should there be only one capital, the first three letters of the
signal name.

Signal expression:

Enter the user-defined signal name here, e.g. input torque.


The selection is stored. The name will be indicated in the sample rate menu window, e.g. Input Torque.

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Here you may enter the sample rate, e.g. 100.

Rate

Click on the arrow and you can select the required time base
for the sample rate.
:
Note:

The lowest sample rate is 1 unit per half an hour


Click on the button, the following menu will be displayed on the
screen:

The automatic transfer mechanism sends the data automatically continuously to the PC via the RS 232 interface. The data
will be stored in ASCII format. The transfer rate of the data is
the same as the sample rate.
Note:

The data will be also stored on the memory card. The data on
the memory card will be stored in Binary format.
Clicking the data will be send to the PC after configuration and
stored on harddisk, when there is a connection between PC
and DALOG.
The data will be stored under a file name, e.g. buf_0002.dat.
The system will set a default file name. The user can define is
own specific file name. The file name must always have the
extension *.DAT. The target directory in this case, is the
DALOG directory. It could be also any other directory, e.g.
C:\transfer\buf_0002.dat
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58

Recursive data filter


After a double click on the function symbol recursive data filter
the following menu will be displayed on the screen:

Click here, the following menu window will be displayed. You


can enter the signal name in this menu window.

Signal expression:

Enter the user-defined signal name here, e.g. input torque.


High-frequency noise and oscillation portions will be suppressed in the signal curve as a function of the selected filter
size.
Low-frequency noise and oscillation portions will be suppressed
in the signal curve as a function of the selected filter size.

Filter size

Select the filter size

Number of values:

Click on the arrow beside the menu item "Number of values",


and the following options display will be indicated.
The filter size may now be freely selected with the mouse button in increments of power of two in a range of 2 - 4096

Note:

The recursive data filter calculates the filter value recursively on


the basis of the previous, filtered signal values and the nonfiltered signal value.

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59

Violation of limit value / Limit above


Double click on the function symbol limit above and the following menu will be displayed at the screen:

Click here, the following menu window will be displayed. You


can enter the signal name in this menu window.

Signal expression:

Enter the user-defined signal name here, e.g. input torque.

Type:

Type of limit value check, in this case TEST


(rising edge)

Limit:

Here you can enter the limit value.

Note:

With a correct configuration set-up, the limit value must be entered in a physical unit, see figure below, after you have previously selected a physical unit at the input channel, too.

FOR UPPER LIMIT

When you have not selected any physical unit, the input may be
within the permissible resolution of 10-Bit (1024 values) or 12Bit (4096 values) only.
For entering the limit value, the icon Limit above must have
been integrated in a configuration.

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60

Violation of limit value / Limit below


Double click on the icon limit above and the following menu will
be displayed at the screen:

Click here, the following menu window will be displayed. You


can enter the signal name in this menu window.

Signal expression:

Enter the user-defined signal name here, e.g. input torque.

Type:

Type of limit value check, in this case TEST


(falling edge)

Limit:

Input field for the limit value.

Note:

With a correct configuration set-up, the limit value must be entered in a physical unit, see figure below, after you have previously selected a physical unit at the input channel, too.

FOR LOWER LIMIT

When you have not selected any physical unit, the input may be
within the permissible resolution of 10-Bit (1024 values) or 12Bit (4096 values) only.
For entering the limit value, the icon Limit below must have
been integrated in a configuration.

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61

Data buffer
After a double click on the icon data buffer the menu below will
be displayed at the screen when the data buffers are configured
for the first time:

Size:

Size of the memory card, e.g. 2048 kBytes (2MByte)

The entry will be stored. The menu window buffer will be displayed at the screen.

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File:

62

File name of the measurement data


The file name is composed as default as follows:
Each measuring data buffer commences with : buf_
For the next three letters the program generates a short
form of the name of the associated sampling rate element. It
uses max. three capitals first. When there is only one capital, the first capital and the following two letters of the signal
name are used, e.g. AnD.
Now follows a consecutive number commencing at 0. It depends on the number of buffers that have been linked to this
channel. The first buffer has the identification number 0.
In this field you may also enter a user-defined name (max. 8
characters) of your own as well as a path where the measurement data are to be written.

Size:

Buffer size for the associated input


Click on the arrow beside the input field Size: A selection menu
will be displayed where you can select the required time base.
The adjustable time base may be varied:
dy, hr, min, sec, msec
as well as the number of the values to be stored.
The software converts the numerical values entered in the field
size directly to the corresponding numerical value when the
time base is altered. Values will automatically be converted to
time units, and time units to values and be displayed as such.

Size:

Corresponds to the max. memory capacity available for this


channel.
Must always be filled in.

Used fraction of the


memory card:

Overall usage of the memory card in percent, e.g. 12.5%

Maximum available
buffer size

Maximum available buffer size taken all the buffers already


configured into consideration.
When this buffer size is exceeded during a measurement, the
old data are overwritten starting at the beginning, so-called ring
buffer.

Note:

Entering the buffer size on a time or value base is only possible


when the buffer is integrated in a configuration. When it is
linked to an event icon block, entering the buffer size may be in
byte only.

Attention:

The memory capacity of the memory card entered by the user


must never exceed the maximum permissible memory capacity
of the memory card.

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13.2.6.1 Explanation how the data buffers work


The icon Buffer has two different means to trigger an action
Buffer
Start symbol

Stop symbol

Linking a triggering element to the Start symbol , as e.g. the


triggering pulse of a timer, limit above and/or below etc. will
initiate the logging of the measurement data when the trigger
event occurs.
Linking a triggering element to the Stop symbol
terminates
the logging of the measurement data when the trigger event
occurs.
Note:
When the start- and/or stop symbol are not used, the data will
be continuously written into the buffer (memory).

13.2.7

Logical AND
Configuring not possible
However, a name may be allocated for each configuration symbol. To do so, double click on the icon, the window below will
then be displayed.

Click here, the menu window below will be displayed. In this


menu window you can enter the signal name.

Note:

A user-defined name may be allocated for each configuration


symbol. Click on the button name and you can enter the name.

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64

Logical OR
Configuring not possible

13.2.9

Logical NOT
Configuring not possible

13.2.10

JK flipflop
Configuring not possible

13.2.11

Pulse generator
When you double click on the function symbol Impulse generator the following menu will be displayed at the screen.
The pulse generator outputs trigger pulses following input
pulses. These input pulses may be initiated e.g. by a timer
(clock), violations of limit values, logical links etc.
Thus measurement data logging can be controlled efficiently,
and references to maintenance intervals that are due etc. may
be given.

Click here, the menu window below will be displayed. In this


menu window you can enter the signal name.

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Signal expression:

Enter the user-defined signal name here, e.g. input torque.

Counter:

Here you determine the number of input pulses after which an


output pulse is to be given.

Pulse length:

Here you can enter the minimum pulse length that the pulse
must have to be counted as input pulse.
Click on the arrow to select the required time base by means of
the mouse. As default, the pulse length is set to Minimal duration.

Validity:

This field is set to Temporary as default.


When the power supply of DALOG is switched off, the counted
pulses will be lost.
The number of input pulses recognised will be kept even when
DALOG is switched off.
With permanent storage, an initial value may be entered in the
field Pulse counter start. The default setting for Pulse counter
start is 0.

13.2.12

Phone messages
Here DALOG may independently give messages to the user in
connection with events (mobile phone messages). The messages are given to Pager, SMS (GSM-network) and modem.

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66

Digital monitoring output


When you click on the icon block digital monitoring output
and insert this into a configuration, the menu window below will
be displayed:

Digital outputs
Total number:

Number of max. available digital outputs, e.g. 4


The total number of the available outputs depends on the type
of DALOG concerned.

In use

Number of digital outputs already used, e.g. 0

Selection:

Selection of a digital output


Click on the arrow. The corresponding pull down menu with the
selectable digital outputs will be displayed.
When the individual digital outputs are not selected specifically,
the individual outputs will be displayed automatically on the
screen one after the other each time you click on the OK button.
The letter behind the term output, e.g. N, corresponds to the pin
assignment of the plug.
The input will be stored. The selected digital output will be
displayed at the screen, e.g.

Note:

Digital outputs of Dalog serve for (optically or audibly)


signalling of events occurred. They are not intended for control
purposes proper.
When they are used for controlling purposes, this is done at the
user's own and exclusive responsibility!

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13.2.13.1 Configure digital output


Double click on the digital output symbol, and the menu below
will be displayed at the screen.

Click here, the following menu window will be displayed. You


can enter the signal name in this menu window.

Signal expression:

Enter the user-defined signal name here, e.g. LowFilter.

Connection:

Indicates the digital output selected, e.g. digital output N.

Name:

Here the user can enter a designation of his own (name) for the
digital output, e.g. LowFilter.
The input will be stored. The following symbol will be displayed.
The input entered in the window Configure digital output will be
indicated directly, e.g. TORQUE > 130%

13.2.14

Timer

With function timer (clocks) you may:


Initiate periodical trigger pulses after specified time intervals
e.g. periodical measurement data logging.
Determine measurement time intervals and starting time for
the measurement.
Double click on the icon timer and the following menu will be
displayed:

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Click here, the following menu window will be displayed. You


can enter the signal name in this menu window.

