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GEA ARIETE Instructions For Use And Maintenance Manual

Homogenizer

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OMOGENEIZZATORE/POMPA AD ALTA PRESSIONE

HOMOGENIZER/HIGH PRESSURE PUMP

ISTRUZIONI D'USO E MANUTENZIONE

INSTRUCTIONS FOR USE AND MAINTENANCE

INSTRUCTIONS D'EMPLOI ET ENTRETIEN

INSTRUCCIONES PARA EL USO Y EL

BETRIEBSANLEITUNG

MANTENIMIENTO

HANDLEIDING

Via M. da Erba Edoari, 29/A

43100 Parma, Italy

Tel: +39 0521/965411

Fax: +39 0521/242819

Internet: htttp://www.niro-soavi.it

E-mail: niro-soavi@niro-soavi.it

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Summary of Contents for GEA ARIETE

Page 1 OMOGENEIZZATORE/POMPA AD ALTA PRESSIONE HOMOGENIZER/HIGH PRESSURE PUMP ISTRUZIONI D’USO E MANUTENZIONE INSTRUCTIONS FOR USE AND MAINTENANCE BETRIEBSANLEITUNG INSTRUCTIONS D’EMPLOI ET ENTRETIEN INSTRUCCIONES PARA EL USO Y EL MANTENIMIENTO HANDLEIDING Via M. da Erba Edoari, 29/A 43100 Parma, Italy Tel: +39 0521/965411 Fax: +39 0521/242819 Internet: htttp://www.niro-soavi.it E-mail: niro-soavi@niro-soavi.it...
Page 2 Niro Soavi S.p.A FOREWORD Dear Customer, we wish to thank you for selecting our product and ensure you our best assistance in order to enable you to make the most of your machine. Also, we remind you that a good understanding of the contents of this manual - through careful reading of all sections - is essential for the correct, safe use and operation of the machine you have purchased.
Page 3 Niro Soavi S.p.A CONTENTS - SECTIONS 1. Technical Specifications 2. General Information 3. Machine Operation and Use 4. Maintenance 5. List of Spare Parts 6. Wiring Diagrams 7. Documentation about Suppliers and Components HOW TO USE THE MANUAL This manual is made of separate sections as indicated in the list of CONTENTS. Each section is divided into chapters and paragraphs, and pages are numbered separately in each section.
Page 4 Niro Soavi S.p.A SECTION 1 TECHNICAL SPECIFICATIONS 1.1. TECHNICAL DATA 1.2. FLOW-SHEET 1.3. FLOW-SHEET LEGEND (SPEC 102) 1.4. MACHINE INSTALLATION DRAWING 1.5. UTILITIES SPECIFICATIONS (SPEC 103) 1.6. RUNNING SEQUENCE (ONLY IF MACHINE IS SUPPLIED WITHOUT ELECTRICAL POWER BOARD BY NIRO SOAVI) 1.7.
Page 5 1.1 TECHNICAL DATA SHEET GENERAL 1.1 Serial Number 4759 1.2 Kind of Machine HOMOGENIZER 1.3 Model ARIETE 1.4 Type NS3018H 1.5 Execution Aseptic 1.6 Special Features CGMP+ELECTRUPOLISHED+3A+FDA 1.7 MAX Operating Pressure 1000 1.8 Flow Rate Type 1.9 MIN Flow Rate...
Page 6 HOMOGENIZING VALVE 3.2.1 Number of Stages 3.2.2 Type of actuator PNEUMATIC 3.2.3 Type of control PNEUMATIC 3.2.4 Homogenizing Valve Type 11,9-30 HP DRIVE END 3.3.1 Main Motor (frame size; type) AC180M/4P 3.3.2 Main Motor Power 18,5 3.3.3 RPM Crankshaft 3.3.4 RPM Crankshaft 3.3.5 Drive Type ROSSI REDUCER 3.3.6 Gearbox speed reduction ratio...
Page 8 SPEC - 102 C LEGEND Niro-Soavi S.p.A. TO CONCEPT FLOW SHEET Specialty Products ____________________ REV. via M. da Erba Edoari, 29/A Division DATE 43100 PARMA (ITALY) PHONE : +39.0521.965411 - FAX : +39.0521.242819 Page 1 of 2 ____________________ SIG. MACHINERY AND EQUIPMENT INSTRUMENT SYMBOLS LOCAL AUTOMATIC ACTUATOR FOR REMOTE...
Page 9 SPEC - 102 C LEGEND Niro-Soavi S.p.A. TO CONCEPT FLOW SHEETS Specialty Products ____________________ REV. via M. da Erba Edoari, 29/A Division DATE 43100 PARMA (ITALY) PHONE : +39.0521.965411 - FAX : +39.0521.242819 Page 2 of 2 ____________________ SIG. LETTER CODE FOR IDENTIFICATION OF INSTRUMENT FUNCTIONS FIRST LETTER SUCCEEDING LETTER (1) MEASURED OR INITIATING VARIABLE...
Page 11: Gear Box
SPEC-103C Niro-Soavi S.p.A. UTILITY SPECIFICATION Specialty Products via M. da Erba Edoari, 29/A 23.01.03 Division 43100 PARMA (ITALY) DATE REV. PHONE : +39.0521.965411 - FAX : +39.0521.242819 NS 3018HA 1/220217 4759 MACHINE MODEL SIG. JOB NIRO SOAVI MACHINE SERIAL NO. LUBRICATING &...
Page 12: Declaration Of Conformity
NIRO SOAVI S.p.A. Via Mario da Erba Edoari 29/A - 43100 PARMA - ITALY Tel +39 0521 965411 - Fax +39 0521 242819 e-mail: niro-soavi@niro-soavi.it DECLARATION OF CONFORMITY MACHINE: HOMOGENIZER ARIETE Model: NS3018H Serial number: 4759 Machine TAG number 242X1100 Cabinet TAG number 242MC1100 Max Press.
Page 13 Niro Soavi S.p.A SECTION 2 GENERAL INFORMATION - INDEX 2.1. SAFETY 2.1.1 SAFETY INFORMATION 2.1.2 PERSONNEL SAFETY 2.1.3 USE OF THE MACHINE IN DANGEROUS ZONES 2.2. CE MARK AND ISO 9000 CERTIFICATION 2.3. IDENTIFICATION OF THE MACHINE 2.4. GUARANTEE 2.4.1 SCOPE OF THE GUARANTEE 2.4.2 DURATION OF THE GUARANTEE...
Page 14 Niro Soavi S.p.A 2.1. SAFETY These INSTRUCTIONS FOR USE & MAINTENANCE are part of the machine and should accompany it throughout its service life until disposed of. Before starting ANY operation, consult the relevant Section of these INSTRUCTIONS. Make sure that nobody has access to the machine before getting thoroughly acquainted with these Instructions.
Page 15 Niro Soavi S.p.A 2.1.1 SAFETY INFORMATION Although this machine has been designed to prevent all risks for operators the possibility of risk for both personnel and materials or equipment is not excluded; the general safety instructions and norms for operators and objects must be observed scrupulously, taking every precaution to prevent accidents.
Page 16 Niro Soavi S.p.A 2.1.3 USE OF THE MACHINE IN DANGEROUS ZONES Use of the machine in dangerous zones is allowed only if the machine has been designed specifically for use in such conditions using suitably certified components. Identification and classification of danger zones is the responsibility of the customer who is required to specify them.
Page 17 Niro Soavi S.p.A 2.2. CE MARK AND ISO 9000 CERTIFICATION The machine has been designed and built in accordance with EEC standards on the safety of equipment (CEE/98/37). NIRO-SOAVI guarantees that this machine complies with the above-mentioned standard by marking the front of the machine with "CE" as shown in figure 2.2.1 here below, on the front part of the machine.
Page 18 Niro Soavi S.p.A FIGURE 2.2.2 2C001E0C.DOC 2.2.2...
Page 19 Niro Soavi S.p.A 2.3. IDENTIFICATION OF THE MACHINE The machine is identified by the name plate (fig.2.2.1) located on the front panel (or on the pulley protection panel, for the Hercules versions without casing), which includes the manufacturer's name model and type serial number.
Page 20 Niro Soavi S.p.A 2.4. GUARANTEE If not specified otherwise in the order confirmation, the terms and conditions of guarantee are as follows: 2.4.1 SCOPE OF THE GUARANTEE NIRO-SOAVI guarantees the good quality and workmanship of its products and shall - during the specified guarantee period - repair or replace free of charge any part whose failure or premature wear and tear are the result of poor quality of materials, defective workmanship or assembling.
Page 21 Niro Soavi S.p.A 2.4.2 DURATION OF THE GUARANTEE The guarantee shall last for 12 MONTHS from the date of delivery of the machine, unless otherwise specified in the Order Confirmation. Such period shall remain unchanged even in the event that spare parts replacements or repairs are carried out during the 12-month period.
Page 22 Niro Soavi S.p.A 2.5. HANDLING CAUTION: These instructions shall be made available to the personnel involved in the handling and installation of the machine. The machine is sent to the Customer usually packed in a properly sized wooden crate and wrapped in plastic film for additional protection, unless otherwise specified in the Order Confirmation.
Page 23 Niro Soavi S.p.A Concerning the dimensions and weight of the machine, see the “Installation Drawing” shown in Section 1 – TECHNICAL SPECIFICATIONS, in order to use the proper lifting equipment. The weight given is merely indicative and should be used only to select the correct handling and transport means.
Page 24 Niro Soavi S.p.A WARNING: Before handling the machine, make sure that the route to be followed and the intended place of installation are clear of any obstacle. WARNING: Operators are required to read these instructions before handling the machine; all personnel involved in handling of the machine must be acquainted with transport and handling regulations, as well as with regular safety standards.
Page 25 Niro Soavi S.p.A 2.6. RECEIVING AND CHECKING THE MACHINE Unless specified otherwise in the Order Confirmation, once the machine has left the Manufacturer's premises, any damage shall be under the responsibility of the carrier - whether an independent one or a Customer's employee. Therefore, when receiving the machine, the following should be checked: - contents of the packing against the Packing List;...
Page 26 Niro Soavi S.p.A 2.7. STORAGE 2.7.1 STORAGE BEFORE INSTALLATION During the time preceding installation, the machine and its apparatus should be conveniently stored in closed, clean premises to avoid deterioration and preserve its efficiency. If no storage place can be provided other than outdoor, a waterproof cover should be provided to prevent contact with dust, humidity, rain, etc.
Page 27 Niro Soavi S.p.A 2.8. INSTALLATION 2.8.1 POSITIONING The correct positioning of the machine within the production line is a pre- condition for ideal performance and easy access for ordinary maintenance. For this reason, according to the machine dimensions (see Section 1 – TECHNICAL SPECIFICATIONS), allow enough space around the machine for the service personnel to carry out the necessary maintenance.
Page 28 Niro Soavi S.p.A 2.8.2 ACCESS TO THE INSIDE OF THE MACHINE The machine is provided with a satin-finish stainless steel fairing for: - protection of the internal components from dirt, water or fouling with product; - easy cleaning of the external parts; - operator's protection from moving, under voltage or hot parts which may be hazardous for the personnel, in compliance with EC standards and CE mark requirements, and safety regulations in force in the country where the...
Page 29 Niro Soavi S.p.A 2.8.3 MACHINE LEVELING To ensure a smooth, vibration free operation, the machine should be properly leveled and its legs should rest evenly on the floor. To this effect, the machine is supplied with adjustable legs and rubber pad (figure 2.8.1, item 1);...
Page 30 Niro Soavi S.p.A 2.8.4 CONNECTION TO UTILITIES AND PRODUCT LINE The type, dimension and position of the connectors normally used to connect the machine to the production line are specified in the dimension drawing in Section 1 – TECHNICAL SPECIFICATIONS. The machine also includes (section 1 –...
Page 31 Niro Soavi S.p.A Cooling air is discharged through grids, situated on the top of the machine, controlled by a fan of suitable size for free discharge (not for all models). In case the discharged air needs to be conveyed via ducts, please contact NIRO-SOAVI's Technical Office for details.
Page 32 Niro Soavi S.p.A 2.8.5 INSTALLATION These guidelines are provided to ensure correct machine installation and operation and guarantee long life to the machine and its components while preventing situations of danger for operators. • For high-pressure positive displacement pumps and homogenizers, infeed pressure must ALWAYS be kept over a minimum level for correct operation without cavitation conditions which could damage the machine.
Page 33 Niro Soavi S.p.A prevent loss of load; the radius of curves must be as large as possible to prevent loss of load especially in the infeed stage and to avoid noise problems at delivery. • we recommend you install a pressure gauge near the area where product is fed into the homogenizer / piston pump in order to check infeed pressure;...
Page 34 Niro Soavi S.p.A • Never use the machine to fully drain the feeding tank, to avoid product suddenly running out during operation under pressure, but provide at least one level sensor to remove pressure (in the case of a homogenizer) and stop the machine before the product being fed runs out •...
Page 35 Niro Soavi S.p.A 2.8.6 POSITIONING THE ELECTRIC EQUIPMENT Our machines are supplied in the standard version without electric power board; this will be designed and constructed according to the specifications of the machine as an optional; in any case the machine is fitted with a terminal box which houses all the connections of the electric devices installed in the machine, excluding the motors.
Page 36 Niro Soavi S.p.A 2.8.7 ELECTRICAL CONNECTIONS The power line to the control board should be of appropriate type according to the length, type of routing, ambient temperature, nature of the load, and always in accordance with the provisions of the local regulations on this matter. If no specific agreements have been made in writing with NIRO-SOAVI, the user shall be responsible for establishing the features of the power line and earthing conductor up to the terminal board of the machine, as well as selecting...
Page 37 Niro Soavi S.p.A 2.8.8 DIRECTION OF ROTATION OF ELECTRIC MOTORS At the time of wiring, make sure that all motors rotate in the correct direction: CAUTION: To check the direction of rotation, the motors should be operated ONLY by impulses. When performing these operations, follow strictly the safety rules and stay away from any moving part inside the machine.
Page 38 Niro Soavi S.p.A 2.9. SPECIAL NOTES 2.9.1 CONTROL BOARD TO BE PROVIDED BY THE CUSTOMER If the electric power and control board (optional) is not supplied with the machine, NIRO-SOAVI will include a Technical Sheet (Section 1 - TECHNICAL SPECIFICATIONS) showing the electrical requirements of the machine, together with an operation sequence to enable the Customer to establish the elements of the control board and the operating features of the required protection devices for a correct execution and the selection of appropriate...
Page 39 Niro Soavi S.p.A 2.10. NOTES ON MACHINE TEST Before shipment all of our machines are accurately tested by qualified personnel through operational tests which simulate the normal working conditions. Through the operational tests - run with cold water - it is possible to verify the actual performance of the machine against the design data, the calibration of safety, control and check devices, the conditions of any seals, as well as the noise and vibration-free operation of the machine and the parameters...
Page 40 2.11. CLEANING THE MACHINE The machine is supplied with external paneling in glazed stainless steel plate (ARIETE version) which is easy to clean with water. Washing prevents the deposit of product residuals on the machine: wash the bodywork with running water from time to time, paying particular attention to the compression head and the sump.
Page 41 Niro Soavi S.p.A 2.12. DEMOLITION AND DISPOSAL The demolition and disposal of the machine must be carried out in compliance with various procedures according to the type of material to be disposed of. First of all, it is necessary to: - discharge lubricating and hydraulic oils for separate disposal;...
Page 42 Niro Soavi S.p.A 2.13. OPTIONS 2.13.1 SECOND STAGE HOMOGENIZING VALVE As an option, a second homogenizing stage can be installed on NIRO-SOAVI Homogenizers in series with the first stage valve. In this way it is possible to reduce the increase of viscosity produced by the treatment of the product, in case it contains colloidal or thickening substances.
Page 43 Niro Soavi S.p.A Ptot = P1 FIGURE 2.13.1 2.13.2 ASEPTIC EXECUTION Whenever a sterile plant and product needs to be ensured, an aseptic version of the NIRO-SOAVI machine is available. This can be achieved by running sterile condensate through the plungers in the seal section and through the seal of the homogenizing valve shaft using appropriate sterile chambers to avoid contamination from outside sources.
Page 44 Niro Soavi S.p.A 2.13.2.1 STERILIZING THE MACHINE Before starting up the machine following an extended period of standstill - or at first start-up - we recommend sterilizing the areas to be maintained aseptic with live steam (max temperature 150 °C at 3.8 bar) and with the machine stopped: to do so, open the steam on/off tap without sending any water to the exchanger.
Page 45 Niro Soavi S.p.A 2.13.3 PARTIAL HOMOGENIZING SYSTEM NIRO SOAVI homogenizers can have installed, as an option, a partial homogenizing system, to homogenize only a part of the total flow which is then mixed with the remaining non homogenized part in a special mixing chamber (see figure 2.13.2).
Page 46 Niro Soavi S.p.A 2.13.3.1 HOW THE BYPASS SYSTEM WORKS To make the by-pass circuit work properly, it is necessary to open and close the pneumatic butterfly valve (position A, figure 2.13.3) with a signal coming from the centrifuge. This valve must be closed during normal operation, opened during desludging phase and cleaning of the equipment.
Page 47 Niro Soavi S.p.A • Close the pneumatic butterfly valve few seconds after the desludging phase of the centrifuge has been completed; • Keep downstream the homogenizer a minimum backpressure of 1÷2 bar, to allow the backflow of the homogenized product into the suction manifold through the by-pass, when opened.
Page 48 Niro Soavi S.p.A SECTION 3 OPERATION & USE OF THE MACHINE - INDEX 3.1. GENERALS 3.2. CHECKS BEFORE START-UP 3.3. START-UP PROCEDURE 3.3.1 OPERATOR’S POSITION 3.3.2 CONTROL PANEL 3.3.3 START-UP 3.4. OPERATION AND ADJUSTMENT 3.4.1 HOMOGENIZING PRESSURE ADJUSTMENT – 1 STAGE 3.4.2 HOMOGENIZING PRESSURE ADJUSTMENT - 2 STAGES 3.4.3...
Page 49 Niro Soavi S.p.A 3.1. GENERALS The NIRO-SOAVI Homogenizer consists of a positive-displacement piston pump provided with automatic valves with suction and delivery spring , connected to a homogenizing section where the product undergoes the process of high-pressure micronization to reduce the size of the solid particles suspended in the fluids and achieve homogenous dimensional distribution.
Page 50 Niro Soavi S.p.A 3.2. CHECKS BEFORE START-UP WARNING: The operating temperature of the machine must be between +5°C and +40°C; maximum humidity 90%; maximume altitude 1000 m. For operating conditions outside these value limits a special version must be used. WARNING: Any operation involving the removal of the machine panelling should be performed with the MACHINE STOPPED AND ISOLATED from the power line by locking the isolator switch with a padlock, so that...
Page 51 Niro Soavi S.p.A • Verify the level of lubrication oil through the sightglass: this should be covered with oil by 3/4 or reach the level shown on the special visual indicator. When checking the oil level, the machine should be stopped, because normally the start-up causes the level to lower as it fills the circuits.
Page 52 Niro Soavi S.p.A FIGURE 3.2.1 FIGURE 3.2.2 3C001E0C.DOC 3.2.3...
Page 53 Niro Soavi S.p.A 3.3. START-UP PROCEDURE 3.3.1 OPERATOR’S POSITION To ensure the safe use of the machine during start-up and adjustment operations, we recommend that the operator should stand as indicated in figure 3.3.1. The control panel - configurated according to the Customer's requirements - is on the left hand side of the machine front;...
