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Fairford Electronics QFE Series Manual

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Summary of Contents for Fairford Electronics QFE Series

  • Page 1 If, by permission of the copyright owner, any part of this document is quoted, then a statement specifying  the original document shall be added to the quotation. Any such quotation shall be according to the original  (text, figure or table) and may not be shortened or modified.  Fairford Electronics • Innovation in Soft Start Technology Bristow House, Gillard Way, Lee Mill Industrial Estate, Ivybridge, PL21 9GG. United Kingdom Tel: +44 (0) 1752 894554 • Fax: +44 (0) 1752 897145 • Email: info@fairford.com • www.fairford.com...
  • Page 2 19   Communications Application Note  19   Fairford Electronics • Innovation in Soft Start Technology Bristow House, Gillard Way, Lee Mill Industrial Estate, Ivybridge, PL21 9GG. United Kingdom Tel: +44 (0) 1752 894554 • Fax: +44 (0) 1752 897145 • Email: info@fairford.com •...

  • Page 3: Qfe‐O

    Basic Guide to the Soft Starters and Energy Installation and Operation Optimising Soft Starters Of the Soft Starter Guide to contents - applicable to 5MC software V56 Mechanical Outlines Referring to the appropriate size of QFE, mount the QFE ensuring that correct clearances are maintained for adequate ventilation and operation of the QFE.
  • Page 4 Mechanical Outlines Size2 QFE174 to QFE370 Size1 QFE9 to QFE146 All dimensions in mm Mounting Centres 250 x 500 suitable for M6 fixings All dimensions in mm 2 "keyholes" at top 2 open Mounting holes suitable for M6 slots at the bottom. fixings unit weights Unit weights:-...
  • Page 5 Wiring Diagrams The Electronic control card is located underneath the cover in the Size 1 and 2 units and inside the hinged door panel in Size 3 units. Connections shown in the Fig 2.1 Control circuit wiring control circuit wiring diagram are made to the elec- Control Note Supply...
  • Page 6 (The corresponding default Starts or stops motor (provided keypad control is selected). settings are shown in brackets). For the full menu structure, refer to the QFE Manual. Menu structure Typical Keypad menu. Contact Fairford Electronics Ltd for details. ENTER ENTER ENTER ENTER...
  • Page 7 Set-up examples Starter Enable/Disable An additional safety feature has been added so that following certain actions the starter will be disabled. It is strongly recommended that before any changes to parameter values are made, that the starter is disabled via the Basic Menu. Once disabled, the starter remains unable to drive the load, until it has been enabled via the Basic Menu, or the control supply is removed and reapplied, or the key is pressed when prompted.
  • Page 8 Product information Design standards and Approvals IEC 60947-4-2; EN 60947-4-2 ‘AC Semiconductor Motor Controllers and Starters’. Models QFE and QFE-G bearing the UL Listing mark, , are UL Listed to U.S. and Canadian safety standards. 5.2 Basic ratings Connector/ terminal Rated freq.
  • Page 9 5.3 Safety and installation. Table 5.3 Semiconductor Fuse types Rated insulation voltage (Ui) 690V Short UL Recognized JFHR2 Fuses Circuit Bussman Ferraz Model Name Ingress Protection IP20 (Arms) International Mod. No. Amps Inc. 6.6 URD (kA) Mod. No. followed by Pollution degree 170M3110 30 D08A 0063...
  • Page 10 Soft Starters and Energy Optimising Soft Starters Fairford Electronics Limited, Bristow House, Gillard Way, Ivybridge, Devon PL21 9GG, United Kingdom TEL: + 44 (0) 1752 894554 FAX: + 44 (0) 1752 897145 EMAIL: sales@fairford.co.uk...
  • Page 11 Note #1: Limits Rated Operational Voltage to 500VAC. Copyright ©Fairford Electronics Ltd. 2007, Document Number FD85D104-F. Published: June 2007. M-85D1-F Fairford Electronics Limited, Bristow House, Gillard Way, Lee Mill Industrial Estate, Ivybridge, PL21 9GG, UK TEL: + 44 (0) 1752 894554 FAX: + 44 (0) 1752 894554 EMAIL: sales@fairford.co.uk...
  • Page 12 Mechanical Outline 400 Amp to 600 Amp "O" Range Soft Starters Airflow may be reversed on some assemblies L1,L2,L3 T1,T2,T3 M10 Earth connection point M10 clearance Please Note Fans are fixed voltage and must be Current Transformers specified as either 115V or 230V. Due to the Current ratings of this size of Soft Starters, ALL DIMENSIONS IN mm.
  • Page 13 Mechanical Outline 750 Amp "O" Range Soft Starter Airflow may be reversed on some assemblies T1,T2,T3 L1,L2,L3 M10 clearance Please Note Fans are fixed voltage and must be specified as either 115V or 230V. ALL DIMENSIONS IN mm. Minimum top/bottom clearance - 200mm Minimum side clearance - 25mm Minimum front clearance - 25mm NOTE - LIVE HEATSINKS...
  • Page 14 Mechanical outline - 900 Amp and 1100 Amp “O” Range Soft Starters L1, L2, L3 T1, T2, T3 ALL DIMENSIONS IN mm. Minimum top/bottom clearance - 200mm Minimum side clearance - 25mm Minimum front clearance - 25mm NOTE - LIVE HEATSINKS Current Transformers Due to the Current ratings of this size of Soft Starters, an “Interposing CT”...
  • Page 15 Mechanical Outline 1200 Amp “O” Range Soft Starter all terminations are for M12 ALL DIMENSIONS IN mm. Minimum top/bottom clearance - 200mm Minimum side clearance - 25mm Minimum front clearance - 25mm NOTE - LIVE HEATSINKS Current Transformers Due to the Current ratings of this size of Soft Starters, an “Interposing CT” is required. A small CT is fitted internally to these units and an additional CT, rated for the size of the Starter, is provided separately.
  • Page 16 Mechanical Outline 1400 Amp to 1800 Amp "O" Range Soft Starters L1, L2, L3 L1, L2, L3 T1, T2, T3 T1, T2, T3 Minimum front clearance 25mm. Minimum side clearance 25mm Minimum top/bottom clearance 200mm. All dimensions in mm. NOTE - LIVE HEATSINKS Current Transformers Due to the Current ratings of this size of Soft Starters, an “Interposing CT”...