Signal expression:

Enter the user-defined signal name here, e.g. Timer01.

First pulse:

Here you may determine the time for the first starting pulse.
Input is in the format:
Day.Month.Year Hour:Minute:Second,
e.g. 16.12.1996 15:25:31

When you enter only a date, the measurement will be started at


00:00:00 h of that day.
When you do not enter anything, the timer will be started
immediately after the first configuring of DALOG.
Interval:

Here you determine the interval, i.e. the interval at which the
trigger pulse is to be initiated, e. g.

Click on the arrow to select the required time base.

13.2.15

Delay timer

With the function Delay timer you may initiate the following:
A trigger pulse for delayed start or for delayed terminating
a measuring data logging after an exactly defined period
Pretriggering, e.g. following a limit value violation
Double click on the icon Delay timer and the following menu
will be displayed at the screen:

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Click here, the following menu window will be displayed. You


can enter the signal name in this menu window.

Signal expression:

Enter the user-defined signal name here, e.g. DELAY01

Delay:

Here you determine the length of the delay until the trigger
pulse occurs.
Click on the arrow to select the required time base.

Restart:

The Delay timer is restarted:


Only after the delay has elapsed, despite new trigger pulses
having occurred in the meantime
At each pulse, thus also while the delay timer is running.
Measuring time will be extended automatically.

Important:

Entering a pretriggering time is only possible when the delay


timer has been linked to the start symbol (triangular symbol) of
a buffer in a configuration! Thus, the rise with a limit value
violation may also be logged.

Explanation:

Trigger:

is a trigger pulse, e.g. a limit value violation, a


time pulse, etc.

Pretrigger:

is a trigger pulse that records the signal curve


prior to the occurrence of the trigger pulse.

Posttrigger:

is a trigger pulse that records the signal curve


from the time the trigger pulse occurs.

Note:

When a Delay timer has been linked to the start symbol


correctly, the following window will be displayed. Here you can
enter the negative delay times for storing the pretriggering.

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Pretrigger:

70

A pretrigger is set by entering a negative delay time in the menu


window Delay timer. You may select:
Whether the running time of the delay will be started only
at the end and at the occurrence of a new trigger event.
Whether with each trigger event that occurs during logging
an extension by the set time delay will be effected
automatically.

13.2.16

Stop watch

You can log the following with the function stop watch:
Individual or sum periods, such as operating times of
machines, the duration of a limit value violation etc.
Double click on the icon stop watch and the following menu will
be displayed at the screen:

Resolution:

With a resolution of 1msec the maximum measuring duration is


49.7 days.

Result:

Here you can determine the value to be stored.

Current time counter

The currently measured time value after the start of the stop
watch will be stored.

Last maximum value

The last maximum value that occurred between two trigger


pulses will be stored.

Validity:
temporary

The time counter will be kept on memory during the operating


time of DALOG only.

permanent

The time counter will remain stored even after the supply
voltage has been switched off.

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Starting value:

71

Only active with the setting: permanent


Here you can determine the time values for the start, e.g.
operating time of the machine, to record the operating period
and to determine the maintenance intervals. Click on the arrow
to select the time base.
The icon Stop watch has three different ways to trigger function
mechanisms:

Start symbol

, as e.g. the
Linking a triggering element to the Start symbol
trigger pulse of a timer, limit above and/or below, will set the
stop watch going.

Stop symbol

Linking a triggering element to the Stop symbol


the stop watch.

, will stop

Note:
When the stop watch is started again, the measured times will
be summed up one after the other!
Reset symbol
Note:

Linking a triggering element to the Reset symbol


the stopwatch to zero.

, will reset

With another start the stop watch is started again and will begin
at "zero".

13.2.16.1 Uploading the data of the stop watch symbol


In order to upload the data into a data buffer or into an event, a
sample rate icon must be linked to the stop watch.

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13.2.17

72

Data vector
Here you can generate a data vector. With the data vector,
statistical characteristics such as average, variance, effective
value can be formed and/or may also be used for carrying out a
FFT.
Linking a triggering element, as e.g. trigger pulse of a timer,
limit above and/or below is via the Start symbol .
Double click on the opposite symbol and the window below will
be displayed.

Here you may enter the name of the data vector.

Sampling

As default, sampling is set to 1x, corresponding to the sample


rate set in the sample rate icon.
You can only click on the 10-fold sample rate when the vector is
triggered by an event, such as timer, limit value etc.

Size:

Here you can define the vector length in a time unit or number
of values. The maximum length of the vector is 8192 values.

Core memory usage:

Indicates the rate of usage of the DALOG core memory.

Note:

Exceeding the rate of usage with parallel data processing will


result in data losses. This may be avoided by skilful sequential
processing.

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13.2.18

73

Formula interpreter Calculation of measured variables


Icon for calculation of measured variables.
A configuration for the calculation of measured variables is
formed by connecting the icons by means of the mouse (also
see chapter 14.1.).
The online representation of the calculated variable is by
linking the online window to the icon formula interpreter.
The offline representation is by linking the offline window to the
icon data buffer.
Double click and the following menu window Calculation
formula will be displayed.

Result

Here you define the name and the type of result of the variable
calculated.

Name:

Here you can enter the user-defined name. e.g.:

Result type:

Here you define whether the result is to be analog or binary:

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binary logic

When this is selected, the following menu Signal will remain


inactive. The result range and die logical resolution will be
displayed automatically.

analog value

When this is selected, the following menu field Signal will


change as follows:

Signal

Here you can enter a user-defined name and a physical


conversion table can be stored by means of the button New.

Name:

When you click here, the user-defined signals will be


displayed, e.g.:

When you click on an already defined signal, the result range


and the logical resolution will be displayed automatically, e.g.:

Result range:

Here the user-defined result range of the signal is displayed.

logical resolution:

Here the user-defined logical resolution of the signal is


displayed. The permissible range is between 8 bit and 14 bit.
The following menu Defining signal will be displayed.
In this menu field you can define the following (also see
chapter III 13.2.1.1):
the signal,
the physical unit and
the internal conversion

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Formula:

75

Here you define the relationship in terms of formulas of the


variables that are to be calculated.
Click on the field formula to activate the button variable.
Click here to get a display of the variables you can select, e.g.:

The variable selected is integrated in the formula menu.

The arithmetic operator is next, e.g. * (enter the arithmetic


operators via the keyboard) and subsequently the next signal,
again by either clicking on the button variable or by entering a
fixed number or a newly defined signal.
Note:

The formula interpreter internally calculates all physical units


back to the base units (SI units).
The result must be convertible to the specified physical unit;
failing this, an error message will be given.
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13.2.18.1 Arithmetic

76

Arithmetical terms will be given in the usual formula notation:


Point has priority over dash
Brackets are permitted and will be calculated with priority.
In arithmetical terms analog signal values or other available
calculated results may be used as input variables.
The basic arithmetic operations: *, /, +, - are available as
elementary operators.
In addition, may be used for squaring and for the third
power.
Enter the squaring and the third power is by means of the key
combination Strg-Alt-2 and/or Strg-Alt-3.
The function procedure call sqrt ( ) for the square root is also
permitted.

Examples:

for permissible arithmetical terms:


U2 U1
U / (I1 I2)
sqrt (L1 + L2)

Attention:

The physical unit of the actual result of the calculation must be


of the same "kind" as the required target unit. Same "kind"
means that the variable calculated in the formula and the result
as determined in the formula definition (in the DALOG formula
editor ) must be of the same physical quality. (This is not
equivalent to "identical" physical unit!)
You may e.g. multiply a measured voltage signal U by a
measured current I . It does not matter for the formula entered
whether the voltage value U is defined in mV, V or kV or
whether you want to have the result of your calculation in mW,
W, kW or MW.
The formula will always be U * I. It is important that the physical
unit that you define for the result symbolises a performance
value. Any scaling and converting of the units, if required, will
be done entirely by DALOG.
Constants may be used in the formulae. Pay attention to the
fact that constants may have to be supplied with physical units,
to make the formula interpretable for DALOG.
Physical units are entered in the formula editor directly behind
the constant, if required:
10.0 V suitable for elementary physical units known in
the DALOG-System
10.0 [J / s / A] suitable for composite units that may still be
unknown, too
When you intend to compose the physical unit for a constant of
several elementary units, the term must be written in square
brackets!

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Note:

77

You can only correctly add or subtract parts of the formula you
entered to and/or from a constant when the constant represents
the same physical value!
All the following arithmetical terms represent e.g. an electrical
voltage:
U 40 mV
P / 1.1 A
1.1* (P + 10 W) / I 2.5 kV
Incorrect would be for example:
U0
10 mA + U

13.2.18.2 Boolean logic

The physical unit V is missing for the 0.


An mA value cannot be added to a voltage.

In DALOG calculation formulae, Boolean data (i.e.