Page 54 Niro Soavi S.p.A 3.3.2 CONTROL PANEL The control panel is located on the front left side of the machine (in the Ariete version with paneling). There is a single panel for all the different languages which shows the symbols and instruments used to control the machine (see fig. 3.3.2): •...
Page 55 Niro Soavi S.p.A 3.3.3 START-UP WARNING: The lubrication oil indicated in the specifications is suitable for operating temperatures between +5°C ed i +40°C: DO NOT START the machine if ambient temperature is lower than +5°C to avoid damage to the lubrication system.
Page 56 Niro Soavi S.p.A • Give power using the main switch on the electric power board • Press the start push-button. In case the control board has been supplied by NIRO-SOAVI, this operation allows to start the machine according to the correct sequence, depending on the type of machine and optionals provided: - opening of any utility solenoid valve (optional) - start of the oil motor-driven pump (if this type has been provided)
Page 57 Niro Soavi S.p.A 3.4. OPERATION AND ADJUSTMENT Once the machine has been started, before increasing the homogenizing pressure, check that the machine itself is operating normally, with a particular attention paid to the feed pressure, establishing it is stable and within limits as prescribed in Section 1 –...
Page 58 Niro Soavi S.p.A CAUTION: this procedure is allowed ONLY for machines with operating pressure up to 250 bar, to prevent overstressing the machine and avoid too rapid an increase of pressure as this could cause the safety valve to open. FIGURE 3.4.1 3C001E0C.DOC 3.4.2...
Page 59 Niro Soavi S.p.A 3.4.2 HOMOGENIZING PRESSURE ADJUSTMENT - 2 STAGES To adjust the pressure, follow the same steps as for the single-stage machine. In order to adjust the pressure, please read carefully what is written in paragraph 3.4.1, and in specific all warnings. The pressure to be applied by the second stage varies from about 1/10 to 1/5 of the maximum homogenizing pressure, according to the product handled.
Page 60 Niro Soavi S.p.A CAUTION: this procedure is allowed ONLY for machines with operating pressure up to 250 bar, to prevent overstressing the machine and avoid too rapid an increase of pressure. CAUTION: To release homogenizing pressure in a two-stage system you need to reverse the procedure used to give pressure.
Page 61 Niro Soavi S.p.A 3.4.3 REMOTE PNEUMATIC CONTROL (OPTIONAL) The pneumatic control for adjustment of homogenizing pressure can be designed as a remote system using a proportional solenoid valve (requiring minimum 7.5 bar air pressure supply) actuated by a 4÷20 mA signal; the type of system used depends on the configuration selected by the Customer.
Page 62 Niro Soavi S.p.A 3.5. MACHINE STOP To stop the machine, follow these steps: • release the homogenizing pressure by operating either the pneumatic switch to the OFF position, or the remote control electric valve (or proportional valve) via an appropriate electric signal •...
Page 63 Niro Soavi S.p.A 3.6. CLEANING A thouroug of the machine will maintain the sanitary or aseptic conditions as necessary to avoid harmful deterioration or contamination of the product handled. When designing the machine, special care has been given to the parts in contact with the product to make them easily cleanable (C.I.P.) and to avoid recesses where the product may stagnate.
Page 64 Niro Soavi S.p.A TABLE 3.6.A P R O D UCT max concentr. max temp. (°C) Caustic Soda (NaOH) Nitric Acid (HNO Phosphoric Acid (H Hot Water Hot Pressurized Water / Steam CAUTION: Dispose of the cleaning solution and washing fluids as prescribed by the laws in force locally.
Page 65 Niro Soavi S.p.A 3.7. SAFETY DEVICES NIRO-SOAVI machines are provided with safety devices to prevent reaching critical conditions which may cause sudden breakage of the machine and hazards for the personnel. In addition the machines are designed with ample safety margins, in consideration of high pressures which may be reached as a result of improper operations by the user or failures of the line in which the machine has been included.
Page 66 Niro Soavi S.p.A 3.7.1.1 OPERATION The valve consists of a ball maintained in place in its seat by a spring, which allows it to open when the calibration set point is exceeded. The spring loading should not be changed as this would modify the valve opening value and cause the immediate forfeiture of the safety conditions established by NIRO-SOAVI and the guarantee.
Page 67 Niro Soavi S.p.A 3.7.1.2 CLEANING The part in contact with the product is normally cleaned during the machine washing (C.I.P.). CAUTION: it is ALWAYS necessary to disassemble the valve from the compression head and clean it manually, especially the valve seat and the discharge pipe, after any overpressure relief valve discharge.
Page 68 Niro Soavi S.p.A 3.7.4 COMPRESSION HEAD GUARD The compression head is provided with an additional guard to protect the operator from any projection of machine parts, from high temperatures possibly reached by the head and from any injury caused by protruding, sharp parts. WARNING: The machine should not be used if the guard is not correctly secured in place.
Page 69: Troubleshooting
Niro Soavi S.p.A 3.8. TROUBLESHOOTING This chapter lists the most frequent problems which are likely to be encountered during the machine operation, their possible causes and remedies in order to restore normal working conditions. If the failure persists, or does not appear among those listed below, our Service Department will be pleased to give you the advice and means required to achieve the best possible results.
Page 70 Niro Soavi S.p.A TROUBLE POSSIBLE CAUSE REMEDY • • 3. Reduced flow rate slipping belts provide correct belts tension (Section 4 - MAINTENANCE) • low main motor speed • verify the correct motor speed (Section 1 – TECHNICAL SPECIFICATIONS) • •...
Page 71 Niro Soavi S.p.A TROUBLE POSSIBLE CAUSE REMEDY • • 7.Vibrations of the the machine is not check the machine machine properly supported by level adjusting the feet all feet height • • not enough feeding feed properly the pressure machine (see Section 1 –...
Page 72 Niro Soavi S.p.A TROUBLE POSSIBLE CAUSE REMEDY • • 10.Total lack of Not enough flow See trouble point 3 homogenizing pressure • • Damaged Check, clean or homogenizing valve replace (Section 4 - MAINTENANCE) • • No air pressure in Check the pneumatic pneumatic circuit circuit and the air supply...
Page 73 Niro Soavi S.p.A TROUBLE POSSIBLE CAUSE REMEDY • • 12.Fluctuating Air or bubbles in the Remove air or homogenizing pressure product bubbles • • Air into the Release pressure, compression head then apply pressure again • • Not enough or Feed properly the unsteady feeding machine...
Page 74 Niro Soavi S.p.A TROUBLE POSSIBLE CAUSE REMEDY • • 14.Oil level drops Leakage in the Check the plant and quickly lubricating circuit look for leakage, replace gaskets, tighten joints, replace the oil cooler • • 15.White foam in the Water into the oil Stop the machine for lubricating oil at least 1 hour and drain...
Page 75 Niro Soavi S.p.A TROUBLE POSSIBLE CAUSE REMEDY • • 18.Not enough oil Leakage on the Check the oil circuit, pressure and lubricating circuit replace gaskets and intervention of pressure tighten joints switch • • Low oil level Restore correct oil level •...
Page 76 Niro Soavi S.p.A 3.9. SPECIAL FEATURES OF NON STANDARD MACHINES BLANK PAGE Ricerca Guasti - 21.2...
Page 77 Niro Soavi S.p.A SECTION 4 MAINTENANCE - INDEX 4.1. GENERAL INFORMATION 4.2. ORDINARY MAINTENANCE 4.3. TIGHENING BOLTS AND STUDS 4.4. COMPRESSION HEAD 4.5. HOMOGENIZING GROUP 4.6. OVERPRESSURE VALVE AND PRESSURE GAUGE 4.7. TRANSMISSION 4.8. POWER END - CRANKCASE 4.9. LUBRICATION 4.10.
Page 78 Niro Soavi S.p.A 4.1. GENERALS This Section contains the necessary information to maintain your machine in perfect operating conditions. The steps described are easy to follow and normally do not require the back-up of a qualified technician. However, NIRO-SOAVI Customer Service will be glad to provide the necessary supplements of information and means to reach the target quickly and effectively and to dispatch its technicians for on-the-spot assistance or as part of a Planned Maintenance Service;...
Page 79 Niro Soavi S.p.A 4.2. ORDINARY MAINTENANCE OPERATIONS Here below are the tables showing the periodical maintenance required by the machine to operate efficiently and safely. Values shown refer to a normal use of the machine; heavy-duty conditions or particularly abrasive/aggressive products may reduce sensibly the life of some parts, which should therefore be checked more frequently.
Page 80 Niro Soavi S.p.A PERIODICAL MAINTENANCE TABLE – GENERIC FOR ALL MACHINES When Action required Machine hrs • Check belt tensioning After first start- • replace lubrication oil • replace lubrication filter • check oil level and top up and if needed Every day •...
Page 81 Niro Soavi S.p.A When Action required Mach. Operator Date (hrs) • change lubrication oil 4500 • clean/replace filters (lubrication system, pneumatic system, water system) • check drive belt wear, tensioning and if required replace • check wear of plungers and if required replace •...
Page 82 Niro Soavi S.p.A When Action required Mach. Operator Date (hrs) • change lubrication oil 13500 • clean/replace filters (lubrication system, pneumatic system, water system) • check drive belt wear, tensioning and if required replace • check wear of plungers and if required replace •...
Page 83 Niro Soavi S.p.A ORDINARY MAINTENANCE LOG When Action required Mach. Operator Date (hrs) 4c010e0c.doc 4.2.5...
Page 84 Niro Soavi S.p.A 4.3. TIGHTENING NUTS AND STUDS All the studs used in the compression head are subject to vibrating stress so, in addition to being made of special, highly resistant material with an accurate processing cycle, they require specific tightening in accordance with the values shown in Table 4.3.1.
Page 85 Niro Soavi S.p.A ATTENTION: The head maintenance operations require disassembling the parts which are secured by studs and nuts. When tightening them, refer to the torque values shown in Table 4.3.1 to avoid imposing abnormal stress and undermining their strentgh. CAUTION: For safety reasons it is strictly forbidden to replace studs in the high-pressure head with non-original spare parts, which might not be able to stand the stress applied resulting in severe risk of injury!
Page 86 Niro Soavi S.p.A 4.4. COMPRESSION HEAD (MULTI-BLOCK VHP) ATTENTION: The compression head maintenance operations require to remove the head guard, unscrewing the side screws. The machine should not be used if the guard is not correctly secured in place. ATTENTION: The head maintenance operations require disassembling the parts which are secured by stud bolts and nuts.
Page 87 Niro Soavi S.p.A 4.4.1 PUMPING PLUNGERS The plungers normally supplied for very high pressure heads (VHP) are made of solid ceramic. This gives them high surface hardness and excellent resistance to wear, for longer life of plunger gaskets. The ceramic material used is compatible with most of the washing methods normally used;...
Page 88 Niro Soavi S.p.A CAUTION: it is important to periodically and regularly check tightness of both plunger and plunger extension, whether with threaded connector or clamp, to make sure that they will not loosen or disconnect during machine operation, with consequent breakage of the plungers or of other machine parts.
Page 89 Niro Soavi S.p.A In the VHP high-pressure head the plunger gaskets are housed inside removable flanges which can be accessed from the read of the head, inside the water sump. For complete disassembly instructions see paragraph 4.4.2. 4.4.1.2 ASSEMBLING CAUTION: The ceramic plungers fixed by clamps do not have a specific direction for assembly, and can be mounted from either end.
Page 90 Niro Soavi S.p.A CAUTION: During assembly make sure that the plunger and clamp are fixed in the correct position, and that the various clamps do not interfere with one another during alternating plunger movements. We therefore suggest that you rotate the drive pulley by hand to verify that plunger movement is correct.
Page 91 Niro Soavi S.p.A 4.4.2 PLUNGER SEALS The lifetime of these parts is dependent on the following factors: Working pressure conditions of plungers surface; process temperature; type of product; machine underfeeding (not enough feeding pressure, see Section 1 – TECHNICAL SPECIFICATIONS for reference); worn out parts (washers, spacers) in contact with the seals.
Page 92 Niro Soavi S.p.A 4.4.2.1 DISASSEMBLING Plunger gaskets are housed inside the flanges located in the rear part of the head, so disassembly must be carried out through the part of the sump behind the head. CAUTION: To carry out maintenance FIRST remove the packing of the middle plunger (for machines with 3 plungers;...
Page 93 Niro Soavi S.p.A FIGURE 4.4.3 FIGURE 4.4.3 4C042E0C.DOC 4.4.8...
Page 94 Niro Soavi S.p.A 4.4.2.2 ASSEMBLING For assembly refer to figure 4.4.4, which shows how to assemble the elements which make up the plunger packing: • prepare the rings (H) which are supplied ready cut and preformed • insert the rings in the flange which contains the packing (F) as specified below •...
Page 95 Niro Soavi S.p.A • Install the o-ring (P – figure 4.4.3) or, where used, the antiextrusion (R) ring on the front of the flange (F) • Insert the pre-assembled packing on the studs, check position against centering dowels • Tightent the nuts diagonally (N) •...
Page 96 Niro Soavi S.p.A CAUTION: The components to be removed (suction manifold, flanges, delivery manifold) are heavy. You need to wear personal protection devices such as safety boots and gloves, and use suitable lifting gears. The weight of the components can be calculated by assuming a specific weight of approximately 8 kg/dm3.
Page 97 Niro Soavi S.p.A FIGURE 4.4.6 4.4.3.2 ASSEMBLING To mount the valve assemblies refer to figures 4.4.5 and 4.4.6 (as an alternative). • Carefully place the o-rings (H + N + F) and the relative anti-extrusion rings (L + P + G) in the slots provided, if necessary use food-grade vaseline to hold them in position •...
Page 98 Niro Soavi S.p.A • Position the delivery manifold, and tighten the nuts using the torque values specified in table 4.3.1. When tightening proceed gradually through ALL the nuts and tighten them in circle with all the other parts of the head in place. •...
Page 99 Niro Soavi S.p.A 4.5. HOMOGENIZING GROUP 4.5.1 HOMOGENIZING VALVE The homogenizing valve consists of 3 parts (figure 4.5.1): - lower head or passage head (A) - impact head (B) - impact ring (C). The homogenizing effect occurs - at very high speed - during the passage between the exposed surfaces of the two heads, and is completed by the impact with the external ring.
Page 100 Niro Soavi S.p.A When the grooves reach the external diameter, the homogenizing efficiency collapses, therefore the component should be replaced either when the grooves cover nearly 3/4 of the useful surface or whenever a reduced homogenizing efficiency is noticed. In some cases, because of extreme wear of the parts, the homogenizing pressure cannot be achieved anymore, therefore the complete homogenizing valve must be replaced.
Page 101 Niro Soavi S.p.A 4.5.2 HOMOGENIZING GROUP Follow the below listed instructions for the ordinary maintenance of the pneumatic actuated homogenizing group. DISASSEMBLING Taking figure 4.5.2 as reference: − disconnect the line of the pneumatic-hydraulic control of the piston on the front panel of the machine CAUTION: oil dripping may occur when disconnecting the pipes of the pneumatic-hydraulic system: provide a container to collect such oil and...
Page 102 Niro Soavi S.p.A FIGURA 4.5.2 − Disassemble from the bottom the valve group parts (see details in picture 4.5.3): passage head spacer (Y), passage head (V) and impact ring (U) − The above mentioned items are assembled into an housing (D) −...
Page 103 Niro Soavi S.p.A ASSEMBLING CAUTION: the homogenizing assembly is normally subject to high pressure and temperature conditions which impose a considerable stress on the seal gaskets. To ensure a correct operation and avoid product leakage or product contamination, it is recommended to replace all gaskets every time that the homogenizing group is disassembled.
Page 104 Niro Soavi S.p.A − Insert the spacer (Y) complete with Oring gaskets (Z, W) and antiextrusion rings (C, A), if present − Slide the homogenizing chamber on the studs towards the compression head, taking care of the Oring (Z) and of the antiextrusion ring (A) to avoid they can come out of position Prepare for assembling the impact head shaft (S) and its guide (H) (figure 4.5.2):...
Page 105 Niro Soavi S.p.A 4.5.3 POSSIBLE CONFIGURATIONS FOR THE HOMOGENIZING VALVE A characteristic of the homogenizing assembly is that homogenizing valves of different sizes can be installed in the same valve housing. In particular, with reference to figure 4.5.4, the impact head (G) is made as one single element with relative shaft.
Page 106 Niro Soavi S.p.A The pneumatic actuator cylinder, used to close the homogenizing valve and achieve homogenizing pressure, is connected in the bottom part to an hydraulic/pneumatic system for dampening pulsations. The presence of air in the bottom part of the pneumatic cylinder may cause incorrect operation of the dampening system resulting in abnormal noise level and vibrations of the homogenizing valve, particularly if the machine operates with two homogenizing stages.
Page 107 Niro Soavi S.p.A 4.6. OVERPRESSURE VALVE AND PRESSURE GAUGE 4.6.1 OVERPRESSURE VALVE The pressure relief valve (see SECTION 3 - Paragraph 3.7.1) is usually installed on the compression head or on the high-pressure delivery line to protect the machine and operators from accidental overpressure which can create risk of danger.
Page 108 Niro Soavi S.p.A the flange (F) will normally be separate from the beat due to the spring preloading; to disassemble it you need to gradually loosen the nuts (G) on the studs (H) until the valve is fully locked For futher information on operation of the overpressure valve see paragraph 3.7.1.
Page 109 Niro Soavi S.p.A FIGURE 4.6.1 4c063e0c.doc 4.6.3...
Page 110 Niro Soavi S.p.A 4.6.2 PRESSURE GAUGE The pressure gauge installed on the machine is a component of fundamental importance as it makes it possible to measure the machine’s operating pressure and thus keep its operation under control. With a faulty pressure gauge the required working pressure cannot be maintained, so we recommend you keep a spare pressure gauge in stock in case a replacement is needed.