  • Page 27: Electrical Installation

    Soft Start Motor Controller Technical Data for the QFE and QFEplus Electrical Installation FD8413 issue03_F...

  • Page 28: Table Of Contents

    Electrical Installation Electrical Installation Warnings 2.1.1 Isolation ....................2-5 2.1.2 Electrical Control Supply Requirements ..........2-5 2.1.3 Access ....................2-5 2.1.4 Fuse Protection ..................2-5 Electrical Connections 2.2.1 Electrical Supplies ................2-6 2.2.2 Control, Power and Earth Terminations ..........2-6 Standard Wiring Configurations 2.3.1 Wiring Diagram for In-line Connection of Motors ........

  • Page 29: Warnings

    Electrical Installation Electrical Installation Warnings 2.1.1 Isolation Caution: The QFE uses semiconductor devices in the main circuit and is not designed to provide isolation. For this reason isolation means must be installed in the supply circuit in accordance with the appropriate wiring and safety regulations. 2.1.2 Electrical Control Supply Requirements All Models All electrical connections are made to power input and output terminals, control...

  • Page 30: Electrical Connections Electrical Supplies

    Electrical Installation Electrical Connections 2.2.1 Electrical Supplies The unit requires two AC supplies:- A 3-phase balanced Mains Supply to provide the power for the controlled motor. A single-phase supply: 115V/230V, 50Hz/60Hz, for the internal control circuitry. The unit will not operate unless the control supply voltage is within the specified limits. It is recommended that the control supply is maintained between starts to ensure overload integrity, as the overload will reset on control supply removal.

  • Page 31: Standard Wiring Configurations

    Electrical Installation Standard Wiring Configurations There are two standard wiring configurations for the connection of a motor, a motor controller (Soft Start) and the mains supply: Configuration 1: In-Line connection for Delta and Star (Wye) Connected Motors This is the recommended connection and is suitable for most motors. Configuration 2: In-Delta connection for Delta Connected Motors If required the QFE can be installed within the delta windings.

  • Page 32: Wiring Diagram For In-Delta Connection Of Motors

    Electrical Installation 2.3.2 Wiring Diagram for In-Delta Connection of Motors Figure 2.3.2 In-Delta connection for Delta connected induction motors page 2-8 FD8413 issue03_F...

  • Page 33: Motor Control Circuits Bypass Control

    Electrical Installation Motor Control Circuits 2.4.1 Bypass Control A separate bypass contactor may be connected in parallel with the QFE or QFEplus. This allows a solid connection of the motor to the mains supply which will eliminate the heating effect associated with thyristor losses. Soft-Starting and Soft-Stopping remain active as normal when the wiring is configured as in Figure 2.4.1.

  • Page 34: Multiple Motor Starting & Stopping

    Electrical Installation 2.4.2 Multiple Motor Starting & Stopping The QFE is capable of starting parallel-connected motors simultaneously provided each motor has similar characteristics and load. For such configurations the unit rating should be at least the sum of the current ratings of all the motors. Alternatively, the QFE can start and stop motors sequentially using bypass contactors under the control of the programmable relay set as a 'Top of Ramp' relay.

  • Page 35: Wiring Diagram For Motor Reversing

    Electrical Installation 2.4.6 Wiring diagram for Motor Reversing Power Circuit Fuses Contactor Control Circuit Isolator Control Supply Emergency Stop Enable STOP REVERSE FORWARD Soft Start S0, 00 Figure 2.4.6: Typical Power and Contactor Control Circuit for Motor Reversing page 2-11 FD8413 issue03_F...