TRUE/FALSE- and/or 0/1 values) may be calculated. All digital
inputs, comparison values or logical links known in the current
DALOG configuration are available as potential input variables
for the processing. Logical values can be linked by means of
the following logic operators:
&&
||
!
==
!=

logical And
logical Or
logical Not
logical equality
logical inequality

Syntax and semantics of the terms correspond to programming


language C, valid logical terms are thus e.g.:
! digi1
digi1 && digi2
(digi1 || ((! digi2) && (digi3 != digi4))
In addition, the following comparing operations with analog
computing or measurement data may be formed and/or used.
>
>=
<
<=

Examples:

greater
greater or equal
less
less or equal

U >= 5 V

results in a Boolean value TRUE (or 1), when


the voltage value reaches or exceeds the given
limit of 5 V

P1 < (U * I 10 mW)

results in a Boolean value TRUE, when


the performance value P1 drops below
the calculated limit.

(U >= 2 V) && (U <= 5 V) will be TRUE, when the voltage U


is in a range of 2 V to 5 V.

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13.2.18.3 Conditional terms

Note:

DALOG calculation formulae may contain "conditional" terms


(analog to programming language C).
Depending on the result of a Boolean term one of two possible
result terms is selected and calculated. The other term is not
processed.
(Boolean term) ? (TRUE result term) : (FALSE result term)
Example: (U >= 5 V) ? 5 V : U
When the voltage U is greater than or equal to 5 V , the TRUE
term will be evaluated and furnishes as (constant) result 5 V.
When the logical condition is not fulfilled (voltage U thus less or
equal to 5 V), the FALSE result term will be evaluated and
furnishes as input variable U.
If required, conditional terms may be interleaved or linked to
other variables:
(U > 5 V) ? 5V : (U < 2 V) ? 2 V : U
The FALSE result term of the first conditional term contains a
second conditional term (U < 2 V) ? 2 V : U
The indicated total term thus furnishes:
5 V if U is greater than 5 V
2 V if U is less than 2 V or the original value of U
the voltage is U in the range between 2 V and 5 V.
U * ((I > 100 mA) ? 100 mA : I)
The formula given calculates a performance, the current I being
"cut" at 100 mA.

13.2.18.4 Statistics

DALOG makes standard formulae available for forming


statistical characteristics in the time and frequency range. They
may be integrated in mathematical equations. Thus, new and
user-defined characteristics may be formed on the basis of the
given statistical standard formulae.
Designation ahead of the brackets:
Formula designation for the statistical quantity.
Designation within the brackets (in italics):
User-defined vector name and/or vector on the basis of which
the statistical quantity is formed.
These designations must be entered in the DALOG formula
editor, e.g. mean(Vek01). Mean indicates the averaging on the
basis of the vector Vek01.

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Designation

DALOG Standard formula

Minimum of the vector

min(vec)

Maximum of the vector

max(vec)

Number of elements in
the vector, the result is
without physical units

n(vec)

Sum of the original data

s(vec)

yi

Sum of the squares of


the original data

ssq(vec)

y2i

Arithmetical mean of the mean(vec)


original data

Mathematical derivation

(1/nr)y2i

Effective value of the


original data

eff(vec)

((1/nr)y2i)

Variance of the original


data

var(vec)

(1/nr)(yi-y)2

Standard deviation of
the original data

sdev(vec)

((1/nr)(yi-y)2)

The result of the linear regression of the measurement


Linear regression of
the measurement data data plotted against time:
plotted against time
y(t) = t * SLOPE + INTERCEPT
Slope of the regression slope(vec)
line, i.e. the physical unit
of the source data
divided by a time
measure, e.g. A/s
Offset of the regression
line

intercept(vec)

Corr(vec)
The Bravais Pearsoncorrelation coefficient is
a measure for the
quality of the correlation
of the data and the time,
i.e. corr(vec) = 0 means
uncorrelated and
corr(vec) = +1 or 1
means completely
correlated.

(ti-t)*(yi-y)/((ti-t)2)

y-((ti-t)*(yi-y)/((ti-t)2))*t
(ti-t)*(yi-y)/((ti-t)2*(yi-y)2)

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Designation

DALOG Standard formula

80

Mathematical derivation

Special characteristics
for the frequency
range
In a frequency
spectrum, a maximum
frequency amplitude
value is searched within
a user-defined upper
and lower limit and the
associated frequency
value is put out

peak(fft,minf,maxf)
e.g. peak(FFT01, 200Hz,
300Hz)
The maximum amplitude value
is searched between 200Hz
and 300Hz and is put out.
FFT01 = Name of the FFT

power(fft,minf,maxf)
Determines the sum of
the amplitude squares of e.g. power(FFT01, 200Hz,
a FFT in a user-defined 300Hz)
frequency band

The sum of the squares of all


amplitude values is formed in
the frequency range of 200Hz
and 300Hz.

General rules for


calculation
Square of a number of
an amplitude

sqr(val)

Square root of a number sqrt(val)


of an amplitude

13.2.19

val designates a general


variable or number
val designates a general
variable or number

Derivation
Double click on the icon Derivation and the following menu will
be displayed:
You can initiate a trigger pulse with rising and/or falling edge
with the function Derivation.

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Click here, another menu window will be displayed. Here you


can enter the signal name.

Signal expression:

Name of the signal selected, e.g. Torque Derivation.

Measuring range:

Indicates the measuring range selected for this signal and the
associated physical unit, e.g. 0 - 230 kNm/s.
When a sensor type has not been selected, the resolution: 0
8191 will be displayed here. This is a 13 bit value.
The user may create files for generating the derivation by
himself. By forming the difference between two values
(amplitude change) within a given period the derivation (rising
or falling edge) is determined. The rate of change of the
amplitudes is specified by the sample rate.

Log. resolution:

The logical resolution can be chosen between 8 bit and 14 bit.


Click here, another menu window will be displayed. Here you
can enter the signal name.

Name.:

Here you can call already defined physical conversion tables.


The selection will be stored. In the menu window derivation the
name will be indicated, e.g.
torque

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13.2.20

82

Fatigue Load Rainflow - Classification


Here a classification is executed. Double click on the symbol
and the following window will be opened.

Number of classes:

Shows the number of user defined classification classes, e.g. 1.


Click on the sqare, the duration time of a signal in each class
will be stored and summarized.
Load cycles in a class will not counted. This menu item is at the
moment not active.
Click on the square, residu will not be considered.

Affected direction of the


hysteresis

The user can decide in which direction the hysteresis should


effect:
Only in the negativ direction

Only in the positiv direction

Or in both direction, positiv direction and negative direction.

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Reset range

The user can define the reset range of the hysteresis, e.g.
20mV.

File:

File name of the fatigue load data


In this field you may also enter a user-defined name (max. 8
characters) of your own as well as a path where the
classification data are to be written.

Number of seperate
fatigue load matrices

If the classification data are triggered then the user can define,
how many max. number of seperate fatigue load matrices can
be stored on memory card, before the first one will be
overwritten, e.g. 10.

User fraction of the


memory card

Shows the used capacity of the memory card, e.g. 75,9%.

Maximum number of
blocks available

Shows the maximum number of seperate fatigue load matrices,


which can be stored on the memory card, e.g. 36135.

Erase single fatigue load If you build only one fatigue load matrix then you can click on
matrix only after upload the square. The single fatigue load matrix will only erase after
upload to PC.
to PC

Click on classes, the menu below will be displayed at the


screen.

Number of limits

Shows the number of limits which are defined.

Number of defined
classes

Shows the number of defined classes


Put a number in the field beside for to set user defined new
limit, e.g.
the button New Limit will be
active. Click on the button the input will be shown in the field
above.

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Marked numbers in the field below will be deleted by clicking on


the button Erase.

Deletes all defined limit values.


Are there two limit values marked in the field below then the
button Interpolation active.

Click on the button, the menu below will be displayed at the


screen.

Lower limit:

Shows the user defined lower limit, e.g. 2000mV

Upper limit:

Shows the user defined upper limit, e.g. 3000mV

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Number of classes to
insert:

85

Here you can put in the number of classification classes.


The maximum number is 126 classes.
Between the upper and lower limit new classes will be inserted.
The width of all generated classes will be equal.
Click here to store the inputs.

13.2.21

Fast Fourier Transformation


Here a Fast Fourier Transformation (FFT) is executed. Double
click on the symbol and the following window will be opened.

Enter the name here.

Windowing:

In this menu item you may determine the required windowing


for the FFT.

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Number of samples:

86

Indicates the length of the time signal by means of which the


FFT is formed. The maximum length is 8192 values. This
means that a FFT of up to max. 4096 spectral lines may be
formed.

Used fraction of system Indicates the rate of usage of the DALOG system memory.
memory:

Note:

13.2.22

Exceeding the rate of usage with parallel data processing will


result in data losses. This may be avoided by skilful sequential
processing.

Sum
Double click on the icon Sum and the following menu will be
displayed:
The Sum serves for counting the trigger pulses, as limit above
and/or limit below, time pulses etc.

Size:

Determine the resolution (counter range). With a resolution of


15 bit maximum counter value 32.768
with 31 bit maximum counter value 2.147.483.648.

Result:

Here the value to be stored is determined.

Current time value

After the start of the counter, the currently measured counter


value is stored.

last maximum value

The last maximum value that occurred between two trigger


pulses is stored.

Validity:
temporary:

The counter value will be kept on memory during the operating


time of DALOG only.