Page 111 Niro Soavi S.p.A Refer to figure 4.6.2: to disassemble the pressure gauge (or pressure gauge with transmitter, or pressure transducer) you need to loosen the nuts (G) and pull out the pressure gauge complete with flange (F). The pressure gauge (A) and flange (F) can be separated once the semi-rings (D) have been removed.
Page 112 Niro Soavi S.p.A insert the anti-extrusion ring (C), if used, on the manometer; this ring is used in high-pressure versions from 600 bar upwards insert the flange (F) on the pressare gauge body (A) and fit the two semi- rings (D) to hold the flange in position insert the pressure gauge prepared in this way into its housing, and place the flange (F) on the studs (H) screw the nuts on (G) by hand before tightening them fully.
Page 113 Niro Soavi S.p.A In high-pressure versions, equipped with transducer (T) or digital pressure gauge (M) (see figure 4.6.4), a threaded locking ring (D) is used. FIGURE 4.6.4 For disassembly, unscrew the ring (D) and pull the instrument out; remove also the gasket (B) and anti-extrusion rings (A, C) from their housing.
Page 114 Niro Soavi S.p.A The digital pressure gauge (M) will switch off automatically after a few minutes if no pressure is measured, to preserve the internal battery. To start the pressure gauge simply press the front ZERO/ON push-button; keep this button pressed for a few seconds to reset the instrument to ZERO if the reading given is NEGATIVE.
Page 115 Niro Soavi S.p.A 4.7. TRANSMISSION The machine is equipped with a drive system consisting in: − pivot-mounted parallel-axle reduction gear, fitted on the machine’s crankshaft; − pulley and V-belt drive between main motor and reduction gear. CAUTION: All inspection and maintenance operations must be carried out with the MACHINE NOT IN OPERATION;...
Page 116 Niro Soavi S.p.A 4.7.1 REDUCTION GEAR The reduction gear does not require special maintenance precautions; you only need to check the level of lubricating oil through the inspection hole in the casing. It is good maintenance practice to protect the seal rings with waterproofing lubricating grease, and to protect the locking system on the shaft from the effects of oxidation which would make it difficult to disassemble the reduction gear, if necessary.
Page 117 Niro Soavi S.p.A LUBRICATION OIL The type of oil to be used depends on the temperature range where the machine is installed; for normal operating conditions (temperature range +5 ÷ +40 °C) use MINERAL OIL with viscosity ISO VG 220 with EP additives, suitable for use with gears, as specified in Table 4.7.1.
Page 118 Niro Soavi S.p.A OIL CHANGE INTERVALS When the machine is started up for the first time a test run of approximately 500 hours must be made; oil must be changed after the first 500 hours. After that oil must be changed every 5000 hours if using MINERAL OIL or 20000 hours if using SYNTHETIC OIL.
Page 119 Niro Soavi S.p.A ALIGNMENT CHECK Correct alignment is essential to ensure long-life of the drive belts. This operation must be carried out during assembly by skilled personnel: it is important to check alignment by placing a metal ruler on the 2 pulleys (fig.4.7.2). FIGURE 4.7.2 If necessary alignment can be corrected by loosening the retaining bolts of the conic bush and slightly move the driven pulley (by a few mm.) to reach optimal...
Page 120 Niro Soavi S.p.A ASSEMBLY OF THE BELTS In NIRO SOAVI machines equipped with reduction gear (figure 4.7.3, item C) the motor that carries the driving pulley is fixed to the support plate while the reduction gear is fixed to the pivot-mounted crankshaft. An adjustable tie rod makes it possible to change the distance between the driving pulley and the driven one to allow installation and tensioning of the driving belts.
Page 121 Niro Soavi S.p.A 4.7.3 STRETCHING THE BELTS WARNING: Control and servicing operations must be carried out WITH THE MACHINE NOT IN OPERATION and with the sectioning switch of the imput line LOCKED (by means of a lock) IN OPEN POSITION for the safety of the personnel.
Page 122 Niro Soavi S.p.A BELTS TENSIONING – FIRST METHOD Before stretching the belts assembled on the pulleys, trace two fine marks across the back of one belt and measure the distance between them; they should be as far from each other as possible but must remain on the straight-line of the belt. Stretch the belts gradually after having them rotate for approx.
Page 123 Niro Soavi S.p.A FIGURE 4.7.5 Forza / Force P (Newton) Tipo / Type D (mm) V = 0÷10 m/s V = 10÷20 m/s V = 20÷30 m/s 67÷95 12 – 18 10 – 16 8 - 14 > 95 19 – 26 17 –...
Page 124 Niro Soavi S.p.A 4.7.4 MAINTENANCE OF BELTS The belt drive is an efficient, reliable means for power transmission. The following are some simple instructions to ensure reliability and long life of the system. LOOK AND LISTEN This allows you to easily identify the defects to be corrected: - Visual check if any oil or grease is present on the belts, since this may cause premature deterioration;...
Page 125 Niro Soavi S.p.A TENSIONING Check and maintain the correct stretch of the belts, to prevent irregular vibrations. EXPOSURE TO HEAT Check that the belts are not exposed to sources of heat; an exposure to temperatures greater than 60°C will shorten their life. WEAR Check the condition of the sides of the belt: an anomalous wear may cause slipping or excessive wear of the grooves of the pulleys.
Page 126 Niro Soavi S.p.A 4.7.5 ASSEMBLING AND DISASSEMBLING OF PULLEYS Drive pulleys are usually mounted both on the input shaft of the reduction gear and on the motor shaft using a “Taper-Lock” conical bushings. With reference to figure 4.7.6, the procedure for disassembly is the following: FIGURE 4.7.6 loosen retaining screws A use one of the screws in bore B to force the bush open...
Page 127 Niro Soavi S.p.A 4.8. POWER END - CRANKCASE The reciprocating linear motion of the plungers is created by an oversized and sturdy crank mechanism (crankshaft, connecting rod, crosshead). The system is illustrated in the general exploded view (figure 4.8.1) below. FIGURE 4.8.1 The type of construction, the high-quality materials used and the careful assembly by highly-qualified personnel are a guarantee of excellent reliability and...
Page 128 Niro Soavi S.p.A Under normal working conditions and without specific faults, it is recommended to check the sleeve bearings (W) and crank pin bearings (S), the wrist pin (O) and its bearing on the conrod (R) at least every approx 10.000 hours of operation, and to check the roller bearings (B) of the crankshaft at least every 20.000 hours of operation.
Page 129 Niro Soavi S.p.A 4.8.1 REPLACING GUIDE PLUNGER GASKETS Before removing the flanges you need to drain out, at least partially, the oil inside the body to prevent accidental spillage. Refer to figure 4.8.2 for the assembly and disassembly procedures described below.
Page 130 Niro Soavi S.p.A In some models a rubber bellows is installed to protect the guide plunger stem. In this case the bellows must be removed to replace the gaskets, and then inserted onto the guide plunger stem (Q) and snapped on locked against the flange (M) in the seat provided.
Page 131 Niro Soavi S.p.A 4.9. LUBRICATION Proper machine lubrication is required to guarantee its correct operation. For this reason it is absolutely necessari to follow directions for oil change intervals (see Charter 4.2), the cleaning or replacement of filters, check of oil level and use of specified lubricating oil.
Page 132 Niro Soavi S.p.A Any type of oil used should have the following specifications: Suitable for hydraulic circuits, of mineral origin, viscosity ISO VG 150 (150 cSt at 40°C) with non-foaming, antioxidative additives, etc. Class: ISO VG 150 DIN 51524-2-HLP BRAND TYPE BRAND TYPE...
Page 133 Niro Soavi S.p.A 4.9.1 FORCED LUBRICATION WITH MOTOR-DRIVEN PUMP Forced lubrication is by means of a lubrication unit (CONTROL UNIT) with separate electric motor, which makes it possibile to have adeguate flow of lubrication oil and pressure even when the rotation speed of the crankshaft is low (variable load machine).
Page 134 Niro Soavi S.p.A FIGURE 4.9.1 4c091e0c.doc 4.9.4...
Page 135 Niro Soavi S.p.A OIL LEVEL CHECK The oil level needs to be checked every day, before the machine is started; the oil should reach the level indicated on the sightglass located or inside the machine on the crankcase or on the machine front panel. The oil level must be checked with the machine stopped for at least 1 hour.
Page 136 Niro Soavi S.p.A PRESSURE CHECK The pressure gauge located on the front panel is used to measure the pressure in the lubricating circuit. During the final machine test optimal lubrication pressure is calibrated under steady operating conditions; this value is largely affected by oil viscosity and temperature so when the machine is started pressure is usually high and then tends to decrease and become stable as the machine warms up with operation.
Page 137 Niro Soavi S.p.A ATTENTION: If the pressure level is too high the circuit may be damaged, particularly during cold starts: oil viscosity problems can lead to damage in the delivery oil filter and motor overload triggering the electric protection devices. When adjusting pressure you need to take into account ambient conditions and the temperature of cooling water.
Page 138 Niro Soavi S.p.A VAPOUR CONDENSATE DISCHARGE Inside the crankase it is possible to have condensation of vapours depending on the characteristics of the ambient where the machine is working in, therefore it is necessary to remove regularly the condensate to avoid any mixing with lubricating oil.
Page 139 Niro Soavi S.p.A The intake filter housed inside the oil tank does not have a built-in by-pass. If the filter clogs up the pressare drop through the filter will increase leading to cavitation of the gear pump and pressure switch action. Cleaning frequency is given in the “Table of Periodical Maintenance”, Chapter 4.2.
Page 140 Niro Soavi S.p.A 4.10. PNEUMATIC PLANT Machines provided with pneumatic control system of the homogenizing pressure are supplied with specific hydraulic dampening system of the homogenizing valve. The force required to close the homogenizing valve and consequently achieve the homogenizing pressure is applied through a pneumatic actuator using compressed air on its upper part;...
Page 141 Niro Soavi S.p.A FIGURE 4.10.1 The components present on the circuit accordino to the scheme presented in figure 4.10.1 are: Inlet air pre-treatment unit (A) with pressure gauge (B) One pneumatic switch (C) (or as option a solenoid valve) to give pressure to the actuator (G) One manual pressure regulator (D) (or as option a proportional valve for remote controls...
Page 142 Niro Soavi S.p.A vibrations and resonance, which may cause reduction of homogenizing efficiency and can be dangerous for the machine itself. Ordinary maintenance operations are listed below: Check regularly the oil level inside the damper tank through the sightglass Check regularly into the damper tank the correct pressure value: must be 0,5 bar with machine stopped In case refilling of oil is required, close the valve (J) and open slowly the upper filling plug (there is pressure inside);...
Page 143 Niro Soavi S.p.A CAUTION: Used oils are extremely harmful to environment and should be disposed of correctly, in accordance with the local regulations. Class: ISO VG 32 DIN 51524-2-HLP BRAND TYPE BRAND TYPE Agip Oso 32 Texaco Rando oil HP 32 Hydrus Oil 32 Gulf Harmony 32 AW...
Page 144 Niro Soavi S.p.A 4.10.2 PNEUMATIC PLANT WITH REMOTE PRESSURE ADJUSTMENT The pneumatic plant with remote pressure adjustment is using a proportional valve (or I/P converter) to ad just the homogenizing pressare. This proportional valve requires a suitable ramp signal on a 4÷20 mA scale; the signal must be isolated and amplified, with electrical connection to the proportional valve accordino to the following diagram shown in figure 4.10.3.
Page 145 Niro Soavi S.p.A The proportional valve is tested and calibrated durino the machine test run. The setting is related to the range of pneumatic signal output related to the electrical signal input; in case of need it is possible to modify the factory settings by adjusting the “ZERO”...
Page 146 Niro Soavi S.p.A 4.11. ASEPTIC PLANT Machines in aseptic version are equipped with a circuit for the distribution of sterile condensate used to flush the plunger aseptic chambers and the stem of the homogenizing valve in order to prevent external contamination. The distribution circuit and its components do not usually require maintenance;...
Page 147 Niro Soavi S.p.A during the final machine test so we recommend you do not change these settings. FIGURE 4.11.1 These valves (N) can be used to adjust the backpressure inside the exchanger (E), measured by the pressure gauge (K); to ensure proper operation of the exchanger it should be set to 1÷2 bar.
Page 148 Niro Soavi S.p.A With reference to figure 4.11.2, the parts that need to be replaced are gaskets (P) and (S) and any guide rings (T, U). To remove the gaskets you need to disassemble the plungers and remove any sealing elastic rings not shown in the drawing; refer to the exploded view in SECTION 5 –...
Page 149 Niro Soavi S.p.A SECTION 5 SPARE PARTS CATALOGUE - INDEX 5.1. HOW TO USE THE SPARE PARTS CATALOGUE 5.2. HOW TO ORDER SPARE PARTS 5.3. RECOMMENDED SPARE PARTS 5.4. MAINTENANCE BOX 5.5. SPARE PARTS LISTS AND ASSEMBLY DRAWINGS 5C001E0C.DOC 5.1.0...
Page 150 Niro Soavi S.p.A 5.1. HOW TO USE THE SPARE PARTS CATALOGUE To ensure that effective operation and quality characteristics are maintained only original spare parts must be used on NIRO SOAVI machines. The use of non original spare parts shall instantly invalidate the guarantee.
Page 151 Niro Soavi S.p.A 5.2. HOW TO ORDER SPARE PARTS Spare parts can be ordered directly from NIRO SOAVI, Service Department, or through your local NIRO SOAVI agent or Authorized Dealer, who can provide useful advice and forward your request immediately. When placing an order please specify: •...
Page 152 Niro Soavi S.p.A NIRO SOAVI ORIGINAL SPARE PARTS INQUIRY FORM Fax No. From: Name: Reply Fax No. e-mail: Model: Serial No. ! QUOTATION URGENT ORDER No. Part CODE Description Shipping Specs. 5C001E0C.DOC 5.2.2...
Page 153 Niro Soavi S.p.A 5.3. RECOMMENDED SPARE PARTS In order to limit the number of shutdowns during production, and the time required for maintenance of the machine, we recommend you stock a set of spare parts to replace elements which are normally subject to wear. The number of spare parts to be stocked will depend on production needs and on how important it is to avoid long shutdowns due to unavailable spare parts.
Page 154 Niro Soavi S.p.A NIRO SOAVI - CHECKLIST FOR MACHINE INSPECTION Machine Type : Serial Number : Working Hours : Date : Checke Replace Checke Replace 1 Compression head 34 Transmission 2 Suction Valves 35 Main motor 3 Suction Springs 36 Auxiliary motors 4 Suction valve seats 37 Gear box 5 Delivery Valves...
Page 155 Niro Soavi S.p.A 5C001E0C.DOC 5.3.3...
Page 156 Niro Soavi S.p.A 5.4. MAINTENANCE BOX The machine is supplied complete with a set of spanners and tools to be used during ordinary maintenance; they include special tools for installing or removing plungers and packings, where required. The set of spanners DOES NOT INCLUDE a Torque Wrench, which is recommended for correct tightening of nuts and studs to the torque values given in Section 4 - MAINTENANCE.
Page 157 Niro Soavi S.p.A. Item Description Description Qty Part Code CHIAVE COMB 10X10 MIXED WRENCH 10X10 810210 CHIAVE COMB 19X19 MIXED WRENCH 19X19 810219 CHIAVE COMB 24X24 MIXED WRENCH 24X24 810224 CHIAVE COMB 36X36 MIXED WRENCH 36X36 810236 CHIAVE ESAGONALE AD " L " 5 EXAGONAL KEY "...
Page 158 Niro Soavi S.p.A 5.5. SPARE PARTS LIST AND ASSEMBLY DRAWINGS You will find attached assembly drawings and a list of components and spare parts. The first code of each spare parts list indicates the assembly drawing which the components refer to. 5C001E0C.DOC 5.5.1...
Page 159 Rev.0 Item Description Description Qty Part Code ASSIEME ASSEMBLY DRAWING 0132870-3 PIASTRA PLATE 0134657-2 CODICE NON PRESENTE NOT EXISTING CODE ASSIEME ASSEMBLY DRAWING 0134662-1 FLANGIA FLANGE 0134649-2 ORING ORING 140024PU PRIGIONIERO STUD 0118069 DADO 760011 PRIGIONIERO STUD 0133351 DADO 760019 BLOCCHETTO BLOCK 0134617-2...
Page 161 Rev.0 Item Description Description Qty Part Code ASSIEME ASSEMBLY DRAWING 0132876 ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 0134692 ORING ORING 140029PU CONTENTITORE SEDE VALVOLA VALVE SEAT HOUSING 0134629-2 SEDE VALVOLA VALVE SEAT 0134628 SFERA BALL 190064 MOLLA SPRING 0122300-1 COPERCHIO VALVOLA VALVE COVER 0133248-2 ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING...
Page 163 Rev.0 Item Description Description Qty Part Code ASSIEME ASSEMBLY DRAWING 0128496-3 PISTONE PLUNGER 0124559-060 MORSETTO CLAMP 0133638 PROLUNGA EXTENSION 0134656 VITE SCREW 69TE6X20 SPARES_4759 .xls PLUNGER GROUP...
Page 165 Rev.0 Item Description Description Qty Part Code ASSIEME ASSEMBLY DRAWING 0134662-1 RONDELLA WASHER 0133837 PACCHETTO PACKING 41511CX201 RONDELLA WASHER 0134661 SPARES_4759 .xls PACKING GROUP...
Page 167 Rev.0 Item Description Description Qty Part Code ASSIEME ASSEMBLY DRAWING 0123557-4 ORING ORING 140033VF FLANGIA FLANGE 0134650 CAMERA ASETTICA ASEPTIC CHAMBER 0134652 ORING ORING 140166VF ORING ORING 140205VF VITE SCREW 69TCE6X20 SPARES_4759 .xls ASEPTIC CHAMBER...
Page 169 Rev.0 Item Description Description Qty Part Code ASSIEME ASSEMBLY DRAWING 0124219 TRASMETTITORE TRANSMITTER 320127 RONDELLA WASHER 0123486 FLANGIA FLANGE 0133649 ORING ORING 130031S ORING ORING 140393VF PRIGIONIERO STUD 0126273 DADO 760011 SPARES_4759 .xls MANOMETER GROUP...
Page 171 Rev.0 Item Description Description Qty Part Code ASSIEME ASSEMBLY DRAWING 0130259 SEDE VALVOLA VALVE SEAT 0130260-2 ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 0127432-9 ORING ORING 140013VF ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 0127432-9 SFERA BALL 190009 ALBERINO SHAFT 0130261-3 ORING ORING 140030 ANELLO ELASTICO SNAP RING 210030 ORING...
Page 173 Rev.0 Item Description Description Qty Part Code ASSIEME ASSEMBLY DRAWING 0132469 CAMERA OMOGENEIZZANTE HOMOGENEIZING CHAMBER 0132470-2 ANELLO RING 0132321-2 ORING ORING 140027VF ORING ORING 140022VF ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 0130176 ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 0130982 TESTINA DI PASSAGGIO PASSAGE HEAD 0128428 ANELLO DI URTO IMPACT RING...
Page 175 Rev.0 Item Description Description Qty Part Code ASSIEME ASSEMBLY DRAWING 0134555 CORPO DI TRASMISSIONE TRANSMISSION BODY 0134364 ALBERO A GOMITI CRANKSHAFT 0134519 CUSCINETTO BEARING 220155 SUPPORTO SUPPORT 0134541 VITE SCREW 70TE12X35 ORING ORING 140237 FLANGIA FLANGE 0134537 GUARNIZIONE GASKET 180073 BRONZINA BRONZE BEARING 0133610...