  • Page 36: Electrical Connections

    Electrical Installation Electrical Connections QFE and QFEplus 2.5.1 Chassis Size1 and 2 CONTROL VOLTAGE TERMINALS X1, X2 (Input) CONTROL VOLTAGE SELECTOR SWITCH Ensure that the selector switch position corresponds to the control supply used, either 110V or 230V, before you apply the control supply. EARTH STUD POWER TERMINALS L1, L2, L3 (Input) Electrical ground (PE)

  • Page 37: Chassis Size 3

    Electrical Installation 2.5.2 Chassis Size 3 To open covers, unscrew in 4 positions POWER TERMINALS L1, L2, L3 (Input) Isolatable 3-phase supply (via contactor, isolator, etc.). Any phase can connect to any terminal. CONTROL VOLTAGE TERMINALS X1, X2 (Input) CONTROL VOLTAGE SELECTOR SWITCH Ensure that the selector switch position corresponds to the control supply used,...

  • Page 38: Electronic Control Card

    Electrical Installation 2.5.3 Electronic Control Card * INTERNAL FACTORY FITTED CONNECTIONS: Keypad connection header. J1, J2, J3, J5, J6, J12, J13 and J14. D5 (Green)Indicates the presence of the control supply. J14*Connection J13*Connection J12*Connection to chassis mounted to chassis mounted to chassis mounted power device power device...

  • Page 39: Auxiliary Function Card

    Electrical Installation 2.5.4 Auxiliary Function Card QFEplus only 4-20mA DC i/p Trim Trim © FAIRFORD ELECTRONICS Ltd PCB8200X6 4-20mA 120V Terminal Function Description Markings Analogue A voltage (range 0-10V) represents the analogue value of a Output 1 selected parameter. (Advanced user facility)

  • Page 40: Supply Connections Electrical Supply

    Electrical Installation Supply Connections 2.6.1 Electrical Supply Power terminals 1 L1, 3 L2, 5 L3 on all units may be connected to a balanced 3-phase, 3-wire AC supply that is within the limits specified below. Nominal Supply Voltage Range Rated Operational Voltage (U 230 -15% 460 + 10% 230V/460V...

  • Page 41: Control Card Connections

    Electrical Installation Control Card Connections All the control inputs and outputs are on the Electronic Control Card (ELC), mounted within the unit. Diagrams in section 2.5 show the location of the electronic control card. 2.7.1 Control Inputs Identification Description nc th/sw Thermal switch input (2 terminals).

  • Page 42: Control Outputs - All Models

    Electrical Installation 2.7.3 Control Outputs - All models Description Identification Programmable Output, Relay K1. 12, 14, 11 A Bit = 1 on the parameter/bit selected by P57 makes Relay K1 ACTIVE (normal logic sense) or INACTIVE (inverted logic sense). Default setting, P52, Bit 5: Main Contactor Relay change-over contacts: Contact rating:- 230VAC, 3A AC11 11 - Common.
  • Page 43 Electrical Installation page 2-19 FD8413 issue03_F...

  • Page 44: Typical Motor Powers At Rated Voltages

    Electrical Installation Typical Motor Powers at rated voltages The Amps values for the soft starter are the maximun continuous current for the model. 2.9.1 Chassis size1 motor powers 208 Volts 230 Volts 400 Volts 460 Volts 575 Volts 690 Volts G and E E models only models only...

  • Page 45: 2.9.3 Chassis Size3 Motor Powers

    Electrical Installation 2.9.3 Chassis size3 motor powers Model Amps 208 Volts 230 Volts 400 Volts 460 Volts 575 Volts 690 Volts G and E E models only models only 1200 2.9.4 Chassis size4 motor powers Model Amps 208 Volts 230 Volts 400 Volts 460 Volts 575 Volts...

  • Page 46: Fuse And Current Ratings Full-Load, Current Limit And Short-Circuit Protection

    Electrical Installation 2.10 Fuse and Current Ratings 2.10.1 Full-Load, Current Limit and Short-Circuit Protection QFE9 QFE16 QFE23 QFE30 QFE44 QFE59 QFE72 QFE85 QFE105 QFE146 QFE174 QFE202 QFE242 QFE300 QFE370 QFE500 QFE600 QFE750 QFE900 These fuses are for short circuit protection of the semiconductors and must be mounted externally by the user between the unit and the mains supply.

  • Page 47: Overload Current Profile And Duty Cycle Ac-53A

    Electrical Installation 2.10.3 Overload Current Profile and Duty Cycle AC-53a IEC 60947-4-2 Motor Utilisation Category: AC-53a ( not operating in bypass mode) Model AC-53a overload current profiles applicable to specified models. Numbers Overload Duration of Ratio of Number of Current Overload On-load period operating...

  • Page 48: Overload Current Profile Ac-53B

    Electrical Installation 2.10.4 Overload Current Profile AC-53B IEC 947-4-2 Motor Utilisation Category: AC-53b ( operating in bypass mode) Model AC-53b overload current profiles applicable to specified models. Numbers Overload Current Duration of Overload Unit Off Time (X, multiple of I seconds) (OFF-time, seconds) —...