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permanent:

The counter value will remain stored even after the supply
voltage has been switched off.

Start value:

Determines the start value for the counter. Only active when
you have clicked on the menu item: permanent: before.
The icon Sum has two different ways to trigger function
mechanisms:

Start symbol

Linking a triggering element to the Start symbol


, as e.g. the
trigger pulse of a timer, limit above and/or below, will set the
counter going.

Reset symbol

Linking a triggering element to the reset symbol


counter to zero.

will reset the

In order to read the data into a data buffer on into an event etc.,
a sample rate icon must be linked to the sum symbol.

13.2.23

Minimum
Double click on the icon Minimum and the following menu will
be displayed:
You can determine the minimum of a signal within a defined
period by the function minimum.

Absolute value
preservation

Here you can determine for how long the minimum value is to
be preserved before a new minimum will be formed.
Click on the arrow to select the required time base.

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13.2.24

88

One-sided recursive
filtering

The minimum value will be formed continuously. You can select


the filter size in increments of powers of two in a range of 2 4096.

Note:

With the recursive data filter the filter value is calculated


recursively of the previous, filtered signal values and the nonfiltered signal value.

Maximum
Double click on the icon Maximum and the following menu will
be displayed:
You can determine the maximum of a signal within a defined
period by the function maximum..

Type:
Absolute value
preservation

Here you can determine for how long the maximum value is to
be preserved before a new maximum will be formed.
Click on the arrow to select the required time base.

One-sided recursive
filtering

The maximum value will be formed continuously. You can


select the filter size in increments of powers of two in a range of
2 - 4096.

Note:

With the recursive data filter the filter value is calculated


recursively of the previous, filtered signal values and the nonfiltered signal value.

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13.2.25

89

Event
Double click on the icon Event and the following menu will be
displayed:
You can represent the following in tabular form by the event
function:
time (date and hour)
the name of the event
the absolute value of the triggering event as a function of
other variables measured at the same instant.
In an instant you will get a survey of the state of your plant at
the time a trigger event has occurred.

Name:

Here you can enter a name characteristic of this event.

Type:

Here you can determine whether the occurrence of the event


represents a general event, a warning or a failure. In the
tabular representation of the events a symbol corresponding to
the failure concerned will be displayed after the triggering event:
blue i :
yellow ! :
red flash

Protocol

general event
warning
failure occurred

Click here and the following menu window will be displayed:

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Possible data:

90

Here you can select which data are also to be recorded at the
time of the occurrence of the event.
To do so, click on the names that can be selected, as e.g.
speed, etc.
Then click on the field
. The data will also be recorded,
when you exit the menu window by OK.

Note:
Record the following
data:

Up to max. 16 signals and/or values may be recorded


simultaneously.
Indicates the data that are recorded, too
When you want to cancel the simultaneous recording of some
data, click on the names to be selected in this field.
Then click on the field
. The data will not be recorded
when you exit the menu window by OK.

13.2.26

Offline data evaluation


Here you configure which signals are to be displayed offline at
the screen.

13.2.27

Online data evaluation


Here you configure which signals are to be displayed offline at
the screen.
This function block will be displayed after the option Connect
data box in the bottom icon bar has been selected.
Note:

The signal name is also used as identification of the Y axis in


the online and offline representation. The program generates a
short form of the name for this purpose. For generating the
short form, the capitals are always used first, max. three, or
should there be only one capital, the first three letters of the
signal name.

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14

91

Setting up a configuration and explanation of the connecting lines


A configuration is set up by selecting the individual icon blocks
from the bottom icon block bar and by connecting the icons that
are displayed separately at the screen at first. Thus a
configuration is the result of a skilful and efficient interaction of
the icons.

14.1

Setting up a configuration
In the following, you will see a representation of some icons
such as new data channel, sample rate and data puffer, that
appears to be random at the first glance.

The interaction and set-up of a configuration is by connecting


the icons by means of the mouse.
Proceed as follows:

Go to the icon concerned with the mouse pointer (arrow).


Press the right mouse button and keep it pressed.
Keep the mouse button pressed and go to the required icon
with which the connection is to be set up (now a "banana
plug" symbol will be displayed at the screen as mouse
pointer).
When you have reached the corresponding icon and when
the connection is permissible, an arrow will be displayed at
the screen below the "banana plug" symbol. It points in the
direction of the object to be connected.
Release the right mouse button and the two icon blocks will
be connected.

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When you repeat this process, the simplest form of a


measurement task will be generated at the screen. It is
composed of sensor input, sample rate element and buffer.

Interrupting the connection between two icons that are not


required is done in the same way as described above. When
the two icon blocks are interrupted, an arrow will be displayed
below the "banana plug" symbol that points in the opposite
direction.
The following figure shows the configuration of a far more
demanding measurement task.

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This configuration comprises:


two sensor signal inputs, input U and input V.
Several sample rate elements of different sample rates may
be linked to a sensor signal input at one and the same time.
There are e.g. two sample rate elements linked to input V. In
this way, continuous recording at a low sample rate and fast
sampling in the case of a limit value violation may be carried
out.
The number of limit value violations will additionally be
counted at input U
and the duration of the limit value violations at the input V.
Simultaneously with a limit value violation, the event
elements will record the signal of the second channel, too.
The pre- and post trigger data will be logged at input U by
the delay timers.
In the following two graphs, the online and offline signals have
also been entered.

These figures show the various connecting lines and crossings


in a configuration.

14.2

Meaning of the connecting lines


The various connecting lines and crossings serve for a
straightforward representation and a better understanding of the
configurations.

14.2.1

Thin and thick black connecting lines


these lines represent connections between individual icon
blocks, that are used for the set-up of logical links and for
setting the trigger conditions.
these lines represent a continuous data flow, e.g. between a
data source and a data buffer.
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94

Black and white connecting lines


these lines represent a discontinuous data flow, i.e. only
individual data are stored.

14.2.3

Non-interrupted crossing lines


The connection has been set up starting at an icon. The icons
connected to one another are shown in a distributed
representation at the screen.

14.2.4

Interrupted crossing lines


Here different icons cross each other and lead to different
objects.

14.2.5

Crossing lines with branches


When the crossing lines have branches from below, this data
flow is coming from a data source arranged below the
connected object.
When the crossing lines have branches from above, this data
flow is coming from a data source arranged above the
connected object.
Crossing chain with data sources arranged above and below
the point of view.

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15

Data analysis

15.1

Graphical representation of the offline signals


Color mode

95

Open the offline window for the graphical representation of the


signal curve with a double click on the offline icon.

Monochrome mode

Display of the signal


curves

The signal curves may either be displayed individually or max.


up to 8 signals at a time in a data analysis window.
In the example, two signal curves are displayed simultaneously.

Dotted red line

Date, time in the header line as well as the indication of the


physical data below the X-axis are always referred to the zero
mark that is marked by the dotted red line, e.g. Date 27.10.98
Time 23:03:21 Data 22.761kNm 935.2 rpm.

Y-axis

Indicates the amplitude values in the physical unit.


The number of the Y axes corresponds to the number of the
selected signal curves.

X-axis

Indicates the time base.


In the example, the distance between two vertical dividing lines
corresponds to exactly 10 seconds.
In the line below, the amplitude values that are constantly
changing with shifting, are indicated in the physical units. The
user can precisely read off the data.

Header line

Will always indicate date and time, referred to zero mark,


marked by a red dotted line.
The date is indicated when the data acquisition time is not
identical with the current date.
When you want to view the signal curves quickly, click on the
window with the mouse, keep the button pressed (a symbol of
a hand will be displayed now) and go to the right or to the left
with the mouse. The signal curves will be shifted to the right or
to the left simultaneously.

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Will shift the signal curves to the left or to the right point by
point.

or

SHIFT

96

or

Will page up or down the signal curves page by page.

SHIFT
Will shift the signal curve from trigger point to trigger point.

or

SHIFT
SHIFT

At the zero mark of the X-axis, trigger begin or end and/or pretrigger begin or end of the signal curve will be indicated. The
pre- and/or posttrigger point will be marked by a short vertical
line in the signal curve.
or

Goes to the beginning or the end of the signal curve.


At the zero mark of the X-axis, begin or end of the signal curve
will be indicated.
is used for the communication between
The chain symbol
several open analysis and/or event windows. When you click
on the chain icon in the opened windows, the same time (date,
time) will automatically be indicated in all chained windows
when the signal curves are shifted. This means that when you
click e.g. on a selected event, the corresponding signal curve
will be indicated in another opened and chained window simultaneously.
Line Graph Mode, the signals are represented as signal curve.
When you click here, the following configuration menu Offline
analysis will be displayed at the screen.

Name:

In this field, you can enter a user-defined name, e.g. Analog


signals. This name will also be indicated beside the offline
symbol for the identification of the window concerned, e.g.

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Buffer:

97

You can switch between the individual buffers by actuating the


button
or
.
Switching to another signal will be indicated in the menu at the
right side in the topmost line by Buffer. The buffer concerned
will be altered, e.g. Buffer 1.
Here you can select one of 12 different time bases by clicking.
Activation of a time basis by clicking on a radio button is indicated by a block dot in the button. When the time basis is
changed, the signal curves will either be compressed or extended .
The distance between the grey longitudinal lines in the data
analysis window will always be changed automatically according to the time basis set.
The time basis is based on 50 days (50 dy) to 500 microseconds (500 s).

