Pumping Technology OMEGA ECOFLEXX GLANDED PUMPS INSTALLATION AND OPERATION MANUAL

Transcription

1 OMEGA ECOFLEXX GLANDED PUMPS INSTALLATION AND OPERATION MANUAL IMPORTANT INFORMATION These instructions must be read and understood before installing, commissioning, operating or maintaining the equipment.

2 This installation guide gives basic instructions which are to be observed during installation, operation and maintenance of the pump. It is therefore imperative that this document be read by the responsible person/operator prior to the installation and always be kept available at the site. It is not only the general safety instructions under the main heading Safety that are to be observed, but also the specific information provided under the other main headings. SAFETY DANGER Warns of the risk of electric shock, if the precautions are not observed. DANGER Warns of the risk of damage to persons, property or the unit, if the precautions are not observed. CONSTRUCTION AND APPLICATION PUMP MEDIUM Smedegaard Omega pumps are of the in-line type construction with the motor mounted directly to the pump body. The pumps are suitable for commercial and industrial heating systems, district heating schemes, water treatment plants, general water transfer duties and refrigeration plants. Clean, thin, non-aggressive and non-explosive fluids (similar viscosity and specific gravity to water) without any solids or fibres. Antifreeze without any mineral oil (special model upon request). TECHNICAL DATA Note: If any liquid other than water is being pumped, we recommend that you contact Smedegaard, or their representative, as the pump characteristics may change. Electrical data Max. working pressure NPSH requirements Temperature see nameplate 10 bar see pump performance in Omega range leaflet -15 o C to +120 o C AIRBORNE SOUND PRESSURE LEVEL 950 rpm max. 65 db(a) 1450 rpm 0.12 kw to 1.5 kw - max. 47 db(a), 3 kw to 7.5 kw - max. 60 db(a), 11 kw to 45 kw - max. 69 db(a) 2900 rpm 0.12 kw to 3 kw - max. 53 db(a), 4 kw to 11 kw - max 62 db(a), 15 kw to 45 kw - max. 78 db(a) 2

3 INSTALLATION Fig. 1 The pump can be installed with the pump shaft vertical or horizontal (see Fig.1). Direction of flow through the pump casing is indicated by an arrow. Ensure pipework alignment is correct and the pump and pipework is adequately supported. Sharp bends should be avoided adjacent to the pump. If pump is mounted in vertical pipework, flow should be upwards. If flow is downwards (not recommended) it must be ensured that no air is able to collect in the pump body. Pumps should never be allowed to operate for a long period in a closed valve condition. To avoid accumulation of impurities in the pump, ensure that it is not mounted at the lowest point in a system. It is recommended that isolating valves are fitted on either side of the pump. The system should always be thoroughly flushed out to clear any solder, steel wool, plaster or any other foreign matter that may be lodged in the pump. To avoid this risk of the accumulation of air within the pump body the pump should not be situated at the highest point of the system. This may be critical in the case of HWS (bronze) pumps. Twin headed pumps fitted into horizontal pipework and with horizontal motor shaft, then fit an automatic air vent into the top casing. If the head is mounted in the horizontal position then rotate the head to ensure the air vent is at the top. See Fig 2. Filler Pipe Open Open Closed Closed Fig. 3 3