  • Page 49: Overcurrent Trip Graph

    Electrical Installation 2.10.5 Overcurrent Trip Graph Overload start point (adjustable by P34 (or P93) ‡; default setting: 110%) 1000 Seconds to trip ‡ P35 (or P94) Default Delay = 140 Delay = 80 Delay = 30 Delay = 10 0.01 9 10 Fault current ( Motor Current x N ) ‡...
  • Page 50 Electrical Installation page 2-26 FD8413 issue03_F...
  • Page 80 FD8416 ApplicationsData . 11 Software Name Small Pump Start Pedestal % Stop Pedestal Start Time Soft Stop Time Current Limit Time Current Limit Level * FLC Optimise Rate Auto Pedestal Auto Jog Auto End Start Auto 3MC Auto bypass Auto Stop SoftStop Smoothing Low Volt SoftStop Auto ramp...
  • Page 81 Name Conveyor Start Pedestal % Stop Pedestal Soft Stop Time Start Time Current Limit Time Current Limit Level * FLC Optimise Rate Auto Pedestal Auto Jog Auto End Start Auto 3MC Auto bypass Auto Stop SoftStop Smoothing Low Volt SoftStop Auto ramp Auto End Stop Notes...
  • Page 82 Name Crusher Start Pedestal % Stop Pedestal Soft Stop Time Start Time Current Limit Time Current Limit Level 2.8125 * FLC Optimise Rate Auto Pedestal Auto Jog Auto End Start Auto 3MC Auto bypass Auto Stop SoftStop Smoothing Low Volt SoftStop Auto ramp Auto End Stop Notes...
  • Page 83 Name Default Start Pedestal % Stop Pedestal Soft Stop Time Start Time Current Limit Time Current Limit Level * FLC Optimise Rate Auto Pedestal Auto Jog Auto End Start Auto 3MC Auto bypass Auto Stop SoftStop Smoothing Low Volt SoftStop Auto ramp Auto End Stop Notes...