The signal can be extended or compressed continuously in a


range of the 5-fold up to the 0.2-fold with a constant time basis.

Color selection

You can select a color for the individual signal curves by clicking here. In addition, individual signals may be masked by the
menu item invisible.

The signals and the associated Y axis can be shifted continuously at the screen.

The signals can be intensified continuously in a range of the


0.001-fold up to the 1000-fold. The Y axis will be matched
automatically.

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Note:

98

You may observe the consequences of the changes done in


the configuration menu directly in the data analysis window.
Therefore we recommend that you shift the data analysis window and the configuration window on the screen in such a way
that both are represented as completely as possible.
Click on the topmost line of the window. Keep the left mouse
button pressed and shift the window in this way until both windows can be seen as completely as possible.
When you open a second analysis window we recommend to
shift the first one since this will otherwise be covered by the
second window and will no longer be visible. The data analysis
windows will always be displayed at the same spot.

Print

The signal curve can be printed via the icon Print.


Click here and the following menu will be displayed:

Here you can set the printer via the set-up and the signal curve
can be printed (see chapter III 3.3).

Bar Graph

Click here, the signal curve will be indicated as a bar graph.

is used for the communication between


The chain symbol
several open analysis and/or event windows. When you click
on the chain icon in the opened windows, the same time (date,
time) will automatically be indicated in all chained windows
when the signal curves are shifted.

Bar Graph
Line Graph

Bar Graph Mode, signals will be indicated as bar graphs.


Click here, the bar graphs will be represented as signal curve.

Click here, the signals will be indicated as frequency curve.

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Indication of the frequency curve

The time signal is transformed in the frequency range (signal


analysis method). Only one signal can be represented in a
window.

Header line

Data and time of the measurement as well as a user-defined


identification, provided this has been entered, will be indicated
in the header line; e.g. Accelerator No.5, 27.10.98 22:46:22,10.

Y-axis

Indicates the amplitude values in the physical unit, e.g. g.

X-axis

Indicates the frequency values.


Will shift the signal curve from trigger point to trigger point.

or

SHIFT

At the zero mark of the x-axis, trigger begin or end and/or pretrigger begin or end of the signal curve will be indicated. The
pre- and/or posttrigger point will be marked by a short vertical
line in the signal curve.
or

SHIFT

Goes to the beginning or the end of the signal curve.


At the zero mark of the x-axis, trigger begin or end and/or pretrigger begin or end of the signal curve will be indicated.
is used for the communication between
The chain symbol
several open analysis and/or event windows. When you click
on the chain icon in the opened windows, the same time (date,
time) will automatically be indicated in all chained windows
when the signal curves are shifted.

Bar Graph

Bar Graph Mode, the frequency curve will be indicated as bar


graph

Line Graph

Click here, the frequency curve will be represented as signal


curve.
Line Graph Mode, the signals are indicated as signal curve.
FFT mode, the signals will be indicated as frequency spectrum.

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When you click here, the following configuration menu Frequency analysis will be displayed at the screen.

Topmost line

Name of the configuration window Frequency Analysis


Here you can enter the name, the required windowing, and the
number of data for the effective value determination of the
individual frequency data.

Data
Name:

Here you can enter a user-defined name, e.g. Acceleration No.


5. This name will subsequently be indicated for the identification of the window concerned beside the offline icon, too, e.g.

Windowing:

Here you can select a windowing for the FFT.

Here you can determine the number of values, that are to be


used for the effective value determination of the individual amplitude peaks concerned. The maximum number of values that
can be accumulated is 20.
Here you can determine the number of spectral lines and the
frequency range offset.

Samples shown in
window

Here you can set how may spectral lines are to be indicated in
the online window.
The number of spectral lines is a function of the resolution
selected and may be max. 4096.
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Offset:

101

Here you can set the frequency range that is to be indicated in


the analysis window.
The lower the number of the indicated spectral lines that has
been selected in the menu Samples shown in window, the
wider the setting range in the Offset menu.
Here you can set the representation of the frequency spectrum.

Here you can select whether the frequency spectrum is to be


indicated without frame, with contour or as single beams.

Here you can set the color of the bars.


Here you can select the frame colour of the bars. For further
steps see the selection Color of the bars.
Click on the Change button, and the menu below will be displayed where you can select the required color:

Actuate the OK button, the selection will be stored and you will
exit the menu.

Scale:

Here you can select the scaling of the Y axis of the frequency
representation - absolute, logarithmic.

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Acceleration data:

102

Here you can select the representation of the frequency values


power spectrum of the acceleration a in [g],
amplitude spectrum of the acceleration a in [g],
amplitude spectrum of the acceleration a in [dB],
amplitude spectrum of the vibration velocity v in [mm/s],
amplitude spectrum of the vibration velocity v in [dB],
amplitude spectrum of the vibration displacement s in [mm],
effective value of the spectrum of the acceleration aeff in [g],
effective value of the spectrum of the acceleration aeff in [dB],
effective value of the vibration velocity veff in [mm/s],
effective value of the vibration velocity veff in [dB],
effective value of the vibration displacement seff in [mm]
Here you can intensify the representation of the amplitude
values of the Y axis in a range of the 0.001-fold up to the 1000fold of the measuring range.
You can observe the effects of the change in the representation of the Y axis directly at the screen. To be able to do this,
shift the setting window Frequency analysis and the analysis
window of the spectral representation until both windows are
visible.
The menu Factor will only be active, when you have selected
the menu item absolute in the Scale menu.
Here you can adjust the representation of the amplitude values
of the Y axis continuously within the logarithmic basis.
You can observe the effects of the change in the representation of the Y axis directly at the screen. To be able to do this,
shift the setting window Frequency analysis and the analysis
window of the spectral representation until both windows are
visible.
The menu Factor will only be active, when you have selected
the menu item logarithmic in the Scale menu.

15.2

Representation of the offline event data in


tabular form
Color mode

A double click on the offline icon will open the offline window for
the representation of the signal curve in tabular form.

Monochrome mode

The following menu items are indicated in the representation in


tabular form:
Date

Date and time at which the event occurred.


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Event

Kind of weighting and name of the event

Data in the table

Absolute data of the sensors in their physical units at the date


the event occurred, statistical characteristics, etc. In the tables
the name that has been given to the sample rate icons will always be indicated, such as variance, power, etc.

Note:

The columns indicated after these two menu items are a function of the kind of configuration concerned, e.g.:
Period of time during which the event occurs without interruption
Should there be a question mark in this column, there has been
an interruption in data recording while this event has occurred,
e.g. by a data upload or an interruption in the power supply.
In the following columns the signal expression concerned and
the absolute value of the event as well as the individual data
available at that time are given.
Which data are indicated here depends on the configuration.
Should there be more columns and data than can be indicated
at the screen, these may be made visible by the vertical and
horizontal scrollbars.

Period

is used for the communication between


The chain symbol
several open analysis and/or event windows. When you click
on the chain icon in the opened windows, the same time (date,
time) will automatically be indicated in all chained windows
when the signal curves are shifted.
When you click on an event, this field will be highlighted in
color. You will go immediately to the corresponding place in the
chained windows.

Export event data

Click here or actuate the Print button, and the following menu
will be displayed at the screen.

If you want to have only the data columns visible at the screen
butindicated in the ASCII format, click on the
ton, if all data columns are to be exported to ASCII, click on
. After you have clicked on one of the buttons,
the events will be displayed at the screen in the editor below.
Now you can edit or print the data.

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Set-up

104

When you click here, the following Events configuration menu


will be displayed at the screen.

Here you can enter a user-defined name, e.g. Speed. This


name will subsequently be indicated for the identification of the
window concerned beside the offline icon, too, e.g.

Note:

Offline and online windows can be represented simultaneously


at the screen, e.g.

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15.3

105

Representation of the online event data in tabular form


Color mode

A double click on the online icon will open the online window for
the representation of the signal curve in tabular form.

Monochrome mode

Events

The event data are displayed continuously at the screen. The


most current event will always be at the top (Top-DownStrategy). The individual event data are represented in
weighted form.
blue i
yellow !
red flash

Tool button

general event
warning
failure

Click here and the following configuration window will be displayed.

Here you can enter a name for the event window. This name
will be indicated in the configuration menu beside the event
icon, too. The other functions are not active in this mode.

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Event window

Tool button

topmost line

106

Click here and the events will be displayed

Click here and the following configuration window will be displayed.

Here the user-defined name will be indicated, provided you


have entered a name. Otherwise, Events will be printed in this
line.
Here you can enter a user-defined name. It will be displayed in
the title bar of the window and in the configuration beside the
online event icon.
Standard

blue general event,


yellow warning
red failure occurred

Color selection:

You can select a user-defined color


for the event concerned.

The events are represented with a frame.

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15.4

Rainflow - Classification - Analysis

15.4.1

2d - Presentation of the Classification Data

107

Open the offline window for the graphical representation of the


classification with a double click on the offline icon.