Page 177 Rev.0 Item Description Description Qty Part Code ASSIEME ASSEMBLY DRAWING 0134567 MOTORE MOTOR MB4117B1T RIDUTTORE GEARBOX 340064 RONDELLA WASHER 0131627 ANELLO ELASTICO SNAP RING 210045 VITE SCREW 70TSPEI14X45 OLIO 530016 PERNO CONNECTION 0134012 ANELLO ELASTICO SNAP RING 210074 BOCCOLA BUSHING 260530 FLANGIA FLANGE...
Page 179 Rev.0 Item Description Description Qty Part Code ASSIEME ASSEMBLY DRAWING 0130586-15 ORING ORING 140205VF FLANGIA FLANGE 0134697-2 VITE SCREW 69TE12X30 CODICE NON PRESENTE NOT EXISTING CODE CODICE NON PRESENTE NOT EXISTING CODE CODICE NON PRESENTE NOT EXISTING CODE ORING ORING 140335VF ANELLO RING...
Page 181 Rev.0 Item Description Description Qty Part Code ASSIEME ASSEMBLY DRAWING 0134204-4 FLANGIA FLANGE 0134698-2 ORING ORING 140205VF CODICE NON PRESENTE NOT EXISTING CODE CODICE NON PRESENTE NOT EXISTING CODE CODICE NON PRESENTE NOT EXISTING CODE VITE SCREW 69TE16X40 SPARES_4759 .xls OUTLET FLANGE GROUP...
Page 183 Rev.0 Item Description Description Qty Part Code ASS. IMPIANTO PNEUMATICO PNEUMATIC PLANT ASS.DRW 0133613-1 NIPPLO NIPPLE 261148 RONDELLA WASHER 680044 RIDUTTORE PRESSIONE PRESSURE REDUCER 390250 MANOMETRO MANOMETER 320081 DISOLEATORE MIST SEPARATOR 390251 BLOCCHETTO BLOCK 260250 CODICE NON PRESENTE NOT EXISTING CODE REGOLATORE DI PRESSIONE PRESSURE REGULATOR 390270...
Page 185 Rev.0 Item Description Description Qty Part Code ASS. IMPIANTO DI LUIBRIFICAZIONE LUBRICATION PLANT ASS. DRW. 0133377 CENTRALINA LUBRICATION UNIT 260456 MOTORE MOTOR MB4405A1 FILTRO FILTER 230009 CARTUCCIA FILTRO FILTER CARTRIDGE 230002 SCAMBIATORE HEAT EXCHANGER 360034-1 MANOMETRO MANOMETER 320360 PRESSOSTATO PRESSURE SWITCH EF0043 TAPPO PLUG...
Page 187 GEA Niro Soavi S.p.A. 14/06/2001 - Rev. 1.2 Description Code NIRO - SOAVI TT - 0100 Lubricating Unit TP3 Type NSOA Code OR TP3A-GR1-6,1 260454 Description Lubricating unit with gear type oil pump (displacement 6,1 cm3/rev), adjustable bypass valve to regulate the operating pressure, suction side filter and oil tank, volume 8 L.
Page 189 Rev.0 Item Description Description Qty Part Code ASS. IMPIANTO DELL'ACQUA WATER PLANT ASS.DRW. 0133601-22 FILTRO FILTER 230131 RONDELLA WASHER 680045 NIPPLO NIPPLE 260162 VALVOLA VALVE 580016 VALVOLA VALVE 580016 CODICE NON PRESENTE NOT EXISTING CODE PORTAGOMMA HOSE COUPLING 260001 TUBO PIPE 790009 PORTAGOMMA...
Page 191 Rev.0 Item Description Description Qty Part Code IMPIANTO ASETTICO ASEPTIC PLANT 0134719 TRONCHETTO FERRULE 0134757 FLUSSOSTATO FLOW SWITCH EFB039 RIDUZIONE REDUCTION 0134758 RACCORDO CONNECTION 260721/1 RIDUZIONE REDUCTION 0134759 TRONCHETTO FERRULE 0134750-2 CURVA CURVE 0134767 NIPPLO NIPPLE 0134768 GUARNIZIONE GASKET 140013VF GUARNIZIONE GASKET 140173VF...
Page 193 Rev. 0 Item Description Description Qty Part Code PISTONE PLUNGER 0124559-060 PACCHETTO PACKING 41511CX201 RONDELLA WASHER 0133837 MOLLA SPRING 0122300-1 SFERA BALL 190064 SEDE VALVOLA VALVE SEAT 0134628 GUARNIZIONE GASKET 180073 ANELLO RASCHIATORE ROD SCRAPER 160107 GUARNIZIONE GASKET 160111 ORING ORING 140237 ORING...
Page 194 Item Description Description Qty Part Code ASSIEME ASSEMBLY DRAWING 0134027 TELAIO FRAME 0134454-9 RONDELLA WASHER 0134463-9 MANIGLIA HANDLE 170007 VITE SCREW 69CR6 GAMBO SHANK 350450 GUAINA PROTECTING COVERING 350451 PANNELLO PANEL 350057 PROTEZIONE PROTECTION 0134614-9 SUPPORTO SUPPORT 0134688-9 PROTEZIONE PROTECTION 0134651 A COMPLETAMENTO FOR COMPLETION...
Page 196 Niro Soavi S.p.A SECTION 6 ELECTRICAL DIAGRAMS - INDEX 6.1. ELECTRICAL DIAGRAMS 6C001E0C.DOC 6.1.0...
Page 197 Niro Soavi S.p.A 6.1. ELECTRICAL DIAGRAMS In the following pages it is possibile to find the wiring diagrams of the electrical devices installed on-board the machine, or as an alternative, the complete electrical diagram of the Electric Power Board if the same or its engineering is supplied by Niro Soavi.
Page 198 COVER SHEET Niro Soavi S.p.A. Electrical Diagram Machine Type: NS3018H Serial Number: 4759 Job: 1/220217 Date: 10.01.03 Client: BAXTER Project: IM 1 Bohumil Cabinet Number: 242 MC 1100 Draw Check Appr. Scale Date Drawing Page Niro-Soavi S.p.A. 10.01.03 Cover Sheet Description Sign.
Page 199 INDEX PAGE Sheet TAG No. Designation Part Place Latest Revision Date Name Description Cover Sheet Cover Index Page Index Revision Page Revision Internal Switchboard Layout Int. View 242MC1100 23.01.03 UPDATE External Switchboard Dim. Ext.View 242MC1100 Holes disposition Ext.View 242MC1100 Bill of Mat. 23.01.03 UPDATE Bill of Mat.
Page 200 REVISION PAGE Sheet Part Place First Revision Second Revision Third Revision Date1 Name1 Description1 Date2 Name2 Description2 Date3 Name3 Description3 Cover Index Revision Int. View 242MC1100 23.01.03 UPDATE Ext.View 242MC1100 Ext.View 242MC1100 Bill of Mat. 23.01.03 UPDATE Bill of Mat. 23.01.03 UPDATE Bill of Mat.
Page 204 ELECTRICAL EQUIPMENT LIST CABINET NUM.:242MC1100 REV 1 23.01.03 Niro-Soavi S.p.A. Specialty Products via M. da Erba Edoari, 29/A Division Serial No.: 4759 ORDER: 1/220217 Pag. 1 di 7 43100 PARMA (ITALY) PHONE : +39.0521.965411 - FAX : +39.0521.242819 ITEM DENOMINATION CODE MANUFACTURER TYPE...
Page 205 ELECTRICAL EQUIPMENT LIST CABINET NUM.:242MC1100 REV 1 23.01.03 Niro-Soavi S.p.A. Specialty Products via M. da Erba Edoari, 29/A Division Serial No.: 4759 ORDER: 1/220217 Pag. 2 di 7 43100 PARMA (ITALY) PHONE : +39.0521.965411 - FAX : +39.0521.242819 ITEM DENOMINATION CODE MANUFACTURER TYPE...
Page 206 ELECTRICAL EQUIPMENT LIST CABINET NUM.:242MC1100 REV 1 23.01.03 Niro-Soavi S.p.A. Specialty Products via M. da Erba Edoari, 29/A Division Serial No.: 4759 ORDER: 1/220217 Pag. 3 di 7 43100 PARMA (ITALY) PHONE : +39.0521.965411 - FAX : +39.0521.242819 ITEM DENOMINATION CODE MANUFACTURER TYPE...
Page 207 ELECTRICAL EQUIPMENT LIST CABINET NUM.:242MC1100 REV 1 23.01.03 Niro-Soavi S.p.A. Specialty Products via M. da Erba Edoari, 29/A Division Serial No.: 4759 ORDER: 1/220217 Pag. 4 di 7 43100 PARMA (ITALY) PHONE : +39.0521.965411 - FAX : +39.0521.242819 ITEM DENOMINATION CODE MANUFACTURER TYPE...
Page 208 ELECTRICAL EQUIPMENT LIST CABINET NUM.:242MC1100 REV 1 23.01.03 Niro-Soavi S.p.A. Specialty Products via M. da Erba Edoari, 29/A Division Serial No.: 4759 ORDER: 1/220217 Pag. 5 di 7 43100 PARMA (ITALY) PHONE : +39.0521.965411 - FAX : +39.0521.242819 ITEM DENOMINATION CODE MANUFACTURER TYPE...
Page 209 ELECTRICAL EQUIPMENT LIST CABINET NUM.:242MC1100 REV 1 23.01.03 Niro-Soavi S.p.A. Specialty Products via M. da Erba Edoari, 29/A Division Serial No.: 4759 ORDER: 1/220217 Pag. 6 di 7 43100 PARMA (ITALY) PHONE : +39.0521.965411 - FAX : +39.0521.242819 ITEM DENOMINATION CODE MANUFACTURER TYPE...
Page 210 ELECTRICAL EQUIPMENT LIST CABINET NUM.:242MC1100 REV 1 23.01.03 Niro-Soavi S.p.A. Specialty Products via M. da Erba Edoari, 29/A Division Serial No.: 4759 ORDER: 1/220217 Pag. 7 di 7 43100 PARMA (ITALY) PHONE : +39.0521.965411 - FAX : +39.0521.242819 ITEM DENOMINATION CODE MANUFACTURER TYPE...
Page 251 CABLES LIST N° Description TAG No. Type Cable From Cabinet Cabinet Power Inlet 2421100-W0 N1VV-K 4x16mm 140MC0001 242MC1100 Main Motor 242P1100-W1 4x10mm 242MC1100 242X1100 SCREENED CABLE Oil Pump Motor 242PO1100-W1 N1VV-K 4x2,5mm 242MC1100 242X1100 Fan on the Motor 242VMP1100-W1 N1VV-K 4x2,5mm 242MC1100 242X1100...
Page 252 THERMAL PROTECTION DEVICES LIST TAG No. Designation Calibration (A) Main Switch 242 P 1100-F1 Main Motor Power Circuits 242 PO 1100-F1 Oil Pump Motor 242 VMP 1100-F1 Cooling Fan Motor 0,24 -FXS TCXS prot. -FXS1 Lamp + Intake Prot. 8 (30mA Diff.) -FXS2 Fluorescent Tube -FXS3...
Page 253: General Data
SWITCHBOARD SPECIFICATION General Data Wall Mounted Painted steel Vertical Stainless steel (inox) Material Type Mounted on the Machine Mounted inside de Mach. Protection Front Side Natural Right Side Forced ventilation Accessibility Cooling Left Side Conditioned Rear Side Heater Exchanger Cables Inlet Dissipated Power Bottom 0,816 kW...
Page 256 Report of all parameter settings Drive type: 5022 Drive bus address: None Date: 29/01/2003 11.38.52 #4759 1/220217 tag 242MC1100 Name Setup 1 Setup 2 Setup 3 Setup 4 Language Italiano Italiano Italiano Italiano Operation site Remote Remote Remote Remote Active setup Setup 1 Setup 1 Setup 1...
Page 257 Name Setup 1 Setup 2 Setup 3 Setup 4 Slip compensat. Slip time const. 0,50 s 0,50 s 0,50 s 0,50 s Resonance damp. 100 % 100 % 100 % 100 % Damp.time const. 5 ms 5 ms 5 ms 5 ms High start torq.
Page 258 Name Setup 1 Setup 2 Setup 3 Setup 4 Torq limit motor 146,2 % 111,9 % 111,9 % 111,9 % Torq limit gener 146,2 % 111,9 % 111,9 % 111,9 % Warn. current lo 0,0 A 0,0 A 0,0 A 0,0 A Warn.
Page 259 Name Setup 1 Setup 2 Setup 3 Setup 4 Relay 1-3 funct. Alarm Alarm Alarm Alarm Relay 1-3 on dl 0,00 s 0,00 s 0,00 s 0,00 s Relay 1-3 off dl 0,00 s 0,00 s 0,00 s 0,00 s Relay 4-5 funct.
Page 260 Name Setup 1 Setup 2 Setup 3 Setup 4 U1 voltage 380,0 V 380,0 V 380,0 V 380,0 V F1 frequency 50,0 Hz 50,0 Hz 50,0 Hz 50,0 Hz U2 voltage 380,0 V 380,0 V 380,0 V 380,0 V F2 frequency 50,0 Hz 50,0 Hz 50,0 Hz...
Page 261 Name Setup 1 Setup 2 Setup 3 Setup 4 Bus jog 2 freq. 10,0 Hz 10,0 Hz 10,0 Hz 10,0 Hz Telegram profile Fc profile Fc profile Fc profile Fc profile Bus timeout time Bus timeout func Reset kwh count Do not reset Do not reset Do not reset...
Page 262 SPEC-E4C Niro-Soavi S.p.A. RUNNING SEQUENCE via M. da Erba Edoari, 29/A 29.01.03 43100 PARMA (ITALY) DATE REV. PHONE : +39.0521.965411 - FAX : +39.0521.242819 4759 1/220217 NS 3018H JOB NIRO SOAVI MACHINE MODEL SIG. SERIAL NO. RUNNING SEQUENCE REGARDING THE SWITCHBOARD SUPPLIED BY THE CUSTOMER NOTE : SET THE FREQUENCY INVERTER TO ACHIEVE THE : 50 Hz...
Page 263 ACTION RESULT INTERVENTION OF THE THERMISTORS ON THE MAIN MOTOR WINDINGS REPEAT THE RESULT OF THE SEQUENCE DESCRIBED AT POINT 4 INTERVENTION OF THE LUBRICATING OIL PRESSURE SWITCH REPEAT THE RESULT OF THE SEQUENCE DESCRIBED AT POINT 4, AFTER 15 SECONDS DELAY INTERVENTION ON THE EMERGENCY STOP PUSHBUTTON REPEAT THE RESULT OF THE SEQUENCE...
Page 267 SITOP Power 10 6EP1434-2BA00 SITOP Power 20 6EP1436-2BA00 SITOP Power 30 6EP1437-2BA00 SITOP Power 40 6EP1437-2BA10 Betriebsanleitung Best. Nr.: C98130-A7500-A1-06-6419 Operating instructions Instructions Istruzioni di servizio Instrucciones SIEMENS AG ÖSTERREICH, 01.2001 SITOP Power 10/20/30/40...
Page 268 Maßbild Dimension drawings Encombrement Disegno quotato Croquis acotado SITOP Power 10 SITOP Power 30 SITOP Power 20 SITOP Power 40 Hinweis Diese Betriebsanleitung enthält aus Gründen der Übersichtlichkeit nicht sämtliche Detailinformationen zu allen Typen des Produkts und kann auch nicht jeden denkbaren Fall der Aufstellung, des Betriebes oder der Instandhaltung berücksichtigen.
Page 269 English WARNING Hazardous voltages are present in certain parts of this electrical equipment during operation.Incorrect handling of the equipment can result in death, severe personal injury or substantial property damage. Only qualified personnel are allowed to work on or around this equipment. The successful and safe operation of this equipment is dependent on proper transport, storage and installation.
Page 271 Druck-Vorschau Pagina 1 di 1 Industry Product Range 5SY6, 6 kA, 70 mm Mounting Depth : 230/400 V, 50-60 Hz, applicable in networks up to: 250/440 V AC, 60 V DC per pole Standards: EN 60 898, DIN VDE 0641 Part 11, IEC 60 898 Additional components can be retrofitted individually.
Page 273: General Specifications
3RV1 circuit breaker 2.7 Technical specifications 2.7.1 General specifications Type 3RV1. 1 3RV1. 2 3RV1. 3 3RV1. 4 Specifications • IEC 60 947-1, EN 60 947-1 (VDE 0660 Part 100) • IEC 60 947-2, EN 60 947-2 (VDE 0660 Part 101) •...
Page 274 3RV1 circuit breaker Type 3RV1. 1 3RV1. 2 3RV1. 3 3RV1. 4 Shock resistance In acc. with IEC 68 Part 2-27 g/ms 25/11 (rectangular and sine pulse) Degree of protection In acc. with IEC 60 529 IP20 IP 20 Shock protection In acc.
Page 275 3RV1 circuit breaker Conductor cross-sections - main circuit Type 3RV1. 3RV1. 2 3RV1. 3 3RV1. 4 Connection type Screw-type terminal Screw-type terminal with box termi- Terminal screw Pozidriv size 2 Pozidriv size 2 Allen screw 4 mm Specified tightening torque 0.8 to 1.2 Nm 2 to 2.5 3 to 4.5...
Page 276 3RV1 circuit breaker Permissible rating of approved devices for North America, u s The circuit breakers in the SIRIUS 3RV1 series are approved for and can also be used in acc. with UL 508 and C22.2 No.14 with a contactor as a load feeder. You can use these circuit breakers as a "Manual Motor Starter" for "Group Fusing" or for "Group Installation" or as a "Combination Motor Controller Type E".
Page 277 3RV1 circuit breaker Permissible rating of approved devices for North America, u s 3RV10.A circuit breaker as "Combination Motor Controller Type E" Since 16.07.2001, 1 inch air clearance and 2 inch creepage distance is required for a "Combination Motor Controller Type E" on the input side with UL 508 The 3RV10 circuit breaker in frame sizes S0 and S3 are therefore approved with the terminal blocks listed below in acc.
Page 278 3RV1 circuit breaker 2.7.2 Rated short-circuit breaking capacity I in acc. with IEC 60 947-2 The table lists the rated limit short-circuit breaking capacity I and the rated service short-circuit breaking capacity I of 3RV1 circuit breakers with different inception voltages and related to the rated current I of the circuit breakers.
Page 279 3RV1 circuit breaker Circuit Rated To 240 VAC To 400 VAC )/415 V To 440 VAC )/460 V To 500 VAC )/525 V To 690 VAC breaker current Max. Max. Max. Max. Max. Fuse Fuse Fuse Fuse Fuse (gL/gG) (gL/gG) (gL/gG) (gL/gG) (gL/gG)
Page 280 3RV1 circuit breaker 2.7.3 Limiter function with standard devices for 500 VAC and 690 VAC in acc. with IEC 60 947-2 The table lists the rated limit short-circuit breaking capacity I and the rated service short-circuit breaking capacity I with an upstream standard circuit breaker that fulfills the limiter function at 500 VAC and 690 VAC.
Page 281 3RT1/3RH1 contactors 3.7 Technical specifications 3 3RT1/3RH1 contactors 3RT10 contactors for switching motors rating data of the contactors Contactor Frame size Type 3RT10 15 3RT10 16 3RT10 17 3RT10 23/24 3RT10 25 3RT10 26 Rated insulation voltage Continuous current at 40 °C Open and enclosed Maximum horsepower ratings (s and u approved values)
Page 282 3RT1/3RH1 contactors 3RT1 contactors for switching motors Auxiliary circuit Rating of the auxiliary contacts in acc. with IEC 60 947-5-1/DIN EN 60 947-5-1 (VDE 0660 Part 200) Data apply to integrated auxiliary contacts and contacts in the auxiliary switch blocks for contactors in frame sizes S00 to S12 Contactor Frame sizes S00 to S12...
Page 283 3RT1/3RH1 contactors 3RT1 contactors for switching motors Frame size Contactor Type 3 RT1.1. Auxiliary circuit Fuse-links, performance class gL/gG ≥ 1 kA) DIAZED type 5SB, NEOZED type 5SE (unwelded fuse at I Or miniature circuit breaker (up to 230 V) with C characteristic (short-circuit current I <...
Page 284 3RT1/3RH1 contactors 3RT1.1 contactors for switching motors Contactor Frame size Type 3RT1. 15 3RT1. 16 3RT1. 17 Main circuit Current carrying capacity with alternating current Utilization category AC-4 (contact service life of approximately 200,000 operating cycles at = 6 x I Rated operational currentsI Up to 400 V 690 V...
Page 285 3RT1/3RH1 contactors 3RT10 2. contactors for switching motors Contactor Frame size Type 3RT10 2. Rated insulation voltage U (pollution degree 3) Protective separation between the coil and main contacts (in acc. with DIN VDE 0106 Part 101 and A1 [Draft 2/89]) Permissible ambient temperature For operation °C...
Page 286 3RT1/3RH1 contactors 3RT102. contactors for switching motors Contactor Frame size Type 3RT10 23, 3RT10 24 3RT10 25 3RT10 26 Main circuit Current carrying capacity with alternating current Utilization category AC-1, switching resistive loads Rated operational currents I At 40 °C up to 690 V At 60 °C up to 690 V Rated power At 230 V...
Page 287 3RT1/3RH1 contactors 3RT10 2. contactors for switching motors Current carrying capacity with direct current Contactor Frame size Type 3RT10 23, 3RT10 24 3RT10 25 3RT10 26 Utilization category DC-1, switching of resistive loads (L/R ≤ 1 ms) Rated operational current I (at 60 °C) Number of conducting paths in series connection up to 24 V...
Page 288 3RT1/3RH1 contactors 3RT10 3. contactors for switching motors Contactor Frame size Type 3RT10 34 3RT10 35 3RT10 36 Auxiliary circuit Fuse applications, performance class gL/gG DIAZED type 5SB, NEOZED type 5SE ≥ 1 kA) (unwelded fuse at I Or miniature circuit breaker with C characteristic (short-circuit current I <...
Page 289 3RT1/3RH1 contactors 3RT103. contactors for switching motors Contactor Frame size Type 3RT10 34 3RT10 35 3RT10 36 Main circuit Current carrying capacity with alternating current Utilization categories AC-2 and AC-3 Rated operational currents I Up to 400 V 500 V 690 V Rated power of motors at 127 V...
Page 290 3RT1/3RH1 contactors Current carrying capacity with direct current Contactor Frame size Type 3RT10 34 3RT10 35 3RT10 36 Utilization category DC-1, switching of resistive loads (L/R ≤ 1 ms) Rated operational current I (at 60 °C) Number of conducting paths in series connection Up to 24 V 60 V 110 V...
Page 291 3RT1/3RH1 contactors 3RT10 4. contactors for switching motors Contactor Frame size Type 3RT10 4. Mechanical Basic units Opera- 10 mill. life Basic unit with attached auxiliary switch block ting 10 mill. Electronically optimized auxiliary switch block cycles 5 mill. Rated insulation voltage U (pollution degree 3) 1000 Protective separation between the coil and main contacts...
Page 292 3RT1/3RH1 contactors 3RT10 4. contactors for switching motors Contactor Frame size Type 3RT10 44 3RT10 45 3RT10 46 Main circuit Current carrying capacity with alternating current Utilization category AC-1, switching of resistive loads Rated operational currents I At 40 °C up to 690 V 1000 V At 60 °C up to 690 V 1000 V...
Page 293 3RT1/3RH1 contactors 3RT10 4. contactors for switching motors Contactor Frame size Type 3RT10 44 3RT10 45 3RT10 46 Current carrying capacity with direct current Utilization category DC-1, switching of resistive loads (L/R ≤ 1 ms) Rated operational current I (at 60 °C) Number of conducting paths in series connection Up to 24 V 60 V...
Page 294 3RT1/3RH1 contactors 3RT14 contactors, 3-pole Contactor Frame size Type 3RT14 46 Short-circuit protection for contactors without overload relay Main circuit Fuse applications, performance class gL/gG Type 3NA Coordination type "1" Fuse-links, performance class gR SITOR Type 3NE Coordination type "2" Control circuit Fuse-links, performance class gL/gG DIAZED...