  • Page 84: Bit Parameters

    03 September 2003 FD8416 5MC Bit Parameters . 11 Software Parameter STATUS 1 Default Bitmask Name Type Description = ON Stopped Status start/stop signal inactive thyristors 00000001 off main contactor open Starting Status Starter is in start ramp 00000010 Current Limit Status During a softstart indicates motor 00000100...
  • Page 85 03 September 2003 FD8416 5MC Bit Parameters . 11 Software Parameter STATUS 3 Default Bitmask Name Type Description = ON Status Status of relay K1 00000001 Status Status of relay K2 00000010 Status Status of relay K3 (QFE+) 00000100 Status Status of relay K4 (QFE+) 00001000 I/P 1...
  • Page 86 03 September 2003 FD8416 5MC Bit Parameters . 11 Software Parameter USER FLAGS 1 Default Bitmask Name Type Description = ON Kickstart read/write Selects Kickstart (except in 3MC 00000001 mode) Current Limit read/write Selects Trip or continue on Current 00000010 Timeout selected Limit timeout Overload selected...
  • Page 87 03 September 2003 FD8416 5MC Bit Parameters . 11 Software Parameter USER FLAGS 3 Default Bitmask Name Type Description = ON pf1 pol read/write Polarity of programmable flags (1) 00000001 pf2 pol read/write Polarity of programmable flags (2) 00000010 User Current limit read/write Bus requests a Start ramp hold 00000100...
  • Page 88 03 September 2003 FD8416 5MC Bit Parameters . 11 Software Parameter Auto Config 2 Default Bitmask Name Type Description = ON Auto Ramp read/write Gently ramps the voltage to the 00000001 starter acting a bit like an automatic current limit. Auto 3MC read/write Enable automatic removal of low...
  • Page 89 03 September 2003 FD8416 5MC Bit Parameters . 11 Software Parameter USER FLAGS 2,2 Default Bitmask Name Type Description = ON Low Voltage read/write 00000001 SoftStop (2) Not Global enable 1 read/write 00000010 Not Global enable 2 read/write 00000100 Pod Start/stop (2) read/write 00001000 Board Start/stop (2) read/write...
  • Page 90 03 September 2003 FD8416 5MC Bit Parameters . 11 Software Parameter STATUS 5 Default Bitmask Name Type Description = ON Over Temperature Status Inhibits re-start if set. Effectivley 00000001 The heatsink is too hot to start but is ok to run. Offline Command read/only The last offline command failed ,...
  • Page 91 03 September 2003 FD8416 5MC Bit Parameters . 11 Software Parameter Hidden Trip Flags Default Bitmask Name Type Description = ON Trip 1 Enabled read/write Enable or disable Trip 1 Phase Loss 00000001 Trip 8 Enabled read/write Enable or disable Trip 8 Motor side 00000010 Thyristor Loss Trip 9 Enabled...
  • Page 92 FD8416 5MC Parameters 03 September 2003 Software . 11 Parameter Name Default Units Type Scaling 0 dummy parameter none Read Only Description Hints Dummy used for mapping unused bit parameters etc. Parameter Name Default Units Type Scaling 1 STATION NUMBER none Read/Write Description...
  • Page 93 FD8416 5MC Parameters 03 September 2003 Software . 11 Parameter Name Default Units Type Scaling 8 STATUS 1 flags Read Only Description Hints no description Parameter Name Default Units Type Scaling 9 STATUS 2 flags Read Only Description Hints no description Parameter Name Default Units...
  • Page 94 FD8416 5MC Parameters 03 September 2003 Software . 11 Parameter Name Default Units Type Scaling 16 SOFT STOP PEDESTAL Read/Write Description Hints percentage of supply voltage at which the soft stop will cease. The actual value is affected by certain load variations.
  • Page 95 FD8416 5MC Parameters 03 September 2003 Software . 11 Parameter Name Default Units Type Scaling 24 RATED CURRENT( HUNDREDS) 3000 Amps Read/Write Description Hints Units rated current is stored in two bytes parameter 24 & 25, Parameter 24 holds the number of hundreds.These parameters should not be changed since they go hand in hand with the burden resistors fitted to the board.
  • Page 96 FD8416 5MC Parameters 03 September 2003 Software . 11 Parameter Name Default Units Type Scaling 31 CURRENT LIMIT TIME Secs Read/Write Description Hints The maximum time allowed for the current limit before it trips or continues the ramp regardless of motor current level. Parameter Name Default Units...
  • Page 97 FD8416 5MC Parameters 03 September 2003 Software . 11 Parameter Name Default Units Type Scaling 39 POT2 none Read Only Description Hints This parameter is normally mapped to stop time. Now only used on special edition boards Parameter Name Default Units Type Scaling...
  • Page 98 FD8416 5MC Parameters 03 September 2003 Software . 11 Parameter Name Default Units Type Scaling 48 SET LEVEL DC I/P 5.01961 9.96078 0.03922 Volts Read/Write 0.03922 Description Hints value is level at which the DC-I/p level bit will be set. Parameter Name Default Units...
  • Page 99 FD8416 5MC Parameters 03 September 2003 Software . 11 Parameter Name Default Units Type Scaling 57 MAP K1 TO prmtr Read/Write Description Hints Value is parameter number which is the Source for the K1 bit. Parameter 58 holds the mask for mapping to Parameter Name Default Units...
  • Page 100 FD8416 5MC Parameters 03 September 2003 Software . 11 Parameter Name Default Units Type Scaling 65 I/P1 MAP TO prmtr Read/Write Description Hints Value is parameter number which is the destination for the This is normally the start/stop I/p (remote). I/p1 bit.
  • Page 101 FD8416 5MC Parameters 03 September 2003 Software . 11 Parameter Name Default Units Type Scaling 73 LAST TRIP trips Read Only Description Hints the number of the last trip E1 Phase Loss E2 Too Hot E3,5,6 SCR Signal E4 SCR Firing E7,8,9 Sensing Signal E10 SCR Shorted E11 Low Current...
  • Page 102 FD8416 5MC Parameters 03 September 2003 Software . 11 Parameter Name Default Units Type Scaling 76 4TH LAST TRIP trips Read Only Description Hints the number of the 4th to last trip E1 Phase Loss E2 Too Hot E3,5,6 SCR Signal E4 SCR Firing E7,8,9 Sensing Signal E10 SCR Shorted...
  • Page 103 FD8416 5MC Parameters 03 September 2003 Software . 11 Parameter Name Default Units Type Scaling 81 KICK PED 2 Read/Write Description Hints kickstart pedestal to use with the second parameter set Edit in P Menu Parameter Name Default Units Type Scaling 82 KICK TIME 2 cycles...
  • Page 104 FD8416 5MC Parameters 03 September 2003 Software . 11 Parameter Name Default Units Type Scaling 90 CURRENT LIMIT TIME 2 Secs Read/Write Description Hints Current limit timeout to use with the second parameter set Edit in P Menu Parameter Name Default Units Type...
  • Page 105 FD8416 5MC Parameters 03 September 2003 Software . 11 Parameter Name Default Units Type Scaling 98 ipf1_mask mask Read/Write Description Hints User flag mapping through parameters 97,98,99,100. 97,98 give source flag address 97=parameter 98 = bit mask 99,100 give the destination flag address. 99=parameter 100 = bit mask Parameter Name Default...
  • Page 106 FD8416 5MC Parameters 03 September 2003 Software . 11 Parameter Name Default Units Type Scaling 104 opf2_mask mask Read/Write Description Hints User flag mapping through parameters 101,102,103,104. 101,102 give source flag address 101=parameter 102 = bit mask 103,104 give the destination flag address. 103=parameter 104 = bit mask Parameter Name Default...
  • Page 107 FD8416 5MC Parameters 03 September 2003 Software . 11 Parameter Name Default Units Type Scaling 112 STATUS 4 flags Read Only Description Hints More useful control flags Parameter Name Default Units Type Scaling 113 drive type none Read Only Description Hints Unused Parameter Name...
  • Page 108 FD8416 5MC Parameters 03 September 2003 Software . 11 Parameter Name Default Units Type Scaling 121 USER_FLAGS4 flags Read/Write Description Hints Yet more control flags Parameter Name Default Units Type Scaling 122 ss_smoothing none Read/Write Description Hints Arbitrary filter to smooth soft stop jitters caused by unstable load.
  • Page 109 Tech Hints General Category No : Date : Subject : 10/07/2002 Motor configuration If the motor starts ok but stalls as soon as a load is applied then check the configuration of the motor, i.e it may be that the motor is meant to be connected in delta but is actually connected in star No : Date : Subject :...
  • Page 110 No : Date : Subject : 02/09/2003 Contactors Contactors marked for example K1 on wiring diagrams are not included within the soft starters. No : Date : Subject : 02/09/2003 Soft Starts Soft starters reduce motor starting current at the expense of reducing starting torque and increasing start time.
  • Page 111 No : Date : Subject : 02/09/2003 Commissioning 2 If the softstart trips on overload during the start, check starter is large enough for the load. No : Date : Subject : 02/09/2003 "Too Hot" Check ventilation into the cabinet. If the unit has worked for a long time check fans and airflow through unit.