The classification will be shown 2 dimensional.


Will shift the classification block from block to block.

or

SHIFT

or

Goes to the first or to the last classification block.

SHIFT
is used for the communication between
The chain symbol
several open analysis and/or event windows. When you click on
the chain icon in the opened windows, the same time (date,
time) will automatically be indicated in all chained windows
when the signal curves are shifted. This means that when you
click e.g. on a selected event, the corresponding signal curve
will be indicated in another opened and chained window simultaneously.

Export data

Click here the classification data will be converted to ASCII and


shown at the screen.
The classification blocks will be shown in chronological order.
The classification will be shown 2 dimensional.

Print

The classification block can be printed via the icon Print.


Click here and the following menu will be displayed:

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108

When you click here, the following configuration menu Offline


analysis will be displayed at the screen.

Name:

In this field, you can enter a user-defined name, e.g. Fatigue


Load Torque. This name will also be indicated beside the offline
symbol for the identification of the window concerned.

Raw data:

Shows the stored classification blocks.


The single classification blocks can be user defined cumulated.
For the cumulation of the classification blocks you have to set
date and time of the start block, e.g. 10.09.98 08:00 and the
end block, e.g. 19.09.98 15:30.

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109

Here you can select one of 6 different classification analysis


methods class limit exceedings, range pairs, minimum, peak
values, range pair averages and time duration.
Activation of a classification analysis by clicking on the menu.

Here you can select the scaling of the Y-axis of the classification percent, absolute or logarithmic.

Scaling:

If you have chosen a logarithmical presentation then the Y-axis


can be intensified continuously.

Layout:

Here you can select whether the frequency spectrum is to be


indicated without frame, with contour or as single beams.

Here you can set the color of the bars.


Here you can select the frame colour of the bars. For further
steps see the selection Color of the bars.
Click on the Change button, and the menu below will be displayed where you can select the required color:

Actuate the OK button, the selection will be stored and you will
exit the menu.

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15.4.2

Working with the DALOG Software

110

2d/t - Presentation of the Classification Data


Click on the button the classification blocks will be shown in
chronological order.

The data will be shown in a chronological order. The X-axis is


the time axis and the Y-axis shows the classes. The color
shows qualitativly how often the signal was in each class. The
dark color signs, that the signal was very often in this class and
the light color shows that the signal was not so often in this
class.
When you click here, the following configuration menu Offline
analysis will be displayed at the screen.

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111

Here you can select one of 7 different time bases by clicking.


Activation of a time basis by clicking on a radio button is indicated by a block dot in the button. When the time basis is
changed, the signal curves will either be compressed or extended .

The signal can be extended or compressed continuously in a


range of the 5-fold up to the 0.2-fold with a constant time basis.

Name:

In this field, you can enter a user-defined name, e.g. Fatigue


Load Torque. This name will also be indicated beside the offline
symbol for the identification of the window concerned.

Y-axis

Here you can select one of 6 different classification analysis


methods class limit exceedings, range pairs, minimum, peak
values, range pair averages and time duration.
Activation of a classification analysis by clicking on the menu.

Show:

Click on Markings, you can choose, if the distribution maxima


will be marked in the fatigue load matrix or the averages are
marked in the fatigue load.

Marking

Here you can choose the Layout for the Marking.

Colors

In this menu item you can choose the color distribution in dependence of the classification frequency. Shifting the arrows the
color distribution at screen will be more light or more dark.

Actuate the OK button, the selection will be stored and you will
exit the menu.

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15.4.3

112

5/2d - Presentation of the Classification Data


Click on the button the classification blocks will be shown 5/2
dimensional

When you click here, the following configuration menu Offline


analysis will be displayed at the screen.

Raw data:

Shows the stored classification blocks.


The single classification blocks can be user defined cumulated.
For the cumulation of the classification blocks you have to set
date and time of the start block, e.g. 10.09.98 08:00 and the
end block, e.g. 19.09.98 15:30.

Name:

In this field, you can enter a user-defined name, e.g. Fatigue


Load Torque. This name will also be indicated beside the offline
symbol for the identification of the window concerned.

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X-axis

113

Here you can select one of 5 different classification analysis


methods starting class (class limit exceedings), range pairs,
minimum, peak values and range pair averages.
Activation of a classification analysis by clicking on the menu.

Y-axis

Here you can select one of 5 different classification analysis


methods starting class (class limit exceedings), range pairs,
minimum, peak values and range pair averages.
Activation of a classification analysis by clicking on the menu.

Layout

Here you can select different presentation layouts for the 5/2
dimensional classification analysis without marking, with dots,
with crosses, with wireframe.

Color

Here you can select different colors for the presentation of the
markings black, grey, light grey, white.

Colors

In this menu item you can choose the color distribution in dependence of the classification frequency. Shifting the arrows the
color distribution at screen will be more light or more dark.

Actuate the OK button, the selection will be stored and you will
exit the menu.

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16

114

Data-Upload
Double click and the following menu will be displayed:

Buffer

Upload

Here you can transfer individual data for the data buffer selected or all the measurement data for all data buffers to the
PC. During the transfer of the measurement data from the
DALOG System to the PC, the measurement in the DALOG
System is stopped.

Erase:

In the menu item Erase you can delete only data that are stored
on the PC.
No data will be deleted. This menu item is set as default and
need not be activated.
Measurement data stored at a former date will be erased automatically during the data upload.
Only data from a specified date will be deleted. Time and date
must be entered in the format: 10:15 12.03.95
Here you can transfer selected measurement data stored on the
memory card of the DALOG System to the PC.

Load:

No measurement data will be transferred.


All measurement data of the selected data buffer will be transferred to the PC.
:

Single data blocks of the selected data buffer can be transferred from the memory card to the PC. To do this, click on the
individual data blocks that are to be transferred. The data
blocks on which you have clicked will be highlighted in color.
The selection will be stored. The following display mask will be
indicated at the screen.
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Upload

115

The following will be indicated:


The total number of the data blocks to be transferred, e.g. upload 1 block with 48032 Bytes:.
The number of old files that are deleted, e.g. 0 blocks deleted
from hard disk.
The number of blocks that have been loaded already, and in the
bar diagram the percentage of the blocks loaded, e.g. 42%.
When you click here, all data buffers will be uploaded, i.e. all
data will be stored on the PC.
Thus the user may:
upload all data buffers completely, i.e. all data will be stored
on the PC
delete all old data in one process.
This is a very easy and fast way to upload all data from the
individual data buffers and to delete all old data of the individual
data buffers stored on the hard disk, especially with very complex configurations with a large number of data buffers.
When you click on the Batch button, the following window will
be displayed at the screen.

The upload process as described above, is started for all data


buffers. The individual data buffers are uploaded one after the
other.
Attention:

When the data blocks are indicated and are transferred from the
DALOG System to PC, all measurements will be stopped until
cancelled or until the uploading is completed.
The data on the memory card will not be deleted by an upload
process, i.e. data transfer from the DALOG System to the PC.

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17

Online representation

17.1

Graphical representation of the online signals


Color mode

116

A double click on the online icon will open the online window for
the graphical representation of the signal curve

Monochrome mode

Header line

Indicates the user-defined name, e.g. Acceleration or the number of the signal curves indicated simultaneously in the online
window when a name for this window has not been entered.
The numerical value given in square brackets corresponds to
the time between two longitudinal lines, e.g. 100ms.

Y axis

Indicates the amplitude values in the physical unit with an abbreviation to allow a definite attribution of the measuring input
concerned

Note:

The window can be enlarged, reduced or shifted at random by


dragging it with the mouse.
When you are going to open a second online window, we recommend that you shift the first window since this would be covered by the second window and would no longer be visible. The
online windows will always be displayed at the same spot.

Tool button

Click on the "tool" button and the configuration window below


will be displayed at the screen.
In this window you may alter the representation of the measuring signals with reference to time base, scaling, the position and
the color representation.

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117

Topmost line

Number of the measuring inputs represented simultaneously in


the online window concerned, e.g. 3 channel scope

Name:

Here you can enter a user-defined name. It will be indicated in


the title bar of the online window as well as in the configuration
opposite the online window symbol.

Channel selection:

You can switch between the individual channels by actuating


or
with the mouse.
the button
Switching over to another channel is indicated in the menu at
the right side in the topmost line, here channel 1 - FAST. The
channel number concerned, e.g. 1 and the name of the channel
will be changed.
You can make a selection of 6 different time bases by clicking
with the mouse.
The window width corresponds to the time base selected. With
time base 500ms and factor 1 the visible online screen width
will correspond to 500ms. In this case, the distance between
two grey longitudinal lines will be 100ms.
Activation of a time base by clicking on a radio button is indicated by a black dot in the button selected. The online signals
will either be compressed or extended when the time basis is
changed.
You can vary continuously within a set time basis between the
5-fold and the 0.2-fold of the signal by means of the scroll bar in
the menu item Factor. Extending or compressing is possible
with a constant time base.

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Trigger

118

After clicking on the rectangular field, the user can enter a trigger threshold. The measuring signal will thus no longer be displayed continuously, but at rest, similar to an oscilloscope operation.
In the configuration window the indication triggering by e.g.
channel 1 will be given.