Page 295 3RT1/3RH1 contactors 3RT14 contactors, 3-pole Contactor Frame size Type 3RT14 46 Utilization categories DC-3 and DC-5, shunt and series motors Number of conducting paths in series connection Rated operational currents I (at 60 °C) Up to 24 V 60 V 110 V 1.25 220 V...
Page 296 3RT1/3RH1 contactors 3RT13 contactors, 4-pole (4 NO contacts), for switching resistive loads Contactor Frame size Type 3RT13 16 3RT13 17 3RT13 25 3RT13 26 3RT13 36 3RT13 44 3RT13 46 Main circuit Current carrying capacity with alternating current Utilization category AC-1, switching of resistive loads Rated operational currents I (at 40 °C) Up to...
Page 297 3RT1/3RH1 contactors 3RT15 contactors, 4-pole (2 NO contacts + 2 NC main contacts) Contactor Frame size Type 3RT15 16/17 3RT15 26 3RT15 35 General specifications Mechanical life Opera- 30 mill. 10 mill. 10 mill. ting cycles Electrical service life with I /AC-1 Opera- Approx.
Page 298 3RT1/3RH1 contactors 3RT15 contactors, 4-pole (2 NO contacts + 2 NC main contacts) Contactor Frame size Type 3RT15 16 3RT15 17 3RT15 26 3RT15 35 Current carrying capacity with alternating current Utilization category AC-1, switching of resistive loads Rated operational currents I (at 40 °C) Up to 690 V (at 60 °C)
Page 299 3RT1/3RH1 contactors 3RT16 capacitor-switching contactors The technical specifications for frame size S0 correspond, unless listed below, to those of the 3RT10 26 contactors, for frame size 2 to those of the 3RT10 36 contactors, and for frame size S3 to those of the 3RT10 45 contactors. Contactor Frame size Type...
Page 300 3RT1/3RH1 contactors Accessories for 3RT1. contactors Type Solid-state time relay blocks Time-delay auxiliary switch blocks with semiconductor output 3RT19 .6- 2C 3RT19 .6- 2E Rated insulation voltage Pollution degree 3 Overvoltage category III in acc. with DIN VDE 0110 Energizing operating range 0.8 to 1.1 x U 0.85 to 1.1 x U 0.95 to 1.05 times the...
Page 301 3RT1/3RH1 contactors Accessories for 3RT1. contactors Type Solid-state time relay blocks Time-delayed auxiliary switch with semiconductor output blocks 3RT19 .6- 2C 3RT19 .6- 2E Shock resistance g/ms 15/11 15/11 half-sine in acc. with IEC 60 068-2-27 Hz/mm 10 to 55/0.35 10 to 55/0.35 Vibration resistance in acc.
Page 302 3RT1/3RH1 contactors 3RA14 contactor combinations for star-delta starting Starter Frame sizes S . . - S . . - S . . 00-00-00 00-00-00 0-0-0 0-0-0 2-2-0 2-2-2 2-2-2 3-3-2 3-3-2 Type 3RA ..14 15 14 16 14 23 14 25 14 34...
Page 303 General-purpose Relay MY New model Versatile and Function-filled Miniature Power Relay for Sequence Control and Power Switching Applications Many variations possible through a selection of operation indicators (mechanical and LED indica- tors), test button, built-in diode and CR (surge suppression), bifurcated contacts, etc. Arc barrier standard on 4-pole Relays.
Page 304 MY New model MY New model Accessories (Order Separately) Sockets Back-mounting Socket Poles Front-mounting Socket (DIN Socket (DIN- PCB terminals Solder terminals Wire-wrap terminals track/screw track/screw mounting) Without clip With clip Without clip With clip PYF08A-E PY08 PY08-Y1 PY08QN PY08QN-Y1 PY08-02 PYF08A-N PY08QN2...
Page 305 MY New model MY New model Contact Ratings 2-pole 4-pole 4-pole (bifurcated) Item Resistive load Inductive load Resistive load Inductive load Resistive load Inductive load (cos$ = 1) (cos$ = 0.4, L/R (cos$ = 1) (cos$ = 0.4, L/R (cos$ = 1) (cos$ = 0.4, L/R = 7 ms) = 7 ms)
Page 306 MY New model MY New model CSA C22.2 No. 14 Listings (File No. LR31928) No. of poles Coil ratings Contact ratings Operations 6 to 240 VAC 10 A, 30 VDC 6 x 10 6 to 125 VDC 6 to 10 A, 250 VAC 5 A, 250 VAC (Same polarity) 5 A, 30 VDC (Same polarity) IMQ (File No.
Page 307 MY New model MY New model Life Expectancy MY2 (Resistive Loads) MY2 (Inductive Loads) 10000 10000 5000 5000 3000 3000 250 VAC 250 VAC 1000 1000 30 VDC 30 VDC 30 VDC 30 VDC 250 VAC 250 VAC Switching current (A) Switching current (A) MY4 (Resistive Loads) MY4 (Inductive Loads)
Page 308 MY New model MY New model Dimensions Note: All units are in millimeters unless otherwise indicated. 2-Pole Models 1.2-dia. x 2.2 long holes 28 max. 36 max. 21.5 max. 4-Pole Models 1.2-dia. x 2.2 long holes 28 max. 36 max. 21.5 max.
Page 309 MY New model MY New model MY2N-CR/MY2IN-CR MY2N1/MY2IN1 MY2N1-D2/MY2IN1-D2 (AC Models Only) (DC Models Only) (DC Models Only) MY4(Z) MY4(Z)N/MY4(Z)IN MY4(Z)N/MY4(Z)IN MY4(Z)N-D/MY4(Z)IN-D2 (AC Models) (DC Models) (DC Models Only) MY4(Z)N-CR/MY4(Z)IN-CR MY4(Z)N1/MY4(Z)IN1 MY4(Z)N1-D2/MY4(Z)IN1-D2 (AC Models Only) (DC Models Only) (DC Models Only) Note: The DC models have polarity.
Page 310 MY New model MY New model Socket for MY Track-mounted (DIN Track) Socket Conforms to VDE 0106, Part 100 Snap into position along continuous sections of any mounting track. Facilitates sheet metal design by standardized mounting dimensions. Design with sufficient dielectric separation between terminals eliminates the need of any insulating sheet.
Page 311 MY New model MY New model Dimensions Note: All units are in millimeters unless otherwise indicated. Socket Dimensions Terminal arrangement/Internal Mounting holes connections (top view) PYF08A-E Two, M3, M4, or 4.5-dia. holes Two, 4.2 x 5 mounting Eight, M3 x 8 holes sems screws 72 max.
Page 312 MY New model MY New model Socket Dimensions Terminal arrangement/Internal Mounting holes connections (bottom view) PY08/PY08-Y1 (See note) Eight, 3 x 1.2 elliptical holes 25.5 max. 29.5 max. 20 max. 24 max. 42 max. Note: The PY08-Y1 includes sections indicated by dotted lines.
Page 313 MY New model MY New model Hold-down Clips PYC-A1 PYC-E1 (2 pcs per set) (2 pcs per set) 36.3 36.3 5.75 4.25 # 0.1 PYC-P PYC-P2 29 max. 38.5 Mounting Plates for Back-connecting Sockets PYP-36 PYP-1 Two, 3.4-dia. holes 72 elliptical holes t=1.6 PYP-18 72 elliptical holes...
Page 314 MY New model MY New model Tracks and Accessories Supporting Tracks PFP-50N/PFP-100N 7.3#0.15 35#0.3 27#0.15 15 (5) 1000 (500) * Note: The figure in the parentheses is for PFP-50N. PFP-100N2 29.2 35#0.3 1000 End Plate PFP-M M4 x 8 pan head screw 35.5 35.3 11.5 M4 spring washer...
Page 315 Solid-state Timer H3YN Miniature Timer with Multiple Time Ranges and Multiple Operating Modes Minimizes stock. Pin configuration compatible with MY Power Relay. Standard multiple operating modes and multiple time ranges. Conforms to VDE 0435/P2021 and approved by UL and CSA. Conforms to EMC standards.
Page 316 H3YN H3YN Hold-down Clips Model Applicable Socket Y92H-3 PYF08A, PYF08A-N, PYF08A-E PYF14A, PYF14A-N, PYF14A-E Y92H-4 PY08, PY08QN(2), PY08-02 PY14, PY14QN(2), PY14-02 Specifications Ratings Item H3YN-2/-4/-4-Z H3YN-21/-41/-41-Z Time ranges 0.1 s to 10 min (1 s, 10 s, 1 min, or 10 min 0.1 min to 10 h (1 min, 10 min, 1 h, or 10 h max.
Page 317 H3YN H3YN Characteristics Item H3YN-2/-21/-4/-41 Accuracy of operating time 1% FS max. (1 s range: 1% 10 ms max.) Setting error 10% 50 ms FS max. Reset time Min. power-opening time: 0.1 s max. (including halfway reset) Influence of voltage 2% FS max.
Page 318 H3YN H3YN Engineering Data Electrical Life Expectancy (Reference Value) H3YN-2/-21 250 VAC, cosφ = 1 250 VAC, cosφ = 0.4 5,000 5,000 24 VDC, cosφ = 1 24 VDC, L/R = 7 ms 1,000 1,000 Load current (A) Load current (A) Reference: A maximum current of 0.6 A can be switched at 125 VDC (cosφ...
Page 319 H3YN H3YN Nomenclature Output Indicator (Orange) Run/Power Indicator (Green) (Lit: Output ON) (Lit: Power ON) Main Dial Set the desired time according to time range selectable by DIP switch. Operation Timing Chart Operating mode Timing chart H3YN-2/-21 H3YN-4/-41 ON-delay Power (13-14) Power (13-14) Power Time limit contact...
Page 320 H3YN H3YN DIP Switch Settings The 1-s range and ON-delay mode for H3YN-2/-4/-4-Z, the 1-min range and ON-delay mode for H3YN-21/-41/-41-Z are factory-set before shipping. Time Ranges Model Time range Time setting Setting Factory-set range H3YN-2, 0.1 to 1 s H3YN-4 H3YN-4-Z H3YN-4-Z...
Page 321 H3YN H3YN Dimensions Note: All units are in millimeters unless otherwise indicated. Timers H3YN-2/-21 Front Mounting Eight, 3 x 1.2 elliptic holes 28 max. 21.5 max (63) H3YN-4/-41 Front Mounting H3YN-4-Z/-41-Z Fourteen, 3 1.2 elliptic holes 28 max. 21.5 max Mounting Height PYF08A/PYF08A-N/PYF08A-E PY08 (PY14 (see note))
Page 322 H3YN H3YN Accessories (Order Separately) Connecting Sockets Use the PYF A, PY , PY -02, or PY QN(2) to mount the H3YN. When ordering any one of these Sockets, replace “ ” with “08” or “14.” Track Mounting/Front Connecting Sockets PYF08A Two, 4.2 Terminal Arrangement...
Page 323 H3YN H3YN PYF08A-E (Top View) Two, 4.2 Eight, M3 Two, 4.5 dia. mounting holes 8 sems M4 or M3 72 max. 23 max. 31 max. PYF14A-E (Top View) Eight, M3 Two, 4.2 Two, 4.5 dia. 8 sems mounting holes M4 or M3 72 max.
Page 324 H3YN H3YN Socket Mounting Plates The PYP-1 is a Socket Mounting Plate for a single Socket and the PYP-18 is a Socket Mounting Plate for 18 Sockets. The PYP-18 can be cut appropriately according to the number of Sockets to be used. PYP-1 PYP-18 Two, 3.4-dia.
Page 325 H3YN H3YN Installation Connection H3YN-2/-21 H3YN-4/-41 H3YN-4-Z/-41-Z DIN Indication DIN Indication Timer Timer circuit circuit Pulse Operation A pulse output for a certain period can be obtained with a random external input signal. Use the H3YN in interval mode as shown in the following timing charts. H3YN-2/-21 Power (9-14) External short circuit...
Page 326 H3YN H3YN Precautions The operating voltage will increase when using the H3YN continu- Do not set to the minimum setting in the flicker modes, otherwise the ously in any place where the ambient temperature is in a range of contact may become damaged. 45 C to 50 C.
Page 327 Emergency Stop Relays, Safety Gate Monitors Category 3, EN 954-1 PNOZ 1 Technical Details PNOZ 1 Electrical Data Supply Voltage AC: 24, 42, 48, 110, 115, 120, 230, 240 V DC: 24 V Tolerance 85 ... 110 % £ 3.5 W/6 VA Power Consumption Voltage and Current at the Input and, 24 VDC, 50 mA...
Page 328 Emergency Stop Relays, Safety Gate Monitors Category 3, EN 954-1 PNOZ 1 l Increase in safety contacts Internal Wiring Diagram The number of output contacts can be increased by using expander Input circuits Feedback Safety Auxiliary control loop contacts contact modules or relays/contactors with (L+) (L-)
Page 329 Emergency Stop Relays, Safety Gate Monitors Category 3, EN 954-1 PNOZ 1 General Technical Data Unless stated otherwise in the technical details for the specific unit Electrical Data Frequency Range AC 50 ... 60 Hz Residual Ripple DC 160 % Contact Material AgSnO Continuous Duty...
Page 333 aus SK 2000 Seite 138 Technical description: Fan-and-ﬁlter units Outlet ﬁlter Mounting cutout Quick fastening system without screws. SK 3325..SK 3325.200 SK 3325..Simply lock into position and voilà! Optimised air throughput. Super-slimline structure with the typical 17.5 Rittal grille design. 12.5 12.5 Low noise generation.
Page 334 aus SK 2000 Seite 139 D E S I G N E R F A N - A N D - F I LT E R U N I T S Air throughput 230 m Air throughput 230 m Axial fan DC motor Self-starting shaded pole motor Voltage...
Page 335 ® 5000 Series Contents Safety ........................3 Safety regulations ....................4 Warning against unintended start ................4 Introduction ......................6 Available literature ....................7 Technical data ..................... 8 General technical data ..................... 8 Electrical data ......................14 Mechanical dimensions ..................38 Installation ......................
Page 336 ® 5000 Series Control of mechanical brake .................. 94 PID for process control ..................97 PID for speed control ..................... 98 Quick discharge ..................... 99 Flying start ......................102 Normal/high overload Torque control, open loop ..........102 Programming of Torque limit and stop ..............103 Programming ....................
Page 337 ® 5000 Series Software version VLT 5000 Series Operating instructions Software version: 3.5x These operating instructions can be used for all VLT 5000 Series frequency converters with software version 3.5x. The software version number can be seen from parameter 624. MG.51.A1.02 - VLT is a registered Danfoss trade mark...
Page 338 ® 5000 Series Warning against unintended start The voltage of the frequency converter 1. The motor can be brought to a stop by means of is dangerous whenever the equipment is digital commands, bus commands, references or connected to mains. Incorrect installation a local stop, while the frequency converter is con- of the motor or the frequency converter may cause nected to mains.
Page 339 ® 5000 Series Warning: Touching the electrical parts may be fatal - even after the equipment has been disconnected from mains. Also make sure that other voltage inputs have been disconnected, such as external 24 V DC, load-sharing (linkage of DC intermediate circuit), as well as the motor connection for kinetic back-up.
Page 340 ® 5000 Series Introduction These Operating Instructions are a tool intended for persons who are to install, operate and program the VLT 5000 Series. Speciﬁc technical publications on the VLT 5000 Series: Operating Instructions, Design Guide and Quick Setup. Operating Instructions: Gives instructions in optimum installation, commissioning and ser- vice.
Page 341 ® 5000 Series Available literature Below is a list of the literature available for VLT 5000. It must be noted that there may be deviations from one country to the next. Supplied with the unit: Operating instructions ........................MG.51.AX.YY Quick setup (supplied with Bookstyle units) ................... MG.50.DX.YY Quick Setup ...........................
Page 342 ® 5000 Series General technical data General technical data Mains supply (L1, L2, L3): Supply voltage 200-240 V units ..............3 x 200/208/220/230/240 V ±10% Supply voltage 380-500 V units ............... 3 x 380/400/415/440/460/500V ±10% Supply frequency ........................48/62 Hz +/- 1% Max.
Page 343 ® 5000 Series Reliable galvanic isolation: All digital inputs are galvanically isolated from the supply voltage (PEL V). In addi- tion, the digital inputs can be isolated from the other terminals on the control card by connecting an external 24 V DC supply and opening switch 4.
Page 344 ® 5000 Series Control card, analogue inputs: No. of programmable analogue voltage inputs/thermistor inputs ............... 2 Terminal nos..............................53, 54 Voltage level ........................0 - ±10 V DC (scalable) Input resistance, R ............................10 k No. of programmable analogue current inputs ....................1 Terminal no.
Page 345 ® 5000 Series Control card, 24 V DC supply: Terminal nos..............................12, 13 Max. load (short-circuit protection) ......................200 mA Terminal nos. ground ..........................20, 39 Reliable galvanic isolation: The 24 V DC supply is galvanically isolated from the supply voltage (PEL V), but has the same potential as the analogue outputs.
Page 346 ® 5000 Series Connectors are for use of both cupper and aluminium cables, unless other is speciﬁed. Accuracy of display readout (parameters 009-012): Motor current [6] 0-140% load ............Max. error: ±2.0% of rated output current Torque % [7], -100 - 140% load ..............Max. error: ±5% of rated motor size Output [8], power HP [9], 0-90% load ...............
Page 347 ® 5000 Series VLT 5000 Series protection: • Electronic motor thermal protection against overload. • Temperature monitoring of heat-sink ensures that the VLT frequency converter cuts out if the temperature reaches 90 C for IP 00 and IP 20. For IP 54, the cut-out temperature is 80 C.
Page 348 ® 5000 Series Electrical data Mains supply 3 x 200 - 240 V According to international requirements VLT type 5001 5002 5003 5004 5005 5006 Output current 10.6 12.5 15.2 VLT,N (60 s) [A] 12.5 24.3 VLT, MAX Output (240 V) [kVA] VLT,N Typical shaft output...
Page 349 ® 5000 Series Mains supply 3 x 380 - 500 V According to international requirements VLT type 5001 5002 5003 5004 Output current [A] (380-440 V) VLT,N (60 s) [A] (380-440 V) VLT, MAX [A] (441-500 V) VLT,N (60 s) [A] (441-500 V) VLT, MAX Output [kVA] (380-440 V)
Page 350 ® 5000 Series Mains supply 3 x 380 - 500 V According to international requirements VLT type 5005 5006 5008 5011 Output current [A] (380-440 V) VLT,N (60 s) [A] (380-440 V) 11.5 20.8 25.6 VLT, MAX [A] (441-500 V) 14.5 VLT,N (60 s) [A] (441-500 V)
Page 351 ® 5000 Series Mains supply 3 x 200 - 240 V According to international requirements VLT type 5001 5002 5003 5004 5005 5006 High overload torque(160 %): Output current 10.6 12.5 15.2 VLT,N (60 s) VLT, MAX 12.5 24.3 Output (240 V) [kVA] VLT,N Typical shaft output...
Page 352 ® 5000 Series Mains supply 3 x 200 - 240 V According to international requirements VLT type 5008 5011 5016 5022 5027 Normal overload torque (110 %): Output current 61.2 VLT,N (60 s) VLT, MAX 35.2 50.6 67.3 80.3 96.8 Output (240 V) [kVA] 13.3...
Page 353 ® 5000 Series Mains supply 3 x 380 - 500 V According to international requirements VLT type 5001 5002 5003 5004 High overload torque (160 %): Output current [A] (380-440 V) VLT,N (60 s) [A] (380-440 VLT, MAX [A] (441-500 V) VLT,N (60 s) [A] (441-500 VLT, MAX...
Page 354 ® 5000 Series Mains supply 3 x 380 - 500 V According to international requirements VLT type 5005 5006 5008 5011 High overload torque (160 %): Output current [A] (380-440 V) VLT,N (60 s) [A] (380-440 V) 11.5 20.8 25.6 VLT, MAX [A] (441-500 V) 14.5...
Page 355 ® 5000 Series Mains supply 3 x 380 - 500 V According to international requirements VLT type 5016 5022 5027 Normal overload torque (110 %): Output current [A] (380-440 V) 37.5 VLT,N (60 s) [A] (380-440 V) 35.2 41.3 48.4 VLT, MAX [A] (441-500 V) 27.9...
Page 356 ® 5000 Series 1. If UL/cUL is to be complied with, pre-fuses type Bussmann KTS-R must be used. If UL/cUL is not to be complied with, we recommend using the above-mentioned Bussmann fuse or type gG fuse. Not following the recommendation may result in unnecessary damage of the drive in case of malfunc- tion.
Page 357 ® 5000 Series Mains supply 3 x 380 - 500 V According to international requirements VLT type 5032 5042 5052 5062 Normal overload torque (110 %): Output current [A] (380-440 V) VLT,N (60 s) [A] (380-440 V) 67.1 80.3 VLT, MAX [A] (441-500 V) VLT,N (60 s) [A] (441-500 V)
Page 358 ® 5000 Series 1. If UL/cUL is to be complied with, pre-fuses type Bussmann KTS-R must be used. If UL/cUL is not to be complied with, we recommend using the above-mentioned Bussmann fuse or type gG fuse. Not following the recommendation may result in unnecessary damage of the drive in case of malfunc- tion.
Page 359 ® 5000 Series Mains supply 3 x 200 - 240 V According to international requirements VLT type 5032 5042 5052 Normal overload torque (110 %): Output current [A] (200-230 V) VLT,N (60 s) [A] (200-230 V) VLT, MAX [A] (231-240 V) VLT,N (60 s) [A] (231–240 V) VLT, MAX...