  • Page 112: Programming Guide

    Soft Start Motor Controller Technical Data for the QFE and QFEplus Programming Guide FD8420 issue02_F...

  • Page 113: Form

    All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical including photocopying, recording, or by any information storage or retrieval system without written permission. Copyright ©Fairford Electronics Ltd. 2003 Document Number FD8420 Issue 02. Published September 2003. page 5-2...
  • Page 114 Programming Programming Versions ....................5-5 5.1.1 Useful Information ................5-5 5.1.2 Conventions ..................5-5 5.1.3 Quick Start .................... 5-5 User Interface 5.2.1 The Keypad and Keypod ..............5-6 5.2.2 Menu Structure ..................5-6 5.2.3 System Status Mode ................5-8 5.2.4 Menu Navigation Mode .................
  • Page 115 Programming 5.5.4 Selecting Optimising with Programmable Input 1....... 5-50 5.5.5 Selecting a ‘Kick’ Start with Programmable Input 3, (applies to plus units only)..............5-52 5.5.6 Selecting a Parameter Group with Programmable Input 2, (applies to plus units only)..............5-54 5.5.7 Using the K3 relay to indicate the Main Contactor status, (applies to plus units only).

  • Page 116: Programming Versions

    Programming Programming Versions This manual applies to the following versions of software; 5MC software version: 5MC V 55.11 Keypad software version: V1.063 Menu software version:Menu V1.017 5.1.1 Useful Information Further useful information can be found in the following documents which are available on the website, http://www.fairford.co.uk;...

  • Page 117: User Interface The Keypad And Keypod

    Programming User Interface 5.2.1 The Keypad and Keypod There are two types of user interface for use with the QFE - the keypad (refer to Figure 5.2.1) and the keypod (refer to Figure 5.2.1a). The keypad is the user interface which is internally mounted on the QFE.

  • Page 118: Delay

    Programming QFE Menu Structure Level 2 Level 0 Level 1 Level 3 Settings Stopped and ready Applications Default (Keypad) Settings Auto Features Default Auto Auto Jog (Off) Small Pump Auto Pedestal (Off) Large Pump Auto end start (Off) Conveyor Auto stop (Off) Auto Features Starter Disabled Low Inertia Fan...

  • Page 119: System Status Mode

    Programming Notes for Figure 5.2.2 1. Parameters that are listed in boxes with white writing on a dark background, thus; White will only be effective if the Auxiliary Function Card is fitted, as they are for use in conjunction with the extra hardware functionality that pcb provides.

  • Page 120: Changing Parameter Values

    Programming A user can tell whether the menu item or parameter is writeable as there will be a flashing cursor present on the bottom line of the display if writing is permitted. Writeable values may be changed by using the up and down keys (for a numerical value) or by pressing Enter (for a change in a logic value).

  • Page 121: Keypad/Keypod Boot-Up Messages

    Programming 5.2.8 continued A cursor would be flashing at the character on the display which represents the Least Significant Bit (LSB, also known as bit 0; i.e. the 0 or 1 on the right hand side of the eight 0’s and/or 1’s).

  • Page 122: Using The Menus

    Programming Using the Menus This section gives a brief description of the individual menus and the functions that their parameters perform. 5.3.1 The Applications Menu This menu contains a list of typical applications for which a set of parameters have been predefined by the manufacturer.