Color:

The individual measuring signal curves can be represented in


different colors. You can select between black, red, green,
blue, grey, brown, violet, cyan, light red, light green, light
blue, pink, turquoise and light grey. The selection is made by
clicking with the mouse. In addition, individual channels may be
masked by the menu item invisible.

The measuring signals and the associated Y axis can be shifted


continuously at the screen.

The measuring signals can be intensified continuously in a


range of the 0.001-fold up to the 1000-fold. The Y axis will be
matched automatically.

Note:

You may observe the consequences of the changes done in the


configuration menu directly in the online window. Therefore we
recommend that you shift the online window and the configuration window at the screen in such a way that both are represented as completely as possible.
Click on the topmost line of the window. Keep the left mouse
button pressed and shift the window in this way until both windows can be seen as completely as possible.
When you open a second online window we recommend to shift
the first one since this will otherwise be covered by the second
window and will no longer be visible. The online windows will
always be displayed at the same spot.

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17.2

119

Online representation of the bar graphic


Bar button

When you click here, switching over will be from continuous


signal curve to bar representation.
The following online bar representation will be displayed at the
screen.

When you click on the sinus button, the bar representation will
be switched back to continuous signal curve.

Tool button

When you click here, the following configuration window will be


displayed at the screen.
Here you can alter the representation of the online bars as well
as the color of the bars.

Topmost line

Number of the measuring channels represented at the same


time in the online window concerned, e.g. 3 channel scope

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120

Name:

Here you can enter a user-defined name. It will be indicated in


the title bar of the online window as well as in the configuration
opposite the online window symbol.

Channel select:

When you actuate the button


or
with the mouse, you
can switch between the individual channels, e.g. channel 1 FAST

Color:

The individual measuring signal curves can be represented in


different colors. You can selected between black, red, green,
blue, grey, brown, violet, cyan, light red, light green, light
blue, pink, turquoise and light grey. The selection is made by
clicking with the mouse. In addition, individual channels may be
masked by the menu item invisible.

The configured bar is represented with a frame.


In the online bar, that name will be indicated that has been
entered in the sample rate element.
Only the measured data and the associated physical unit will
be indicated at the screen.
Indication at the screen will be without colored background.
The following selection can be made:
Continuous:
continuous bar representation
Rastered:
discontinuous bar representation
With min/max.
the measuring range of the signal values
will be indicated below the bar
Limit value may be entered.
Limit: Enter the limit value
Color:
You may select a separate color for
the warn schedule.
The bars will be represented with a frame.

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121

Online representation of the frequency curves


A double click on the online icon will open the online window for
the graphical representation of the frequency curve. The online
symbol for the representation of the frequency curve must be
linked to vectors, e.g.

Header line

Indicates the user defined name, e.g. bearings, or frequency


analysis when a name has not been entered for this window, as
well as date and time.

Y axis

Indicates the amplitude values in the physical unit

Note:

The window can be enlarged, reduced or shifted at random by


dragging it with the mouse.
When you are going to open a second online window, we recommend that you shift the first window since this would be covered by the second one and would no longer be visible. The
online windows will always be displayed at the same spot.

Export data
Print

Function key without function for the time being.


The signal curve can be printed by means of the function key
Print.
When you click here, the following menu will be displayed:

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Start symbol

Stop symbol

Tool button

Topmost line

122

Click on the start symbol and a continuous online frequency


analysis will be indicated at the screen. When the vector is triggered as a result of time or an event, a new frequency analysis
will only be indicated at the screen when triggering has been
effected.
Click on the stop symbol and the continuous online frequency
analyses will be stopped. When you click on the start symbol
again, the continuous representation of online frequency analyses will be continued.
When you click here, the following configuration window frequency analysis will be displayed at the screen.

Name of the configuration window frequency analysis


Here you can determine the name, the required windowing and
the number of data for the effective value determination of the
individual frequency values.

Name:

Here you can enter a user-defined name. e.g. bearings. This


name will subsequently be displayed for the identification of the
window concerned beside the online symbol, too, e.g.

Windowing:

Here you can select a windowing for the FFT.

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123

Here you can determine the number of values that are to be


used for the effective value determination of the individual amplitude peaks concerned. The maximum number of values that
can be accumulated is 20.
Here you can determine the number of spectral lines and the
frequency range offset.

Samples shown in
window:

Here you can set how may spectral lines are to be indicated in
the online window.
The number of spectral lines is a function of the resolution
selected and may be max. 4096.

Offset:

Here you can set the frequency range that is to be indicated in


the online window.
The lower the number of the indicated spectral lines that has
been selected in the menu Samples shown in window, the
wider the setting range in the Offset menu.
Here you can set the representation of the frequency spectrum.

Number of data blocks:


:

Here you can determine the number of the online frequency


curves displayed one after the other in a window. The maximum number is 9 online frequency curves.
Here you can select whether the frequency spectrum is to be
indicated without frame, with contour or as single beams.

Here you can set the color of the bars.


Here you can select the frame colour of the bars. For further
steps see the selection Color of the bars.
Click on the Change button, and the menu below will be displayed where you can select the required color:

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124

Actuate the OK button, the selection will be stored and you will
exit the menu.

Scale:

Here you can select the scaling of the Y axis of the frequency
representation - absolute, logarithmic.

Acceleration data:

Here you can select the representation of the frequency values


power spectrum of the acceleration a in [g],
amplitude spectrum of the acceleration a in [g],
amplitude spectrum of the acceleration a in [dB],
amplitude spectrum of the vibration velocity v in [mm/s],
amplitude spectrum of the vibration velocity v in [dB],
amplitude spectrum of the vibration displacement s in [mm],
effective value of the spectrum of the acceleration aeff in [g],
effective value of the spectrum of the acceleration aeff in [dB],
effective value of the vibration velocity veff in [mm/s],
effective value of the vibration velocity veff in [dB],
effective value of the vibration displacement seff in [mm] .
Here you can intensify the representation of the amplitude
values of the Y axis in a range of the 0.001-fold up to the 1000fold of the measuring range.
You can observe the effects of the changes in the representation of the Y axis directly at the screen. To be able to do this,
shift the setting window Frequency analysis and the analysis
window of the spectral representation until both windows are
visible.
The menu Factor will only be active, when you have selected
the menu item absolute in the Scale menu.
Here you can adjust the representation of the amplitude values
of the Y axis continuously within the logarithmic basis.
You can observe the effects of the changes in the representation of the Y directly at the screen. To be able to do this, shift
the setting window Frequency analysis and the analysis window of the spectral representation until both windows are visible.
The menu Factor will only be active, when you have selected
the menu item logarithmic in the Scale menu.
Here you can set the representation of the frequency curves
indicated one after the other in an online window.

Shifting the online frequency curves in direction X


Shifting the online frequency curves in direction Y

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18

Printing the event tables

18.1

Exporting data
Export event data

125

Click here or actuate the Print button, the following menu will
be displayed at the screen.

If you want to have only the data columns visible at the screen
indicated in the ASCII format, click on the
button, if all data columns are to be exported to ASCII, click on
. After you have clicked on one of the buttons,
the events will be displayed at the screen in the editor below.
Now you can edit or print the data.

18.2

Print Editor
Menu item File

When you click here, the following pull-down menu will be


displayed.

Menu item Print

When you click here, the contents of the event window shown
at the screen will be printed. When the printer has not been
connected or is not ready, a corresponding error message will
be displayed at the screen.

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19

126

Printing the signal and frequency curves as well as the classifications


Print

The signal curve can be printed via the icon Print.


Click here and the following menu will be displayed at the
screen:

In the Set-up menu you can enter the printer-related settings for
an optimum printing result of the signal and frequency curves as
well as the classifications. For further information please see
your printer manual.
The window will be printed automatically, when a ready-tooperate printer has been connected. Otherwise a corresponding
error message will be given.

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IV

Converting the binary files to ASCII or DIA PC format

127

Converting the binary files to ASCII or DIA PC format

Converting the binary files to ASCII format


First click with the right mouse button on the buffer whose
data are to be converted. The following menu will be displayed
at the screen.

Configure

Click on the menu item Configure and the following menu will
be displayed at the screen.

Delete

When you click on the menu item Delete, the buffer will be deleted.

Memory Card

When you click on the menu item Memory Card, the buffer size
set by the user will be indicated at the screen.

Upload

When you click on the menu item Upload, the upload window
will be displayed at the screen. Proceed as described in chapter
III 15 to upload the data. This menu item will only be active,
when there is a direct connection to the DALOG System and/or
to the memory card.

Show data offline

When you click on the menu item Show data offline, an analysis window will automatically be linked to the buffer selected
and the analysis window with the data will be opened.

Convert data to ASCII.

When you click on the menu item Convert data to ASCII, the
following window will be displayed at the screen.

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Converting the binary files to ASCII or DIA PC format

File short name

128

Here the name of the buffer selected is indicated as default.