4 Air Venting Closed Circuits Open valves on suction and discharge, allowing water to enter the pump casing. Open the air vent screw on the pump seal chamber (see Fig. 2) and allow all the air to escape. Close the air vent screw. Open Circuits - Flooded suction Proceed as for closed circuits above but with discharge valve closed. Open Circuits - Suction lift, with foot valve (see Fig. 3). Break the pipework at a suitable place on the discharge side of the pump. Open suction and discharge valves and fill pump and pipework to level of break. Open the air vent screw on the pump seal chamber (see Fig. 2) and allow all the air to escape from this area. Close the air vent screw. The water level in the pipe should remain constant, proving that the foot valve is holding. Reconnect the pipework. It is very important that the pump is fully vented otherwise the mechanical seal can be damaged. ELECTRICAL CONNECTION AND DIRECTION OF ROTATION Motors should always be connected, through a suitable starter, to the mains supply. Ensure that the electrical supply available agrees with the motor details shown on the nameplate. Connection details are shown inside the terminal box cover. Refer to the motor data plate to check for star/delta connection. If the pump is supplied with an inverter fitted, then refer to the inverter operating and maintenance instructions. The direction of rotation is shown with an arrow on the motor cowl and should always be checked after wiring. ALL OMEGA RANGE UNITS UP TO OMEGA SHOULD ROTATE IN AN ANTI- CLOCKWISE DIRECTION WHEN VIEWED FROM THE MOTOR NON-DRIVE END. ALL OMEGA RANGE UNITS OMEGA 12 AND ABOVE SHOULD ROTATE IN A CLOCKWISE DIRECTION WHEN VIEWED FROM THE MOTOR NON-DRIVE END. The direction of rotation of three phase motors can be altered by interchanging any two of the three main connecting leads. Single phase motors have the direction of rotation pre-set before despatch. STARTING THE PUMP MUST NOT RUN WITHOUT WATER. Open suction valve and close discharge valve. Start the pump and slowly open the discharge valve until fully open. The pump should never be allowed to operate for long periods in a closed valve condition. SERVICE/MAINTENANCE Motor bearings fitted to Omega pumps are sealed for life and do not need greasing. The mechanical seal fitted to this range of pumps should be checked periodically and replaced if necessary. We recommend that the casing O ring (and circlip when fitted) is replaced when a mechanical seal is changed. 4

5 OMEGA ECOFLEXX PRESSURE TRANSDUCER FITTING GUIDE Warning: If the transducers are not fitted prior to the operation of the pump it will not run/operate SINGLE PUMP Remove both pump flange tapping screws with a 6mm Allen Key/T-Bar and replace with the transducers. PTFE tape/loctite or similar maybe required to obtain a water tight seal but in most cases is not required. Fit the transducer cables to the transducers taking care to correctly align, screwing up the knurled collar and pushing in the plug as you tighten. Wire back to the Drives cutting out the White & Black, connecting Discharge transducers to S1N (blue) and S1P (brown). Suction transducers to S2N (blue) and S2P (brown). TWIN PUMP Remove both pump flange tapping screws with a 5mm allen key and replace with ¼ nipple & ¼ equal tee using PTFE tape/loctite or similar to obtain a watertight seal. Fit the transducers into the equal tee, some PTF tape/ Loctite or similar maybe required to obtain a water tight seal but in most cases is not required. Care should be taken that the transducer wires are fitted correctly in the terminals (it is easy to clamp the cables behind the terminals) and the correct cable colours are inserted into the corresponding terminals or Error 1 will be shown. 5

6 SINGLE PHASE WIRING Discharge Transducer Blue Brown To Motor Fault Signal Run Signal Remote Stop/Start (Bridge To Run) MCB-C Ground L N 1Phase /60 Brown Suction Transducer Blue 6

7 Blue Suction Transducer Brown Analogue Input MCB-C /60Hz Power Supply 0/10 VDC 4-20mA Ground Remote (Bridge To Run) Stop/Start To Motor Fault Signal Run Signal Brown Discharge Transducer Blue THREE PHASE WIRING 7