  • Page 123: The Auto Menu

    Programming 5.3.2 The Auto Menu The Auto Menu contains commonly used parameters that may be automatically adjusted by the unit. A brief description of each entry is given below. When active this menu item will provide a brief Settings report on which, if any, Auto options have been switched On. A downwards facing arrow will appear on the right hand side of the top line of the user interface display.
  • Page 124 Programming This menu item turns On and Off the automatic Auto Stop adjustment of the soft stop. When On the unit attempts to automatically adjust the soft stop profile to suit the load. The default value is Off. This menu item turns On and Off the automatic detection Auto End Stop of a stalled motor during soft stop.

  • Page 125: The Basic Menu

    Programming 5.3.3 The Basic Menu The Basic menu holds the parameters which control the primary functions of the unit (see Figure 5.3.3). Changing the values of these parameters will vary the starting and stopping duties, the trip protection set for the unit and the source of the start signal (Keypad or Remote).

  • Page 126: The Advanced Menu

    Programming This is the level of load current at which the unit stops Current Limit ramping up the voltage applied to the load, and prevents the ramp from continuing within a time limit. At the end of the time limit (Limit Time Out, P31, see section 5.3.5) the unit will either stop or continue depending on the value of C/L Time Out in the Current menu (section 5.3.5).
  • Page 127 Programming This parameter sets a tolerance level for the unit’s Trip Sensitivity sensitivity towards trips. The higher the value this parameter is set to, the less sensitive the unit is to trip conditions. This is set to one (1) by default. This parameter holds the local network ID for this Station Number unit.
  • Page 128 Programming Firing Mode 4, for static loads with the star point connected to the neutral, and the soft start unit using a closed loop control method (QFE+ only); Firing Mode 5, for static loads with the star point connected to the neutral, and the soft start unit using an open loop control method.

  • Page 129: The Current Menu

    Programming 5.3.5 The Current Menu The Current submenu contains all the parameters associated with the Unit Full Load Current, and it’s associated trip levels. A short explanation of each item in the menu is given below. This parameter holds the value of the soft starter’s rated Rated Current current.
  • Page 130 Programming This menu item turns On and Off the Shearpin trip. The Shearpin Shearpin trip is intended to catch transient current peaks which exceed the value specified in the Shearpin Level parameter for a time that is specified in the Shearpin Time parameter.
  • Page 131 Programming This parameter holds the level in Amps at which an Overload Level Overload trip will start integrating (see the graph below). The default value for this parameter is 1.1 × Unit Full Load Current, but is expressed in Amps. Special case: if a load current exceeding 7.2 x FLC occurs for longer than 60 mS, a Shearpin Trip is forced whenever the Overload is On, see section 5.3.11.

  • Page 132: Permanent Store Menu

    Programming 5.3.6 Permanent Store Menu This item saves all the parameter settings to a permanent Save Param store. This means that if the control supply is removed from the main control board, the parameters will still remain stored and will be recalled the next time the unit boots up. See section 5.4.5.

  • Page 133: The Outputs Menu

    Programming 5.3.9 The Outputs Menu This menu item is only of use to a customer who is using the Pot’s and Switches software, which is covered by another publication (FD50E3 & FD50EJ). This menu item allows the customer to program the K1 relay (section 2.7.3 of Electrical Installation).

  • Page 134: The Trips Menu

    Programming 5.3.11 The Trips Menu This menu holds all the parameters that are associated with control of the various trips This sub menu accesses a trip history of the unit’s last Trips five trips. These trips are recorded automatically and need no intervention from the user. They are useful in fault-finding a unit.
  • Page 135 Programming C/L Time Out The unit will trip if during start-up the unit’s output current reaches the Current Limit level (P30 )for a time specified in Limit Time Out (P31). Overload The unit will trip if the output current exceeds the previously set Overload Level (P34), and will trip in a time governed by the size of the load current and a previously set arbitrary number, Overload Delay (P35), (see Figure 5.3.5d).

  • Page 136: Setup Examples

    Programming Setup Examples This section holds common programming examples that any customer might wish to use. They explain how to set up the QFE for common tasks. Further, more advanced examples are given in section 5.5.2 and following. 5.4.1 Enabling and Disabling the QFE In this software release, the QFE has an additional safety feature, the Enable/Disable parameter;...

  • Page 137: How To Read The Setup Examples

    Programming To sum up, when the unit is disabled, all writeable parameters can be written to. When the unit is enabled, most, but NOT all, writeable parameters can be written to. Examples of parameters that cannot be written to whilst the unit is enabled, are the password and the currently loaded application: also default parameter values cannot be loaded whilst the unit is enabled.
  • Page 138 Programming Press the # button to cancel the instruction, or the Enter button to confirm it. Instruction 7 will state, “Press the up button this many times.” This instruction is associated with the up button icons at this position. These icons represent the buttons on the keypad and keypod.

  • Page 139: Loading The 'Large Pump' Application Into Memory

    Programming 5.4.3 Loading the ‘large pump’ application into memory. There are a number of pre-programmed applications included for speed and ease of setup. The parameters loaded by each selection characterise the standard setup of each particular application. Note: This example assumes that the unit has been disabled (see section 5.4.1). 1.