However, you may also enter a name of your own. The file
name should not exceed five letters when a separate ASCII file
is to be created for each data block.
When you tick the field Generate Header information, the
following data will be stored in ASCII file:
Time of first data: e.g. 15.05.96
9.06:45,510
Number of pretrigger data: e.g. 50
Number of posttrigger data: e.g. 500
Sample rate: e.g. 10Hz
This field is always ticked as default.
When you tick the field List data in physical units, the data
will be stored in physical units. Otherwise the data will be stored
in digits.
This field is always ticked as default.
When you tick the field One file for each data block, a file will
be created for each data block.
Note: The file name should not exceed five letters, since the
numbering of the data blocks will automatically be appended to
the file name.
The number of data blocks must not exceed 1000.
When you do not tick this field, a large file with all data blocks,
each separated by the associated header, will be created.
This field is always ticked as default.

Convert from:

In this field, date and time of the first block to be converted, e.g.
22.05.1996 9:06:46, will be indicated. Date and time may be
changed by the user, so that converting will be started at a later
date. When you do not enter anything in this field, starting will
be with the first block as default.

Convert until:

In this field, date and time of the last block to be converted, e.g.
22.05.1996 10:45:32, will be indicated. Date and time may be
changed by the user, so that converting will be completed at an
earlier date. When you do not enter anything in this field, converting will be to the last block as default.

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File

129

When you click on the menu item File, the following window will
be displayed at the screen.

You can enter a name of your own for ASCII files in the menu
window ASCII-file. The window will be closed when you click on
the OK button, and you will return to the previous menu.

File short name:

is the selected ASCII file name.

Convert

When you click on the field Convert, the selected data will be
converted to ASCII format. After converting, the number of files
converted will be displayed at the screen.

The ASCII files can be viewed with any word processing program.

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130

Converting the binary files in DIA PC format


When you click on the menu item Convert data to DIA PC
format, the following menu will be displayed at the screen.

Project:

Here the name of the buffer selected is indicated as default.


However, you may also enter a name of your own. A project,
designation of the data to be converted, comprises two files.
The files *.DAT contain the Header information. The files *.I16
contain the binary data.

Data format:

In this field you may select whether the data are to be stored in
the INTEL format or the Motorola format.
The field INTEL format is ticked as default.

Convert from:

In this field, date and time of the first block to be converted, e.g.
22.05.1996 9:06:46, will be indicated. Date and time may be
changed by the user, so that converting will be started at a later
date. When you do not enter anything in this field, starting will
be with the first block as default.

Convert until:

In this field, date and time of the last block to be converted, e.g.
22.05.1996 10:45:32, will be indicated. Date and time may be
changed by the user, so that converting will be completed at an
earlier date. When you do not enter anything in this field, converting will be to the last block as default.

Project

When you click on the menu item Project, the following window
will be displayed at the screen.

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131

In the menu window DIA PC Project file, you can enter a name
for the DIA PC files of your own. When you click on the OK
button, the window will be closed and you will return to the previous menu.

In the field File short name, the selected DIA PC Project file
name will be indicated now.
Convert

Click on the field Convert, and the selected data will be converted to DIA PC format. After converting, the number of files
converted will be indicated at the screen.

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V
1

Binary data format

132

Binary data format


Data format of the binary files
Each data file has the following structure:
Global header (general description of the data)
Any number of data blocks in sequential order
The order is not sorted chronologically!
Note:
All 16/32 bit data are available in the standard INTEL format,
i.e. lower-low bytes are first.
Negative numbers are given in the normal complement of 2.

1.1

Structure of the global header


Length in
Bytes

Type of
data

Fixed value, of
any

Name

Meaning

LOGO

the first two bytes "rS" identify


the file as DALOG file

HDRLEN

fixed length of this global


header

VERSION

internal software version


number:
-19: corresponds to version
2.03
-20: corresponds to version
2.10

DATATYP

Type of the stored data.


Should the value be unequal
to 16, the file does not contain
binary data but:
32: event data
256: classification data

CHAR

'r'

CHAR

'S'

SHORT

36

SHORT

SHORT

LONG

PID

Internal 4 byte buffer identification

15

CHAR[15]

SOURCENA
ME

String in C format with the


name of the source signal;
string end is marked by binary
0

CHAR[8]

CFGNAME

Name of the associated


DALOG configuration

16

132

Chapter V:

1.2

Binary data format

133

Structure of the data files (*.UPT)


After the global header (1.1), any number of data blocks follows. These are comprised of a header structure and the data
that are following directly. The data files have the appendix
*.UPT.

1.2.1

Structure of the header of individual data blocks


Length in
bytes

1.2.2

Type of
data

Name

Meaning

LONG

BLKLEN

Length of the entire data block including the following header data as well as the length of
BLKLEN (=4) proper

LONG

PLEN

Number of pretrigger data in following data block

LONG

TLEN

Number of posttrigger data in following data


block, PLEN and TLEN each contain the number
of stored 16 bit data

LONG

TTRIG.SEC

The value contains the number of seconds from


01.01.1980, 0:00 to the time of triggering.

LONG

CHAR

UID

Identification of the conversion table to be used


(UTB file)

CHAR

BITS

Number of significant bits of the following binary


data
Irrespective of this value, the individual data are
always stored as 16 bit data.

LONG

RATE

Sample rate of the signal in sec

SHORT

DATA

Data block with pre- and posttrigger data.


The block has a size of exactly
(PLEN+TLEN)*2bytes

TTRIG.NSEC Time of triggering


The value contains nano-seconds (10 to the minus 9th power) and defines the fractional digits of
the time of triggering.

Structure of the data ranges


The measurement data proper are always stored uncoded as
16 bit binary data. In order to convert these binary data to
physical data, the suitable conversion table (UTB file with suitable identification UID) must be used.

133

Chapter V:

1.3

Binary data format

134

Structure of the event data files (*.UPE)


After the global header (1.1) descriptions of events follow in
chronological order. All event descriptions have a uniform structure as described in the following:

1.3.1

Frame structure of a single event


Length in
bytes

Type of data

Name

UNSIGNED
CHAR

LEN

Length of the event frame in bytes including this


(and the final) Length counter

SHORT

ID

Characteristic ID of the event; value clearly identifies the event in connection with the associated
measurement configuration.
The ID value (in a range of 1...n) is contained in
bits 5...15; bits 0...4 are reserved and must be
masked, if required.

LONG

TIME

Time of the occurrence of the event; the value


contains the number of seconds from
01.01.1980, 0:00 to the time the event occurred

UNSIGNED
CHAR

TIME5MS Time of the occurrence of the event; the value is


to be interpreted as a multiple of 5ms and is in a
range of 0 to 199. The times symbolised in this
way (0 to 995ms) describe the fractional digits of
the time of the occurrence of the event.
(DATA)

(5)

LONG,
UNSIGNED
CHAR

UNSIGNED
CHAR

Meaning

"Snapshot" data (16 bit or 32 bit binary data


each), that have been recorded and stored at the
time the event occurred.
Note:
"Snapshot" data will only occur when the events
are configured accordingly! A clear interpretation
of the data is only possible by the DALOGSystem in connection with the associated measurement configuration.

(ENDTIME Final time of the event; coding of the time is TIME


/ENDTIME and TIME5MS
5MS)
Note:
The final time will only be available when storing
the length of time has been requested. If determining the final time by the DALOG system has
been requested, but was not possible, ENDTIME
contains the value 0.
LEN

Length of the event frame in bytes including this


(and the introductory) length counter. The value
is identical with the length counter LEN at the
beginning of the event frame.

134

Chapter V:

1.4

Binary data format

135

Structure of the classification data files (*.UPC)


After the global header (1.1) follows any number of classification data blocks. These are composed of a header structure
each as well as the directly following classification data.

1.4.1

Structure of the header of single classification data blocks


Length in
bytes
1

Type of
data
CHAR

Name
TYP

Meaning
Type of the following classification data
0 RAINFLOW classification
1 VERWEILZEIT classification

1.4.2

LONG

LEN

Number of the following classification counting


data; for the RAINFLOW classification this
value is identical with KLASSENZAHL2

LONG

TFIRST.SEC

Starting time of classification; the value contains the number of seconds from 01.01.1980,
0:00 to the starting time

LONG

LONG

TLAST.SEC

Final time of classification recording; the value


contains the number of seconds from
01.01.1980, 0:00 to the final time
Note:
TLAST cannot be recorded by the DALOGSystem in some situations. In these cases,
TLAST=0.

LONG

TLAST.NSEC

Final time of classification recording; the value


contains nano seconds and defines the fractional digits of the starting time.

CHAR

UID

SHORT

LIMNR

Number of class limits; the number of the


classes is calculated as follows:
KLASSZAHL = LIMNR +1

256

SHORT
[128]

LIMITS

The defined class limits as binary values; here


exactly that number of data is stored (sorted
forward) as defined by KLASSZAHL. The remaining data have no importance.

TFIRST.NSEC Starting time of classification; the value contains nano seconds (10 to the minus 9th power)
and defines the fractional digits of the starting
time.

Identification of the conversion tables to be


used (UTB files) for the class limits

Structure of the classification


The following KLASSZAHL2 counter data correspond to a
quadratic matrix. The matrixes contain cycle counts formed to
the rules of the Rainflow classification The individual counter
values have a length of 32 bits (4 bytes) and are always 0.
135