8 PUMP WIRING Each drive is connected to the pump terminals U, V and W. The direction of rotation should be checked, if it is not correct then either, switch any two of the wires to the pump terminals U V W or, reverse the direction of rotation using menu option Dr-20 in the FlexDrive. OMEGAFLEX VARIABLE SPEED DRIVE UNITS QUICK ADJUSTMENT GUIDE Upon initial startup the user menu will display P for *actual pressure across the pump. Using the Up & Down buttons other information can be accessed. P pressure actual/achieved in Bar S pressure setting in Bar H output in Hz O output in % U voltage of the DC link A output current in Amps O outlet pressure in Bar I inlet pressure in Bar Adjustments to the program can only be made whilst the pump is stopped. With the power supply on and the pump stopped use the Up & Down buttons to select S (looks like a 5) in the user menu. If the pump when stopped and the pressure removed, displays in the user menu I and O the outlet transducer needs to be corrected within parameter Pr 4 to the value of 0.3. Make sure the valves either side of the pump are opened, the bleed screw is replaced following venting/bleeding and before the pump is put into operation, failure to do so will result in damage to the pump. Press the Up & Down buttons together until Pr is displayed then use the Up & Down buttons to select Pr 4 for adjustment of the outlet transducer or Pr 6 to adjust the inlet transducer. Care must be taken not to change any other settings parameters. Following this press Set/Reset to see End appear then press and hold the Up & Down buttons together, the display will change to show Dr press and hold Up & Down buttons again, this will take you back to the user menu and will display P. If any further settings require adjustment please contact Smedegaard. Service call outs caused by the users failure to set up the VSD units correctly will result in charges. Press and hold the Set/Reset button until the display flashes and S changes to d then adjust the setpoint (displayed in Bar) to the desired setting using the Up & Down buttons. Press the Set/Reset button and End should appear in the display confirming that the setpoint adjustment has been saved. Press the Run/Stop button or replace the P1 CG link to put the pump back into normal operation. *Note Upon initial start-up up the unit will display a differential pressure across the pump even though it is not running and the transducers will require calibrating. The pump may not run when the Run/Stop button is pressed if the differential pressure shown across the pump is greater or equal to the pressure setting. Transducer Correction First remove all pressure off the pump - this can be done by closing the valves either side of the pump and opening the pump bleed screw. I displays the inlet pressure and O displays the outlet pressure which can be selected with the Up & Down buttons from the user menu. Example If the pump when stopped and the pressure removed, displays in the user menu I and O the inlet transducer needs to be corrected within parameter Pr 6 to the value of

9 OMEGAFLEX DRIVE SETTINGS Please note that under normal circumstances all the below settings are carried out at the factory. To make any adjustments the pump/drive must be stopped and not enabled to run. *To make the adjustments we may require resetting the unit back to factory settings first of all. First hold up & down together to see pr in the menu then cycle to pr90 press set/reset and change 0 to 1 and press set/reset to confirm. The second thing to do is to hold up & down together to see pr then once again to see dr, cycle to dr90, press set/reset and change 0 to 1 and press set/reset. *It may not be necessary to carry out the above but in doing so the user can be sure all settings within are correct. Holding up & down together to get to the pr menu the following parameters require changing or checking: pr2 needs to be set to 0, pr3 should be set to the maximum rating of the transducer e.g. 10 for a 0-10 bar transducer, and the same for pr5. Now the dr menu requires setting up. To get into the dr menu hold up & down to see pr then once again to see dr. dr3 needs to be set to 20 (minimum frequency in HZ to allow for sufficient cooling of the motor) dr10 needs to set to the motor capacity shown on the motor plate (KW), dr11 is 2 or 4 pole motor rpm 4 pole (DR 2)/ 2800 rpm 2 pole (DR 1) displayed again on the motor plate, dr 12 is the amp rating of the motor, dr 13 is the RPM of the motor, dr 14 is the voltage, dr 17 must be set to 0, dr 32 must be set to 5. dr 20 will change rotation direction 0-clockwise 1-anti To change or view the status of any parameter set/reset should be pressed and again to confirm a changed setting. EXTERNAL SPEED CONTROL For 4-20ma input the following parameters require changing: dr2-3, dr64 - l1 min input current, dr65 - corresponding frequency to l1 min input current - 20 (this should not be set below 20hz to allow for sufficient motor cooling), dr66 - l1 max input current, dr67 - corresponding frequency to l1 max input current - 50 (50hz max output of motor). For 0-10v input speed of the pump the following parameters will require changing: dr2-2, dr60 - V1 min input voltage, dr61 - corresponding frequency to V1 min input voltage - 20(this should not be set below 20hz to allow for sufficient motor cooling), dr62 - V1 max input voltage, dr63 - corresponding frequency to V1 max input voltage - 50 (50hz max output of motor). The recommended method for remote start/stop is via the use of terminals P1 & CG, link to run. For this application parameter dr1 should be set to 1. The power supply to the inverter should be via a class C or D MCB rated at 1.5 times the rated output of the drive. The drive must be stopped/not in run mode to enable changing of any parameters and do not switch off the power supply to the drive following changing any parameters for a few minutes as there is a delay before saving to memory. If the enable contact is utilised (CG and Run or P1, Closed link for Run, Open link for Stop/Standby) dr1 in the menu needs to be changed from 0 to 1 and there is a blue dip switch on the PCB board that needs to be changed to NPN, we are currently setting units this way from factory with a link between P1 & CG so it may have to be checked to see if it is present. 9