Page 360 ® 5000 Series Mains supply 3 x 200 - 240 V According to international requirements VLT type 5032 5042 5052 Rated input current I [A] (230 V) 110% 101.3 126.6 149.9 Rated input current I [A] (230 V) 150% 77.9 101.3 126.6 Max.
Page 361 ® 5000 Series Mains supply 3 x 380-500 V According to international requirements VLT type 5060 5075 5100 Normal overload torque (110 %): Output current [A] (380-440 V) VLT,N (60 s) [A] (380-440 V) VLT, MAX [A] (441-500 V) VLT,N (60 s) [A] (441-500 V) VLT, MAX Output...
Page 362 ® 5000 Series 1. If UL/cUL is to be complied with, pre-fuses type Bussmann FWH or FWX must be used. If UL/cUL is not to be complied with, we recommend using the above-mentioned Bussmann fuse or type gR fuse. Not following the recommendation may result in unnecessary damage of the drive in case of malfunc- tion.
Page 363 ® 5000 Series Mains supply 3 x 380-500 V According to international requirements VLT type 5060 5075 5100 Max input current 110% [A] (400 V) L,MAX [A] (460 V) L,MAX Max input current 150% [A] (400 V) 87.6 L,MAX [A] (460 V) 77.9 L,MAX Max.
Page 364 ® 5000 Series 1. If UL/cUL is to be complied with, pre-fuses type Bussmann FWH or FWX must be used. If UL/cUL is not to be complied with, we recommend using the above-mentioned Bussmann fuse or type gR fuse. Not following the recommendation may result in unnecessary damage of the drive in case of malfunc- tion.
Page 365 ® 5000 Series Mains supply 3 x 380-500 V According to international requirements VLT type 5125 5150 5200 5250 Normal overload torque (110 %): Output current [A] (380-440 V) VLT,N (60 s) [A] (380-440 V) VLT, MAX [A] (441-500 V) VLT,N (60 s) [A] (441-500 V) VLT, MAX...
Page 366 ® 5000 Series 1. If UL/cUL is to be complied with, pre-fuses type Bussmann FWH or FWX must be used. If UL/cUL is not to be complied with, we recommend using the above-mentioned Bussmann fuse or type gR fuse. Not following the recommendation may result in unnecessary damage of the drive in case of malfunc- tion.
Page 367 ® 5000 Series Mains supply 3 x 380-500 V According to international requirements VLT type 5125 5150 5200 5250 Max input current [A] (400 V) L,MAX 110% [A] (460 V) L,MAX Max input current [A] (400 V) L,MAX 150% [A] (460 V) L,MAX Max.
Page 368 ® 5000 Series 1. If UL/cUL is to be complied with, pre-fuses type Bussmann FWH or FWX must be used. If UL/cUL is not to be complied with, we recommend using the above-mentioned Bussmann fuse or type gR fuse. Not following the recommendation may result in unnecessary damage of the drive in case of malfunc- tion.
Page 369 ® 5000 Series Mains supply 3 x 380-500 V According to international requirements VLT type 5300 5350 5450 5500 Normal overload torque (110 %): Output current [A] (380-440 V) VLT,N (60 s) [A] (380-440 V) VLT, MAX [A] (441-500 V) VLT,N (60 s) [A] (441-500 V) VLT, MAX...
Page 370 ® 5000 Series Mains supply 3 x 380-500 V According to international requirements VLT type 5300 5350 5450 5500 Rated input current [A] (400 V) L,MAX 110% [A] (460 V) L,MAX Rated input current [A] (400 V) L,MAX 150% [A] (460 V) L,MAX Max.
Page 371 ® 5000 Series 1. If UL/cUL is to be complied with, pre-fuses type Bussmann FWH or FWX must be used. If UL/cUL is not to be complied with, we recommend using the above-mentioned Bussmann fuse or type gR fuse. Not following the recommendation may result in unnecessary damage of the drive in case of malfunc- tion.
Page 372 ® 5000 Series Mechanical dimensions All the below listed measurements are in mm. VLT type ab/be Type Bookstyle IP 20 5001 - 5003 200 - 240 V 5001 - 5005 380 - 500 V 5004 - 5006 200 - 240 V 5006 - 5011 380 - 500 V Compact IP 00 5032 - 5052 200 - 240 V...
Page 373 ® 5000 Series Mechanical dimensions, cont. MG.51.A1.02 - VLT is a registered Danfoss trade mark...
Page 374 ® 5000 Series Type H, Nema 1, IP 54 Type I, IP 00 MG.51.A1.02 - VLT is a registered Danfoss trade mark...
Page 375 ® 5000 Series Mechanical installation Field mounting Please pay attention to the requirements IP 00 IP 20 / IP 54 that apply to integration and ﬁeld mount- Nema 1 ing kit, see the below list. The information Bookstyle given in the list must be observed to avoid serious Compact damage or injury, especially when installing large units.
Page 376 ® 5000 Series Installation of VLT 5001-5006 200-240V,VLT Side-by-side 5001-5011 380-500 V BookstyleIP 20 Cooling All Bookstyle units can be installed side by side with- out any space between them, since the units do not require any cooling on the sides. All Bookstyle units require a minimum space of 100 mm above and below the enclosure.
Page 377 ® 5000 Series Installation of VLT 5001-5006 200-240V, VLT stalled on a plane, vertical surface (no spacers). 5001-5011 380-500 V CompactIP 20 and IP 54 This applies to both IP 20 and IP 54 units. Cooling Side-by-side All Compact units can be installed side-by-side with- out any space between them, since the units do not require any cooling on the sides.
Page 378 ® 5000 Series Installation of VLT 5008-5027 200-240V, VLT Side-by-side 5016-5062 380-500 V CompactIP 20 and IP 54 Cooling Compact IP 20 Compact IP 54 (ﬂange-by-ﬂange) All IP 20 and IP 54 units in the above-mentioned se- All Compact units in the above-mentioned series re- ries can be installed side by side without any space quire a minimum space of 200 mm above and below between them, since these units do not require cool-...
Page 379 ® 5000 Series Installation of VLT 5060 - 5250 380 - 500 V, Side-by-side VLT5032- 5052 200 - 240V Compact IP 00, IP 20 and IP 54 Cooling Compact IP 00 and IP 20 All Compact units in the above-mentioned series re- Compact IP 54 quire a minimum space of 225 mm above and below the enclosure and must be installed on a plane, ver-...
Page 380 ® 5000 Series Installation of VLT 5300-5500 380-500V Compact Side-by-side Nema 1 (IP 20) and IP54 Cooling Compact Nema 1 (IP 20) and IP 54 All Nema 1 (IP 20) and IP 54 units in the above- mentioned series can be installed side by side without any space between them, since these units do not require cooling on the sides.
Page 381 ® 5000 Series Electrical installation The voltage on the frequency converter is dangerous when the unit is connected to mains. Incorrect installation of the motor or VLT frequency converter may lead to material damage or serious injury or it may be fatal. Conse- quently, the instructions in this manual as well as national and local rules and safety regulations must be complied with.Touching the electrical parts may...
Page 382 ® 5000 Series Electrical installation, power cables Bookstyle VLT 5001 - 5006 200 - 240 V VLT 5001 - 5011 380 - 500 V Compact IP 20/IP 54 VLT 5001 - 5006 200 - 240 V VLT 5001 - 5011 380 - 500 V Compact IP 20 VLT 5008 - 5027 200 - 240 V VLT 5016 - 5062 380 - 500 V...
Page 383 ® 5000 Series Electrical installation, power cables Compact IP 54 Compact IP 00/IP 20 VLT 5032 - 5052 200 - 240 V VLT 5032 - 5052 200 - 240 V VLT 5060 - 5100 380 - 500 V VLT 5060 - 5100 380 - 500 V Compact IP 00/IP 20 Compact IP 54 VLT 5125 - 5250 380 - 500 V...
Page 384 ® 5000 Series Electrical installation, power cables Compact IP 20/IP 54 VLT 5300 - 5500 380 - 500 V without disconnector and mains fuses Compact IP 20/IP 54 with disconnector and mains fuses VLT 5300 - 5500 380 - 500 V MG.51.A1.02 - VLT is a registered Danfoss trade mark...
Page 385 ® 5000 Series Electrical installation, enclosures Compact IP 20 VLT 5001-5006, 200-240 V VLT 5001-5011, 380-500 V Bookstyle IP 20 VLT 5001-5006, 200-240 V VLT 5001-5011, 380-500 V Compact IP 54 VLT 5001-5006, 200-240 V VLT 5001-5011, 380-500 V Compact IP 20 VLT 5008-5027, 200-240 V VLT 5016-5062, 380-500 V MG.51.A1.02 - VLT is a registered Danfoss trade mark...
Page 386 ® 5000 Series Electrical installation, enclosures Compact IP 00 VLT 5032-5052, 200-240 V VLT 5060-5100, 380-500 V Compact IP 54 VLT 5008-5027, 200-240 V VLT 5016-5062, 380-500 V Compact IP 20 VLT 5032-5052, 200-240 V VLT 5060-5100, 380-500 V Compact IP 00 VLT 5125-5250, 380-500 V MG.51.A1.02 - VLT is a registered Danfoss trade mark...
Page 387 ® 5000 Series Electrical installation, enclosures Compact IP 20 Compact IP 54 VLT 5125-5250, 380-500 V VLT 5032-5052, 200-240 V VLT 5060-5100, 380-500 V Compact IP 54 VLT 5125-5250, 380-500 V MG.51.A1.02 - VLT is a registered Danfoss trade mark...
Page 388 ® 5000 Series Electrical installation, enclosures Compact IP 20 / IP 54 VLT 5300-5500, 380-500 V MG.51.A1.02 - VLT is a registered Danfoss trade mark...
Page 389 ® 5000 Series EMC-correct electrical installation reduces its effectiveness at high frequencies. Use The following is a guideline to good engineering low impedance cable clamps or glands instead. practice, when installing drives. Following these • It is important to ensure good electrical contact guidelines is advised, where compliance with EN between the mounting plate on which the VLT fre- 50081, EN 55011 or EN 61800-3 First environment...
Page 390 ® 5000 Series MG.51.A1.02 - VLT is a registered Danfoss trade mark...
Page 391 ® 5000 Series Use of EMC-correctcables Transfer impedance (Z ) can be assessed on the Braided screened/armoured cables are recom- basis of the following factors: mended to optimise EMC immunity of the control The conductibility of the screen material. cables and the EMC emission from the motor cables. The contact resistance between the individual screen conductors.
Page 392 ® 5000 Series Earthing of braided screened/armoured control Correct earthing cables Control cables and cables for serial communication Generally speaking, control cables must be braided must be ﬁtted with cable clamps at both ends to en- screened/armoured and the screen must be con- sure the best possible electrical contact nected by means of a cable clamp at both ends to Wrong earthing...
Page 393 ® 5000 Series Tightening-up torques and screw sizes Connection of mains The table shows the torque required when ﬁtting ter- Connect the three mains phases to terminals L minals to the VLT frequency converter. For VLT 5001-5027 200-240 V, VLT 5001-5052 380-500 V the cables must be fastened with screws.
Page 394 ® 5000 Series 3-phase equipment with a bridge rectiﬁer and for a brief discharge on power-up. See also the section Special Conditions in the De- sign Guide. RFI switch Mains supply isolated from earth: If the VLT frequency converter is supplied from an isolated mains source (IT mains), the RFI switch can be turned off (OFF).
Page 395 ® 5000 Series Compact IP 20 VLT 5016 - 5022 380 - 500 V VLT 5008 200 - 240 V Compact IP 20 VLT 5042 - 5062 380 - 500 V VLT 5022 - 5027 200 - 240 V Compact IP 20 VLT 5027 - 5032 380 - 500 V VLT 5011 - 5016 200 - 240 V Compact IP 54...
Page 396 ® 5000 Series Compact IP 54 VLT 5016 - 5027 380 - 500 V VLT 5008 - 5011 200 - 240 V Compact IP 54 VLT 5032 - 5062 380 - 500 V VLT 5016 - 5027 200 - 240 V MG.51.A1.02 - VLT is a registered Danfoss trade mark...
Page 397 ® 5000 Series Installation of motor cables Direction of motor rotation NB!: If an unscreened cable is used, some EMC requirements are not complied with, see the Design Guide. If the EMC speciﬁcations regarding emission are to be complied with, the motor cable must be screened, unless otherwise stated for the RFI ﬁlter in question.
Page 398 ® 5000 Series Installation of relay terminals: The total current consumption of the motors is not to Torque: 0.5 - 0.6 Nm exceed the maximum rated output current I VLT,N Screw size: M3 the VLT frequency converter. Function Problems may arise at the start and at low rpm val- Relay output, 1+3 break, 1+2 make ues if the motor sizes are widely different.
Page 399 ® 5000 Series Load sharing enables linking of the DC intermediate NB!: circuits of several VLT frequency converters. This function is only available on VLT 5032- NB!: 5052 200-240 V and VLT 5060-5500 380-500 Please note that voltages up to 850 V DC may occur on the terminals. If the temperature of the brake resistor gets Load sharing calls for extra equipment.
Page 400 ® 5000 Series Switches 1-4 Function The dipswitch is located on the control card. 12, 13 Voltage supply to digital inputs It is used for serial communication, terminals 68 and For the 24 V DC to be usable for the digital inputs, switch 4 on The switching position shown is the factory setting.
Page 401 ® 5000 Series Electrical installation MG.51.A1.02 - VLT is a registered Danfoss trade mark...
Page 402 ® 5000 Series Connection examples Setup change 2-wire start/stop Selection of setup using terminals 32 and 33. Parameter 306 =Selection of setup, lsb [10] Parameter 307 = Selection of setup, msb [10] Parameter 004 = Multi-setup [5]. - Start/stop using terminal 18. Parameter 302 = Start [1] Digital speed up/down - Quick-stop using terminal 27.
Page 403 ® 5000 Series Parameter 310 = Terminal 53, max. scaling If an encoder is connected that only has one output to Encoder input A [25], Encoder input B [24] must be set to No function [0]. Two-wire transmitter Parameter 314 = Reference [1], Feedback [2] Parameter 315 = Terminal 60, min.
Page 404 ® 5000 Series Digital inputs Terminal no. parameter 303 304 Value: No function (NO OPERA TION) Reset (RESET) [1]* Coasting stop, inverse (COAST INVERSE) [0]* Reset and coasting stop, inverse (COAST & RESET INVERS) Quick-stop, inverse (QSTOP INVERSE) DC-braking, inverse (DCBRAKE INVERSE) Stop inverse (STOP INVERSE)
Page 405 ® 5000 Series Control panel The front of the VLT frequency converter features a control panel - LCP (Local Control Panel), which makes up a complete interface for operation and monitoring of the VLT 5000 Series. The control panel is detachable and can - as an al- ternative - be installed up to 3 metres away from the VLT frequency converter, e.g.
Page 406 ® 5000 Series If certain threshold values are exceeded, the alarm [OK] is used for conﬁrming a change of the pa- and/or warning LED lights up together with a status rameter selected. and alarm text on the control panel. [+/-] is used for selecting parameter and for changing the chosen parameter or for changing The voltage LED is activated when the VLT fre- the read out in line 2.
Page 407 ® 5000 Series Operating variable: Unit: VAR 1.1 VAR 1.2 VAR 1.3 Reference VAR 2 SETUP Reference [unit] Feedback [unit] Frequency [Hz] STATUS Frequency x scaling Motor current Torque Power [kW] Power [HP] Display mode - selection of read-outstate Output energy [kWh] There are three options in connection with the Motor voltage...
Page 408 ® 5000 Series • Read-out state I: • Display state IV: This read-out state is standard after starting up or This display state can be produced during operation after initialisation. if another setup is to be changed without stopping the VLT frequency converter. This function is acti- vated in parameter 005, Programming Setup.
Page 409 ® 5000 Series eter 100), e.g. open loop hides all the P.I.D. parameters. FREQUENCY 50.0 Hz Quick Setup via Quick menu KEYB.&DISPLAY The Quick Setup starts with pressing the [QUICK MENU] key, which brings out the following read-out on the display: Line 3 on the display shows the parameter group number and name.
Page 410 ® 5000 Series Pressing the [CHANGE DATA] key gives access to Inﬁnitely variable change of numericdatavalue changing the selected parameter, following which the If the chosen parameter represents a numeric data underlining in line 4 will ﬂash on the display. value, a digit is ﬁrst selected by means of the [<>] The procedure for changing data depends on keys.
Page 411 ® 5000 Series Read out and programming of indexed parameters Parameters are indexed when placed in a rolling stack. Parameter 615 - 617 contain a historical log which can be read out. Choose the actual parameter, press the [CHANGE DATA] key and use the [+] and [-] keys to scroll through the log of values.
Page 412 ® 5000 Series Menu structure DISPLAY MODE VAR 1.1 VAR 1.2 VAR 1.3 VAR 2 STATUS MENU MODE QUICK MENU MODE FREQUENCY QUICK MENU 1 OF 13 50.0 HZ 50.0 HZ KEYB.&DISPLAY 001 LANGUAGE ENGLISH Choice of Choice of parameter group DATA MODE FREQUENCY...
Page 413 ® 5000 Series Application conﬁguration Speed control, open loop Using this parameter enables the choice of a conﬁg- Speed control, closed loop uration (setting) of the VLT frequency converter that Process control, closed loop ﬁts the application in which the VLT frequency con- Torque control, open loop verter is to be active.
Page 414 ® 5000 Series Select Process control, closed loop if the application temperature, pressure, etc. Set the following param- has a feedback signal that is not directly related to eters in the order shown: motor speed (rpm/Hz), but some other unit, such as Process control, closed loop (Process PID): Parame- Setting:...
Page 415 ® 5000 Series Select Torque control, speed feedback , if an en- Torque control, speed feedback, is selected if it is to coder feedback signal is to be generated. This is be possible to change the speed direction, while at relevant in winder and extruder applications.
Page 416 ® 5000 Series Select Special motor characteristics if the VLT fre- motor, parallel motor operation or if slip- compensa- quency converter is to be adapted to a synchronous tion is not required. Set the following parameters in order shown: Special motor characteristics: Parame- Setting: Data value:...
Page 417 ® 5000 Series Shift between local and remote control via the control panel, the digital inputs or the serial The VLT can be operated manually or remotely. The communication port in the two situations (modes). following is a list of the functions/commands given If parameter 002 is set to Local [1]: On the LCP, the following keys can be used for local control: Key:...
Page 418 ® 5000 Series Control with brake function in which t2-t1 = cycle time in seconds and tb is the The function of the brake is to limit the voltage in the braking time in seconds (of the cycle time). intermediate circuit when the motor is acting as a The maximum permissible load on the brake resistor generator.
Page 419 ® 5000 Series NB!: The max. brake resistance selected should have an ohmic value max. 10% lower than that recommended by Danfoss. If a brake resistor with a higher ohmic value is selected, the 160% braking torque will not be achieved and there is a risk that the VLT 5000 Series will cut out for safety reasons.
Page 420 ® 5000 Series Handling of single references U/f on terminal 53, Using a single reference, only one active reference 54 or 60. f (pulse) signal is connected, either in the form of an external on terminal 17 or 29 or in the form of a preset (internal) reference. External binary (serial port).
Page 421 ® 5000 Series Example 2: External reference signal = 0 V (min) - 10 V (max) Reference = -50 Hz ccw - 50 Hz cw Conﬁguration (parameter 100) =Speed control, open loop. Setting: Parameter: Setting: Data value: Conﬁguration Speed control, open loop Funct.