10 Display Content Description Restarting Remarks Er-01 tsf Pressure sensor error O 7-2 Er-02 top High pressure alarm O Er-03 tlp Low pressure alarm O 7-3 Er-04 tul Low level alarm O Er-05 tash Drive arm short trip X 7-4 Er-06 toc Drive H/W over current trip O Drive H/W over current 7-5 Er-07 SOC restriction trip O Er-08 tmoh Motor overheat (TMOH) O Er-09 toh Drive overheat trip O 7-5/6 Er-10 tlv DC-Link low voltage trip O Er-11 tov DC-Link high voltage trip O 7-6/7 Er-12 tol Overload operation trip O Er-13 tdol Drive overload operation trip O 7-8 Er-14 tgf Ground trip X Er-15 tlde Communication IC X 7-7 duplication trip Er-16 tce Communication error X Er-17 tio Input error X Er-18 too Output error X Er-20 tes External fault input X 7-8 Er-21 tlt Allowable time elapsed X 10

11 FAULT FINDING Fault Cause Action Motor does not start Electrical supply isolated Check motor terminals for correct voltage Blown Fuses Replace fuses and check current Loose electrical connections Tighten all electrical connections Motor runs and then cuts out Undersized wiring Rewire with larger cable Starter overload tripped Check overload sizing with motor F.L.C Incorrect motor links Check motor links for star/delta Pump failing to deliver Not primed Bleed pump of air Suction valve not fully open Open Valve Foot valve not fully submerged (open circuits) Lower suction pipework Air leaks in suction pipework Recheck all joints Wrong Rotation Change Rotation (check wiring phases) Foreign body in pump case Clear obstruction Pump leaking Mechanical seal damaged Replace seal Casing O Ring damaged Replace O ring Pump unduly noisy Pipework not supported correctly Check pipe supports Pipework causing undue strain on pump casing Cavitation (closed systems) Cavitation (open systems) Resupport pipework or reinstall pipework Increase static head Increase size of suction pipework Insufficient flow Incorrect rotation Change rotation (check wiring phases) Low voltage Check Electrical supply Air leaks in suction pipework Recheck all joints Valves not fully open Open all valves Partially clogged pump or pipework Clear obstructions Pump too small Replace pump Motor does not start but emits a hum Foreign body in pump casing Check motor is free to turn 1 phase motors, faulty capacitor Pump will operate correctly if spun but if it fails to re-start, replace capacitor 3 phase motors, phase dropped Check the supply phase 11

12 EC-DECLARATION OF CONFORMITY Representative and manufacture: Smedegaard Pumps Limited 10 Beech Business Park Bristol Road Bridgwater Somerset UK TA6 4FF Machine: Type: Circulation Pump Omega ECOFlexx No: From to Consist of: Pump, Motor Manufactured in accordance with the Machinery Directive 2006/42/EC on the approximation of the laws of machines. Standards used: EN 12100:2011 -EMC Directive, ie. Council Directive 2004/108/EC of 15 December 2004 to approximate the laws of Member States relating to electromagnetic compatibility. Standards used: EN , EN Low Voltage Directive (2006/95/EC) Standards used: EN :2006, EN :2012 -Commission Regulation (EU) No 640/2009 Implementing Directive 2005/32/EC of the European Parliament and of the Council with regard to eco design requirements of water pumps. -Commission Regulation (EU) No 547/2012 Implementing Directive 2009/125/EC of the European Parliament and of the Council with regard to eco design requirements for water pumps. FlexDrive Council Directive Equipment Description Device name/type Serial European Standards Test Certificate No: Declaration: 89/336/EEC Amendment 2004/108/EC Inverter motor drives FlexDrive D02S0191AJG Emission / Immunity BS EN : 2006 Class A (industrial) EMC1392 We hereby declare that the above Device complies with the required Emission and Immunity standards stated above Copenhagen date Tommy Andersen Managing Director - Smedegaard Group Whilst every care has been taken to ensure that data is correct, no responsibility can be accepted for inaccuracies or misprints. It is SMEDEGAARD policy to continually improve and develop the product range. We reserve the right to change specifications without prior notice. Smedegaard Pumps Ltd - United Kingdom Tel. +44 (0) Fax +44 (0) [email protected] T. Smedegaard A/S - Denmark Tel Fax [email protected] Omega 24/05/2013