Page 422 ® 5000 Series Handling of multi-references If the multi-reference is used, two or more reference signals are connected, either in the form of external or preset reference signals. Via parameter 214 these can be combined in three different ways: Multi-ref. –...
Page 423 ® 5000 Series RELATIVE EXTERNAL/PRESET MG.51.A1.02 - VLT is a registered Danfoss trade mark...
Page 424 ® 5000 Series List of handling of multi-references Automatic Motor Adaptation, AMA • For the best adjustment of the VLT frequency Automatic motor adaptation is a test algorithm that converter, it is recommended to carry out AMA measures the electrical motor parameters at a motor on a cold motor.
Page 425 ® 5000 Series How to perform an AMA given. The ﬁgure after the text is the error code, which can be seen in the fault log in parameter 615. 1. Press the [STOP/RESET] key Automatic motor adaptation does not update param- 2.
Page 426 ® 5000 Series WARNING 39 - 42 A fault have been encountered during automatic mo- tor adaptation. Check the possible fault causes in accordance with the warning message. Press the [CHANGE DATA key and select "CONTINUE" if AMA is to continue despite the warning or press the [STOP/RESET] key or disconnect terminal 18 from terminal 12 to discontinue AMA.
Page 427 ® 5000 Series Automatic motor adaptation, AMA, via VLT Soft- ware Dialog Automatic motor adaptation can also be activated by means of the VLT Software Dialog. This can be done locally or in the form of remote-control via a modem. Procedure for automatic motor adaptation via VLT Software Dialog: Start Parameter Setup and select "Start new setting".
Page 428 ® 5000 Series Control of mechanical brake If Extended mechanical brake control [34] is selected For hoisting applications, it is necessary to be able the mechanical brake is closed (voltage-free) during to control an electro-magnetic brake. start until the output current is above the level se- For controlling the brake, a relay output (01 or 04) is lected in parameter 223 Warning: Low Current .
Page 429 ® 5000 Series MG.51.A1.02 - VLT is a registered Danfoss trade mark...
Page 430 ® 5000 Series Control of mechanical brake: Parameter: Setting: Data value: Relay 01 or par. 326 relay 04 Mechanical brake control [32] Relay 01 or par. 326 relay 04 Extended mechanical brake control [34] Warning: Low current approx. 70% of magnetising current Warning: Low frequency 3-5 Hz Function at stop...
Page 431 ® 5000 Series PID for process control Reference type Terminal Parameters Feedback Pulse 17 or 29 301 or 305 The feedback signal must be connected to a termi- Voltage 53 or 54 308, 309, 310 or nal on the frequency converter. Use the list below to 311, 312, 313 decide which terminal is to be used and which pa- Current...
Page 432 ® 5000 Series Differentiator gain limit NB!: If there are quick changes in reference or feedback If necessary, start/stop can be activated in a given application - which means that the error a number of times in order to provoke a varia- changes swiftly - the differentiator may soon become tion of the feedback signal.
Page 433 ® 5000 Series Preset ref. msb Preset ref. lsb Lowpass ﬁlter If are oscillations of the current/voltage on the feed- Preset ref. 1 back signal, these can be dampened by means of a (par. 215) lowpass ﬁlter. Set a suitable lowpass ﬁlter time Preset ref.
Page 434 ® 5000 Series NB!: The power dissipation during quick discharge does not form part of the power monitoring function, parameter 403. When sizing resistors, this fact should be taken into consideration. Parameter 408 = [1] Quick discharge activated TRIP (RESET) Check 24 Volts ALARM:33 external DC supply...
Page 435 ® 5000 Series Mains failure par. Quick discharge par. 408 Mains failure inverse digital Function input No function [0] Disable [0] Logical ’0’ No function [0] Disable [0] Logical ’1’ No function [0] Enable [1] Logical ’0’ No function [0] Enable [1] Logical ’1’...
Page 436 ® 5000 Series Flying start ning motor down to 0 rpm. This requires that the DC This function makes it possible to "catch" a motor brake is active via parameters 125 and 126. If Both that is spinning freely and for the VLT to take control directions is selected, the VLT frequency converter of the motor speed.
Page 437 ® 5000 Series Reset and coasting stop, inverse [1], as well as ter- If a high torque characteristic is chosen, a rated mo- minal 42 to Torque limit and stop [27]. tor with the VLT frequency converter obtains up to 160% torque for 1 min.
Page 438 ® 5000 Series Operation and Display 4. Via parameter 003 the local reference can be controlled by means of the "Arrow up" and "Arrow down" keys. 001 Language 5. An external control command that can be con- (LANGUAGE) nected to terminal 16, 17, 19, 27, 29, 32 or 33. Value: However, [2] or [4] must be selected in parameter English (ENGLISH)
Page 439 ® 5000 Series Setup 2 (SETUP 2) NB!: Setup 3 (SETUP 3) If a general change of data or a copying to Setup 4 (SETUP 4) the active Setup is effected, this immediately MultiSetup (MULTI SETUP) affects the functioning of the unit. Function: The choice in this parameter deﬁnes the Setup num- 006 Copying of Setups (SETUP COPY)
Page 440 ® 5000 Series [22] Select Download power-independent par. [3] if only Status word [Hex] (STATUS WORD [HEX]) Brake effect/2 min. [KW] the power-independent parameters are to be down- [23] (BRAKE ENERGY/2 MIN) loaded. This is used if downloading to a VLT [24] Brake effect/sec.
Page 441 ® 5000 Series Thermal load, VLT [%] states the calculated/esti- have been installed. Without communication options, mated thermal load on the VLT frequency converter. 0 Hex is displayed. 100% is the cut-out limit. RPM [min ] indicates the motor speed. In speed Hours run [Hours] states the number of hours that closed loop, the value is measured.
Page 442 ® 5000 Series Description of choice: Shift from LCP control/as parameter 100 or LCP re- If Local not active [0] is selected, a possible setting mote control as parameter 100 to Remote control. of Local reference via parameter 003 is blocked. The reference will be replaced by the active refer- It is only possible to change to Local not active [0] ence signal from the remote control.
Page 443 ® 5000 Series Description of choice: Description of choice: If Disable [0] is selected in this parameter, the [FWD/ Auto restart, use saved ref. [0] is selected if the unit REV] key will be inactive. is to start up with the same local reference (set in See Parameter 200.
Page 444 ® 5000 Series Load and motor If Torque control, speed feedback [5] is selected, an encoder speed feedback signal must be connected to the digital terminals 32/33. 100 Conﬁguration (CONFIG. MODE) Parameter 205 Maximum reference and parameter Value: 415 Maximum feedback must be adapted to the ap- Speed control, open loop plication if [1], [3], [4] or [5] is selected.
Page 445 ® 5000 Series [150] If a high torque characteristic [1]-[5] is selected, the 1.5 kW (1.50 KW) [220] 2.2 kW (2.20 KW) VLT frequency converter is able to provide 160% [300] 3 kW (3.00 KW) torque. If a normal torque characteristic [11]-[15] is [400] 4 kW (4.00 KW) selected, the VLT frequency converter is able to pro-...
Page 446 ® 5000 Series [240] 240 V Description of choice: [380] 380 V Select a value that equals the nameplate data on the [400] 400 V motor. [415] 415 V Alternatively it is also possible to set the value for [440] 440 V motor frequency inﬁnitely variably , see procedure [460]...
Page 447 ® 5000 Series tion can be activated by means of VLT Software NB!: Dialog. After a normal sequence, the display will If the setting in parameter 102-109 is read "ALARM 21". Press the [STOP/RESET] key. changed, the parameters 110-118 will return The VLT frequency converter is now ready for opera- to factory setting.
Page 448 ® 5000 Series 3. The values are obtained by means of manual NB!: measurements: If the setting in parameter 102-109 is can be calculated by measuring the resis- changed, the parameters 110-118 will return tance R between two phase PHASE-to-PHASE to factory setting.
Page 449 ® 5000 Series slip frequency, parameters 110 and 111 are of no Load compensation at low speed stopped working to signiﬁcance. max. frequency. This function is active for: Motor size Change-over 113 Load compensation at low speed 0.5 kW - 7.5 kW >10 Hz (LO SPD LOAD COMP) 11 kW - 45 kW...
Page 450 ® 5000 Series If low-frequency resonance problems are encoun- The VLT frequency converter begins with the start tered, the time set must be longer. function selected in parameter 121. Description of choice: Set the desired time until acceleration is to begin. 117 Resonance dampening (RESONANCE DAMP.) Value:...
Page 451 ® 5000 Series This is used especially in applications with a cone ensures that the motor can produce torque as armature motor, where the start is to be clockwise, quickly as possible on starting. followed by rotation in the reference direction. Select Start frequency/voltage in reference direction 123 Min.
Page 452 ® 5000 Series nal 27 or via a serial communication port. The DC ETR Trip 1 (ETR TRIP1) ETR Warning 2 (ETR WARNING2) braking current will be active for the duration of the ETR Trip 2 (ETR TRIP2) DC braking time set in parameter 126. ETR Warning 3 (ETR WARNING3) NB!: ETR Trip 3 (ETR TRIP3)
Page 453 ® 5000 Series Description of choice: Set the desired start frequency. It is assumed that the start function in parameter 121 has been set to [3] or [4] and that a start delay time has been set in parameter 120; also, a refer- ence signal must be present.
Page 454 ® 5000 Series References and limits 200 Output frequency range/direction (OUT FREQ RNG/ROT) Value: Only clockwise, 0-132 Hz (132 HZ CLOCK WISE) Both directions, 0-132 Hz (132 HZ BOTH DIRECT .) Only clockwise, 0-1000 Hz (1000 HZ CLOCK WISE) Both directions, 0-1000 Hz (1000 HZ BOTH DIRECT .) Only counter clockwise, 0-132 Hz (132 HZ COUNTERCLOCK)
Page 455 ® 5000 Series NB!: Speed control, open loop: The output frequency of the VLT frequency Speed control, closed loop: converter can never assume a value higher Torque control, open loop: than 1/10 of the switching frequency. Torque control, speed feedback: Process control, closed loop: Process units Description of choice:...
Page 456 ® 5000 Series Description of choice: Program the desired ramp-down time. 209 Ramp-up time 2 (RAMP UP TIME 2) Value: depends on unit 0.05 - 3600 sec. Function: See description of parameter 207. Description of choice: 207 Ramp-up time 1 Program the desired ramp-up time.
Page 457 ® 5000 Series The jog ramp time starts if a jog signal is given via the control panel, the digital inputs or the serial com- External/preset (EXTERNAL/PRESET) munication port. Function: It is possible to deﬁne how the preset references are Description of choice: to be added to the other references.
Page 458 ® 5000 Series Par. 204 Frequency Par. 215 Par. 214 Reference Par. 214 Reference Min. refer- crease by 4.0 V Preset ref. type = Sum [0] type = Relative [1] ence [Hz/V] 20 Hz 15 % Output frequency Output frequency 00+20+7.5 = 27.5 Hz 00+20+3 = 23.0 Hz 16 Hz...
Page 459 ® 5000 Series the percentage (relative) value selected in parameter In order to protect the motor from reaching pull-out 219 will be deducted from the total reference. torque, the factory setting is 1.6 x the rated motor torque (calculated value). If a synchronous motor is used, the torque limit must 221 Torque limit for motor mode be increased in relation to the factory setting.
Page 460 ® 5000 Series See drawing at parameter 223. 226 Warning: High frequency (WARN. FREQ. HIGH) Value: 132.0 Hz parameter 225 - parameter 202 Function: When the motor frequency is above the limit pro- grammed in this parameter, f , the display will HIGH indicate FREQUENCY HIGH.
Page 461 ® 5000 Series Description of choice: See also parameter 229. Set the desired value. 234 Motor phase monitor 229 Frequency bypass, bandwidth (MOTOR PHASE MON) (FREQ BYPASS B.W.) Value: Value: Enable (ENABLE) 0 (OFF) % Disable (DISABLE) 0 (OFF) - 100% Function: Function: In this parameter it is possible to select monitoring of...
Page 462 ® 5000 Series Inputs and outputs Digital inputs Terminal no. parameter 300 301 302 303 304 305 306 307 Value: No function (NO OPERA TION) Reset (RESET) [1]* Coasting stop, inverse (COAST INVERSE) [0]* Reset and coasting stop, inverse (COAST & RESET INVERS) Quick-stop, inverse (QSTOP INVERSE) DC-braking, inverse...
Page 463 ® 5000 Series 300 Terminal 16, input Start , is selected if a start/stop (operating com- mand, group 2) command is desired. Logic ’1’ = (DIGITAL INPUT 16) start, logic ’0’ = stop. Function: In this and the following parameters it is possible to choose between the different possible functions re- lated to the inputs on terminals 16-33.
Page 464 ® 5000 Series parameter 214. Logic ’0’ = external references ac- Terminal Freeze ref./ tive; logic ’1’ = one of the four preset references is (16) (17) Freeze output active in accordance with the table below. No speed change Speed down Preset reference, lsb and Preset reference, msb Speed up enables a choice of one of the four preset refer-...
Page 465 ® 5000 Series charge is to be activated. Mains failure inverted is Description of choice: active in the logical ‘0’ situation. See parameter 300. See also Mains fault/quick discharge on page 66, if required. NB!: 303 Terminal 19, input The VLT frequency converter can be totally (DIGITAL INPUT 19) damaged by repeating the Quick discharge Value:...
Page 466 ® 5000 Series Description of choice: Description of choice: See parameter 300. See parameter 300. 306 Terminal 32, input 307 Terminal 33, input (DIGITAL INPUT 32) (DIGITAL INPUT 33) Value: Value: See parameter 300. See parameter 300. Function: Function: This parameter allows a choice between the different This parameter allows a choice between the different options on terminal 32.
Page 467 ® 5000 Series If a motor features a KLIXON thermal switch instead, See also section Handling of single references . this can also be connected to the input. If motors run in parallel, the thermistors/thermal switches can be connected in series (total resistance < 3 kohm). 310 Terminal 53, max.
Page 468 ® 5000 Series See also section Handling of single references . See also section Handling of single references. 313 Terminal 54, max. scaling 316 Terminal 60, max. scaling (AI 54 SCALE HIGH) (AI 60 SCALE HIGH) Value: Value: 10.0 Volt 20.0 mA 0.0 - 10.0 Volt 0.0 - 20.0 mA...
Page 469 ® 5000 Series 1. Parameter 318 Function after time out frozen at the present value 2. Parameter 346 Function after encoder loss overruled to stop 3. Parameter 514 Bus time interval function overruled to jog frequency overruled to max. frequency Description of choice: overruled to stop with subsequent trip.
Page 470 ® 5000 Series Outputs terminal no. 01(re- 04 (re- lay) lay) parameter Value: 0-100 Hz ⇒ 0-20 mA (0-100 Hz = 0-20 mA) [36] [36] 0-100 Hz ⇒ 4-20 mA (0-100 Hz = 4-20 mA) [37] [37] 0-100 Hz ⇒ 0-32000 p (0-100 Hz = 0-32000P) [38] [38]...
Page 471 ® 5000 Series Function: Under f high , the output frequency is lower than the This output can act both as a digital and an ana- value set in parameter 226. logue output. If used as a digital output (data value Out of feedback range , the feedback signal is out- [0]-[65]), a 24 V DC signal is transmitted;...
Page 472 ® 5000 Series ⇒ 0-32000 p , an output proportional to the fault on the brake modules. To avoid a potential ﬁre 0 - M in the brake resistor, the output/relay can be used to output torque in the interval 0 - T (parameter 221) cut out the supply voltage from the VLT frequency is obtained.
Page 473 ® 5000 Series Activation/deactivation can be delayed in parameter 324/325. Description of choice: See description of parameter 319. Connections - see the below drawing. 321 Terminal 45, output 324 Relay 01, ON delay (AO 45 FUNCT.) (RELAY 1-3 ON DL) Value: Value: See description for parameter 319.
Page 474 ® 5000 Series Description of choice: Function: See description of parameter 319. This is where to set the encoder pulses per revolu- Connections - see the below drawing. tion that correspond to the motor rpm. This parameter is only available in Speed control, closed loop and in Torque control, speed feedback (parameter 100).
Page 475 ® 5000 Series After Freeze output , the PID integrators are reset overruled to stop with subsequent trip. overruled to Setup 4 345 Encoder loss timeout 357 Terminal 42, Output minimum scaling (ENC LOSS TIMEOUT) (OUT 42 SCAL MIN) Value: 1 sec.
Page 476 ® 5000 Series Description of choice: Set the value to the desired maximum value of the current signal output. Maximum value: The output can be scaled to give a lower current than 20 mA at full scale or 20 mA at an output below 100% of the maximum signal value.
Page 477 ® 5000 Series Special functions Warning: If Overvoltage control [2] is used at the same time as the supply voltage to 400 Brake function/overvoltage control the VLT frequency converter is close to or (BRAKE FUNCTION) above the maximum limit, there is a risk that the mo- tor frequency will increase and that, consequently, Value: Off (OFF)
Page 478 ® 5000 Series Function: 2. If the intermediate circuit voltage is unstable, dis- This parameter allows monitoring of the power trans- continue the brake check. mitted to the brake resistor. The power is calculated 3. Carry out a brake test. on the basis of the resistor ohm value (parameter 4.
Page 479 ® 5000 Series Function: In parameter 450 Mains voltage during mains fault , This parameter makes it possible to select the reset the voltage limit must be set at which the Mains fault function desired after tripping. function is to be active. After reset, the VLT frequency converter can be This function can also be activated by selecting restarted.
Page 480 ® 5000 Series Description of choice: NB!: This function is only active in extended units, since it If this value is reduced from the factory requires the connection of external 24 V DC and a setting, the unit may report a fault when the brake resistor or discharge resistor;...
Page 481 ® 5000 Series Set the switching frequency in parameter 411. If If Speed control, closed loop [1] has been selected Possible [1] is selected the switching frequency will in parameter 100, minimum feedback cannot be set decline at an increasing output frequency. under 0.
Page 482 ® 5000 Series [33] gal/h nal connected to terminal 53, 60 or 33 (pulse), will, [34] however, be displayed in the form of the unit se- [35] lb/s lected in parameter 416. If parameter 013 is chosen [36] lb/min as LCP control/as par. 100 or LCP digital control/as [37] lb/h par.
Page 483 ® 5000 Series regulator will take long to regulate if an error has oc- curred. 419 Speed PID differential time (SPEED DIFF. TIME) Value: 30 ms 0.00 (OFF) - 200.00 ms Function: The differentiator does not react to a constant error. It only provides a gain if the error changes.
Page 484 ® 5000 Series See drawing for parameter 422. 426 F 2 frequency (F2 FREQUENCY) Value: par. 424 - par. 428 Factory setting of par. 104 Function: This parameter sets the X-value of the 2nd break point. Description of choice: 423 U 1 voltage Set the frequency desired at the U2 voltage set in (U1 VOLTAGE) parameter 425.
Page 485 ® 5000 Series See drawing for parameter 422. Description of choice: Set the voltage desired at the F5 frequency set in parameter 432. 429 U 4 voltage (U4 VOLTAGE) 432 F 5 frequency Value: (F5 FREQUENCY) 0.0 - U Factory setting of par. 103 VLT,MAX Value: Function:...
Page 486 ® 5000 Series Description of choice: Select Disable [0] if the integrator is to continue Fast control is obtained if the integral time is short. integrating on an error, even if it is not possible to re- However, this time may become too short, in which move the fault by such control.
Page 487 ® 5000 Series Description of choice: Description of choice: Quick control is obtained by a high gain, but if the Quick control is obtained with a long differentiation gain is too high, the process may become unstable. time. However, this time may become too long, which can make the process unstable.
Page 488 ® 5000 Series quency than 1.6 Hz, the Process regulator will not bration of the VLT frequency converter. By adjusting react. parameter 447, Torque compensation , the output torque can be calibrated. See section Setting of parameters, torque regulation, speed feedback . 445 Flying start (FLYING START) Description of choice:...
Page 489 ® 5000 Series Description of choice: Description of choice: Set the required value. Set the required value. 450 Mains voltage at mains fault 454 Dead time compensation (MAINS FAIL VOLT.) (DEADTIME COMP .) Value: Value: 180-240 V for 200-240 V units Off (OFF) 342-500 V for 380-500 V units On (ON)
Page 490 ® 5000 Series Description of choice: At Trip [0] the VLT frequency converter will stop the motor within a few seconds (depending on drive size). At Warning [1] only a warning will be exported when a mains failure occurs, but in severe cases, other ex- treme conditions might result in a trip.
Page 491 ® 5000 Series Serial communication by the set baud rate, is only part of the total commu- nication time. 500 Address (BUS ADDRESS) Value: 502 Coasting 1 - 126 (COASTING SELECT) 503 Quick-stop Function: (Q STOP SELECT) This parameter allows speciﬁcation of the address of 504 DC-brake each VLT frequency converter.
Page 492 ® 5000 Series (active signal = 1) either via a control word or via a Description of choice: digital input. See description under parameter 502. Digital input Control com- 505-508 mand 509 Bus jog 1 (BUS JOG 1 FREQ.) Value: 10.0 Hz 0.0 - parameter 202 Function:...
Page 493 ® 5000 Series See also the dedicated ﬁeldbus manuals for further details. Stop (STOP) Jogging (JOGGING) Max. speed (MAX SPEED) Stop and trip (STOP AND TRIP) 513 Bus time interval Function: (BUS TIMEOUT TIME) This parameter selects the desired reaction of the Value: VLT frequency converter when the set time for bus 1 sec.
Page 494 ® 5000 Series Parameter Description Display Unit Updating text interval Reference % (REFERENCE) 80 msec. Reference Unit (REFERENCE [UNIT]) Hz, Nm or rpm 80 msec. Feedback (FEEDBACK) To be sel- 80 msec. cected via par. Frequency (FREQUENCY) 80 msec. Frequency x Scaling (FREQUENCY X SCALE) 80 msec.
Page 495 ® 5000 Series Frequency, parameter 518: DC link voltage, parameter 525: The value shown corresponds to the actual motor The value shown is a measured value. frequency f (without resonance dampening). The value is ﬁltered, which means that approx. 1.3 Frequency x scale, parameter 519: seconds may pass from an input value changes until The value shown corresponds to the actual motor...
Page 496 ® 5000 Series Brake power/sec., parameter 536: Indicates the given brake power transmitted to an external brake resistor. Stated as an instantaneous value. Heat sink temperature, parameter 537: States the given heat sink temperature of the VLT frequency converter. The cut-out limit is 90 ± 5 while the unit cuts back in at 60 ±...
Page 497 ® 5000 Series Technical functions Parameter no. Description Display text Unit Range Operating data Operating hours (OPERA TING Hours 0 - 130,000.0 HOURS) Hours run (RUNNING HOURS Hours 0 - 130,000.0 kWh counter (KWH COUNTER) Nos. 0 - 9999 No. of cut-ins (POWER UP’s) Nos.
Page 498 ® 5000 Series Free a data-log if there is a trip and release it when DC link voltage, parameter 614: resetting the VLT frequency converter. Data-logging The value of the DC link voltage is stated as Volts in is active when the motor is running. the interval 0.0 - 999.9 V.
Page 499 ® 5000 Series Description of choice: Also, all parameters (except parameters 603-605) Read out as one value. can be initialised. Indication range: 0.0 - 999.9. This function will not become active until the mains Reset the fault log after manual initialisation. supply to the VLT frequency converter has been turned off and then turned on again.
Page 500 ® 5000 Series 1. Select Initialisation. 2. Press the [OK] key. 3. Cut off the mains supply and wait for the light in the display to go out. 4. Connect to mains. Manual initialisation can be carried out by holding down three keys at the same time as the mains volt- age is connected.
Page 501 ® 5000 Series Power section identiﬁcation number, parameter 627: The key data of the unit can be read out via the dis- play or the serial communication port. For example: ID 1,15. Application option type, parameter 628: This gives the type of application options ﬁtted with the VLT frequency converter.
Page 502 ® 5000 Series Description of choice: NB!: Enter the required value. Parameters 700-711 for the relay card are only activatedif a relay option card is installed in the VLT 5000. 702 Relay 6, OFF delay (RELAY6 OFF DELAY) 700 Relay 6, function 705 Relay 7, OFF delay (RELAY6 FUNCTION) (RELAY7 OFF DELAY)
Page 503 ® 5000 Series = factory setting. () = display text [] = value for use in communication via serial communication port MG.51.A1.02 - VLT is a registered Danfoss trade mark...
Page 504 ® 5000 Series Outputs terminal no. Relay Relay Relay parameter Value: No function (NO OPERA TION) Control ready (CONTROL READY) Ready signal (UNIT READY) Ready - remote control (UNIT READY/REM CTRL) Enable, no warning (ENABLE/NO WARNING) Running (VLT RUNNING) Running, no warning (RUNNING/NO WARNING) Running within range, no warning (RUN IN RANGE/NO WARN)
Page 505 ® 5000 Series Status messages Trouble-shooting Symptom How to handle 1. Motor runs unevenly If the motor runs unevenly , but no fault is given, this may be be- cause the VLT frequency converter has been wrongly set. Adjust the motor data settings. Contact Danfoss if the new setting does not make the motor run evenly 2.
Page 506 ® 5000 Series Status messages Output current low (CURRENT LOW): Status messages appear in the 4th line of the dis- The output current is lower than the value set in pa- play, see the below example. The status message rameter 223. This message is only shown when the will be on the display for approx.
Page 507 ® 5000 Series DC stop, remote control (REM/DC STOP): Jog operation, local (LOCAL/ RUN JOG): Remote control has been selected in parameter 002 Local has been selected in parameter 002 and Jog and the VLT frequency converter has stopped via a in parameter 300, 301, 305, 306 or 307, and the ter- DC stop signal on a digital input (or possibly via the minal in question (16, 17, 29, 32 or 33) has been...
Page 508 ® 5000 Series Not ready for operation (UNIT NOT READY): The drive is in Fieldbus proﬁle mode (parameter 512). The drive is not ready for operation as bit 00, 01 or 02 in the control word is "0", the drive has tripped or there is no mains supply (only seen on units with 24 V DC supply).
Page 509 ® 5000 Series List of warnings and alarms Wherever a cross is placed under both Warning and The table gives the different warnings and alarms Alarm, this can mean that a warning precedes the and indicates whether the fault locks the VLT fre- alarm.
Page 510 ® 5000 Series Description Warning Alarm Trip lockeds 10 Volts low (10 VOLT LOW) Live zero fault (LIVE ZERO ERROR) No motor (NO MOTOR) Phase fault (MAINS PHASE LOSS) Voltage warning high (DC LINK VOLTAGE HIGH) Voltage warning low (DC LINK VOLTAGE LOW) Overvoltage (DC LINK OVERVOL T) Undervoltage (DC LINK UNDERVOL T) Inverter overladed (INVERTER TIME)
Page 511 ® 5000 Series Warnings Alarm messages The display ﬂashes between normal state and warn- The alarm comes up in the 2. and 3. line of the dis- ing. A warning comes up on the ﬁrst and second play, see example below: line of the display.
Page 512 ® 5000 Series Alarm/warning limits: VLT 5000 Series 3 x 200 - 240 V 3 x 380 - 500 V [VDC] [VDC] Undervoltage Voltage warning low Voltage warning high 384/405 801/840 (w/o brake - w/brake) Overvoltage The voltages stated are the intermediate circuit voltage of the VLT frequency converter with a tolerance of ±...
Page 513 ® 5000 Series WARNING/ALARM 17 CHECK P.103,105 [0] Standard bus timeout (STD BUS TIMEOUT) See section Automatic motor adaptation, AMA . There is no communication to the VLT frequency LOW P.105 [1] converter. See section Automatic motor adaptation, AMA . The warning will only be active when parameter 514 has been set to another value than OFF .
Page 514 ® 5000 Series ALARM/WARNING 26 ALARM: 31 Brake resistor power 100% Motor phase V missing (BRAKE PWR WARN 100%): (MISSING MOT.PHASE V): The power transmitted to the brake resistor is calcu- Motor phase V between VLT frequency converter lated as a percentage, as a mean value over the last and motor is missing.
Page 515 ® 5000 Series ALARM: 37 Brake IGBT short-circuited Inverter fault (Inverter fault): (BRAKE IGBT FAULT) [2] IGBT or the power card is defective. Contact your The brake IGBT has short-circuited. This fault Danfoss supplier. means that the unit is not able to stop the brake and Auto-optimisation warnings that, consequently, the resistor is constant being en- Automatic motor adaptation has stopped, since...
Page 516 ® 5000 Series Warning word 1, Extended status wordand Alarm Bit (Hex) Extended status word (parame- word ter 541) WWarning word 1, extended status word and alarm 000001 Ramping word are shown on the display in Hex format. If 000002 Automatic motor tuning there are more than one warning or alarm, a sum of 000004 Start clockwise/anti-clockwise all warnings or alarms will be shown.
Page 517 ® 5000 Series Bit (Hex) Alarm word 1 (parameter 538) 000001 Brake test failed 000002 Trip locked 000004 AMA tuning not OK 000008 AMA tuning OK 000010 Power-up fault 000020 ASIC fault 000040 HPFP bus timeout 000080 Standard bus timeout 000100 Short-circuiting 000200 Switchmode fault 000400 Earth fault...
Page 518 ® 5000 Series Deﬁnitions Group 1 Reset, Coasting stop, Reset and Coasting stop, Quick-stop, VLT: DC braking, Stop and the "Stop" key. VLT,MAX Group 2 Start, Pulse start, Reversing, The maximum output current. Start reversing, Jog and Freeze VLT,N output The rated output current supplied by the frequency converter.
Page 519 ® 5000 Series pulse ref. LCP: A signal transmitted to the digital inputs (terminal 17 The control panel, which makes up a complete inter- or 29). face for control and programming of VLT 5000 Series. The control panel is detachable and may, as binary ref.
Page 520 ® 5000 Series An external, digital pulse transmitter used for feeding back information on motor speed. The encoder is used in applications where great accuracy in speed control is required. AWG: Means American Wire Gauge, i.e. the American measuring unit for cable cross-section. Manual initialisation: Press the [CHANGE DATA] + [MENU] + [OK] keys at the same time to carry out manual initialisation.
Page 521 ® 5000 Series Factory Settings Parameter Factory setting Range Changes 4-Setup Conversion Data description during operation index type Language English Local/remote control Remote control 000.000 Local reference Active setup Setup 1 Programming setup Active setup No copying Copying of setups LCP copy No copying Display scaling of motor fre-...
Page 522 ® 5000 Series Parameter Factory setting Range Changes 4-Setup Conversion Data description during operation index type Conﬁguration Speed control, open loop Torque characteristics High - constant torque Motor power Depends on the unit 0.18-500 kW Motor voltage Depends on the unit 200 - 500 V Motor frequency 50 Hz / 60 Hz...
Page 523 ® 5000 Series Parameter Factory setting Range Changes 4-Setup Conversion Data description during operation index type Output frequency range/di- Only clockwise, 0-132 rection Output frequency low limit 0.0 Hz 0.0 - f Output frequency high limit 66 / 132 Hz - par.
Page 524 ® 5000 Series PNU Parameter Factory setting Range Changes 4-Setup Conversion Data description during operation index type 300 Terminal 16, input Reset 301 Terminal 17, input Freeze reference 302 Terminal 18 Start, input Start 303 Terminal 19, input Reversing 304 Terminal 27, input Coasting stop, inverse 305 Terminal 29, input 306 Terminal 32, input...
Page 525 ® 5000 Series PNU Parameter Factory setting Range Changes 4-Setup Conversion Data description during operation index type 400 Brake function/overvoltage control 401 Brake resistor, ohm Depends on the unit 402 Brake power limit, kW Depends on the unit 403 Power monitoring 404 Brake check 405 Reset function Manual reset...
Page 526 ® 5000 Series PNU Parameter Factory setting Range Changes 4-Setup Conversion Data description during operation index type 430 F 4 frequency parameter 104 par.426-par.432 431 U 5 voltage parameter 103 .0 - U VLT, MAX 432 F 5 frequency parameter 104 par.426 - 1000 Hz 433 Torque proportional gain 100%...
Page 527 ® 5000 Series Parameter Factory setting Range Changes 4-Setup Conversion Data description during operation index type Address 0 - 126 Baudrate 9600 Baud Coasting Logic or Quick-stop Logic or DC-brake Logic or Start Logic or Reversing Logic or Logic or Selection of setup Selection of speed Logic or...
Page 528 ® 5000 Series Parameter Factory setting Range Changes 4-Setup Conversion Data description during operation index Operating data: Operating hours Operating data: Hours run Operating data: kWh counter Operating data: Number of power-up’s Operating data: Number of overtemperatures Operating data: Number of overvoltages Data log: Digital input Data log: Bus commands Data log: Bus status word...
Page 529 ® 5000 Series Parameter Factory setting Range Changes 4-Setup Conversion Data type description during operation index 700 Relay 6, function Ready signal 701 Relay 6, ON delay 0 sec. 0.00-600 sec. 702 Relay 6, OFF delay 0 sec. 0.00-600 sec. 703 Relay 7, function Motor running 704 Relay 7, ON delay...
Page 530 ® 5000 Series ..............2-wire start/stop Earthing of braided screened/armouredcontrol cables ..........Electrical installation 47, 67 ..... Electrical installation, enclosures 51, 52, 53, 54 ....... Electrical installation, power cables 48, 49, 50 ......4-20 mA reference with speed feedback .............
Page 531 ® 5000 Series ....................Mechanical installation Vlt output data (u, v, w): 8, 8 ..............Menu mode ............. Menu structure ..........Motor thermal protection ........Warning against unintended start ..Warning word 1, Extended status wordandAlarm word ..............Warnings ....
Page 532 Niro Soavi S.p.A SECTION 7 SUPPLIERS CATALOGUE - INDEX 7.1. SUB-SUPPLIERS AND COMPONENTS CATALOGUE 7C001E0C.DOC 7.1.0...
Page 533 Niro Soavi S.p.A 7.1. SUB-SUPPLIERS AND COMPONENTS CATALOGUE We have included copies of the suppliers’ catalogues and of components installed in the machine. In addition to the maintenance guidelines provided in this USE AND MAINTENANCE MANUAL, you should refer to the specific instructions of any installed components.
Page 534 ® VIA EMILIA OVEST 915/A - MODENA - I * C.P. 310 - 41100 MODENA ( 059 33 02 88 Fax 059 82 77 74 info@rossimotoriduttori.it S.p.A. MODENA - I www.rossimotoriduttori.it ROSSI GETRIEBEMOTOREN ROSSI GEARMOTORS ROSSI MOTOREDUCTEURS ROSSI MOTORREDUCTORES ROSSI GEARMOTORS GmbH DÜSSELDORF - D Ltd.
Page 535 ® Designation Designation (see Two months and year table on the right) of manufacture Product S.p.A. MODENA - Made in Italy Machine Train of gears Size Design TIPO Mounting position (when Non-standard executions R, MR V, IV, 2IV 32 ... 250 UO ... Worm TYPE differing from IM B3 or B5)
Page 536 Gear reducers and gearmotors should be protected whenever pos- Important! The shoulder diameter of the shaft end of the driven sible and by appropriate means from solar radiation and extremes machine abutting with the gear reducer must be at least 1,18 1,25 of weather;...
Page 537 6.2 - Lubrication table Product How supplied* and plugs Directions for first filling FILLED WITH SYNTHETIC OIL AGIP Blasia S 320, KLÜBER Klübersynth GH 6-320, MOBIL Glygoyle HE 320, SHELL Tivela WB/SD Worm sizes 32 ... 81 Worm speed 280 min KLÜBER Klübersynth GH 6-680, MOBIL Glygoyle HE 680 Filler/drain plug...
Page 538 Oil-change interval and lubricant quantity Oil quantity [l] for worm gear reducers sizes 32 ... 81 For the other sizes the quantity is given by the level stated by the proper plug. R V, MR V R IV, MR IV MR 2IV Size B3 , V5, B6, B7...
Page 539 Attention! After a running period, gear reducer (exclu- Be sure that for gear reducers and gearmotors size 100, the filler ding the shaft mounted gear reducers) is subject to a light plug is provided with a valve (symbol ); otherwise, replace it internal overpression which may cause burning liquid dis- with the one normally supplied with.
Page 540 – locate the spacer (with adhesive, check that between keyway 10 - Troubles: causes and corrective actions and motor shaft shoulder there is a grounded cylindrical part of at least 1,5 mm) and pinion on the motor (pinion pre-heated to 80 Trouble Possible causes Corrective actions...
Page 541 Installing fig. 4a) and removing fig. 4b) fig. 4a) fig. 4b) Worm sizes 32 ... 50 Parallel and right angle Worm sizes 63 ... 161 Parallel and right angle shaft size 50 shaft sizes 64 ... 160 Axial fastening Parallel and right angle Worm sizes 200, 250 Parallel and right angle shaft size 63...
Page 545 3 Port Direct Operated Poppet Rubber Seal VT307 Series Model Large Flow Capacity, yet Compact Size. Single unit Manifold style Standard VT307 VO307 Dimensions (W X H X D)······30 X 54.5 X 33 Continuous duty VT307E VO307E (Grommet) Energy saving VT307Y VO307Y VT307······Cv 0.21 or more, Rc(PT)1/4...

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