  • Page 140: Changing From 'Keypad Starting' To 'Remote Starting

    Programming 5.4.4 Changing from ‘Keypad Starting’ to ‘Remote Starting’. With ‘Keypad Starting’ set the unit is started from the keypad/keypod. Whilst ‘Remote Starting’ is set the unit is started with a start signal between S0 and S1. ‘Remote Starting’ is the factory default value.

  • Page 141: Permanently Saving Parameters Set By The User

    Programming 5.4.5 Permanently saving parameters set by the user. To save parameters set by the customer, follow this procedure. Note: This example assumes that the unit has been disabled (see section 5.4.1) 1. With Starter Disabled shown on the display, press button once.

  • Page 142: Loading The Default Parameter Values With 'Keypad Starting' Option

    Programming 5.4.6 Loading the default parameter values with ‘Keypad Starting’ option. Note: This example assumes that the unit has been disabled (see section 5.4.1). 1. With Starter Disabled shown on the display press the Enter button once. 2. With Applications shown on the top line of the display, press the Enter button again.

  • Page 143: Loading The Default Parameter Values With 'Remote Starting' Option

    Programming 5.4.7 Loading the default parameter values with ‘Remote Starting’ option. Note: This example assumes that the unit has been disabled (see section 5.4.1). 1. With Stopped and ready shown on the display press the Enter button once. 2. With Applications shown on the top line of the display, press the button until Permanent Store is on the top line of the display.

  • Page 144: Viewing Basic Operating Parameter Values Via The Settings Menu Option

    Programming 5.4.8 Viewing basic operating parameter values via the Settings menu option. 1. With Starter Disabled shown on the display press the Enter button once. 2. With Applications shown on the top line of the display, press the Enter button again.

  • Page 145: Changing A Password

    Programming 5.4.9 Changing a password. Note: This example assumes that the unit has been disabled (see section 5.4.1) and if necessary has already been unlocked (see section 5.4.10). 1. With Starter Disabled displayed press the Enter button once. 2. With Applications shown on the top line of the display, press the button until Password takes it’s place on the top line.

  • Page 146: Unlocking And Locking The Keypad

    Programming 5.4.10 Unlocking and locking the keypad. 1. With Stopped and ready displayed press the Enter button once. 2. With Applications shown on the top line of the display, press the button until Password takes it’s place on the top line. 3.

  • Page 147: Using The Pre-Programmed Relay Options

    Programming 5.4.11 Using the pre-programmed relay options. This example shows the user how to program any relay on the unit to via the pre-programmed options. The option shown in the example below is the Alarm, but the instructions apply equally for all of the pre-programmed relay options (see section 5.3.9), and for all of the relays - as they are all programmable.

  • Page 148: Setting The Low Amps Level, And Using The K2 Relay To Display The Status Of Low Current Bit

    Programming 5.4.12 Setting the Low Amps Level, and using the K2 relay to display the status of Low Current bit. This example shows the user how to set the Low Amps Level, and how to monitor the status of the Low Current bit via the K2 relay (see section 5.3.5). 1.
  • Page 149 Programming 7. With Low Amps Level showing on the top line press the buttons until the level required is set. 8. Press Enter once to confirm the change. The display will flash to confirm that the change has been made. 9.
  • Page 150 Programming 18. With Map From on the top line of the display, press the button once. 19. Press the Enter button once to select Bit Number. 20. Press the Optimise button three times to move the cursor to bit 3. 21.

  • Page 151: Using The K2 Relay To Mimic Programmable Input 1

    Programming 5.4.13 Using the K2 relay to mimic Programmable Input 1. This example shows the user how energise a relay via the start signal. 1. With Stopped and Ready shown on the display press the Enter button once. 2. With Applications shown on the top line of the display press the button until Outputs is shown at the top of the display.
  • Page 152 Programming 7. With 8 Parameter showing press the button until 10 Parameter is displayed. 8. Press Enter once to apply the change 9. Press # once to return to Map From. 10. With Map From on the top line of the display press button once until Bit Number is displayed.

  • Page 153: Advanced Setup Examples

    Programming Advanced Setup Examples 5.5.1 Using an Alternative Parameter Group For applications that require the control of two motors or where the user requires different control characteristics for a single motor at different stages of the duty cycle, the QFE soft starter offers two parameter groups.
  • Page 154 Programming The Primary group parameters can also be changed via the menu structure, however the Secondary group parameters can only be changed via the dedicated parameter numbers. As a default the soft starter uses the Primary group of parameters. The user can select from between each group from either the keypad or using one of the programmable control inputs.

  • Page 155: Changing The Parameter Group After The Unit Has Passed Top Of Ramp

    Programming 5.5.2 Changing the Parameter Group after the unit has passed Top of Ramp. In this example the user is shown how to change parameter groups whilst running, if, for example, two overload values were required, one for starting and the other for running. 1.
  • Page 156 Programming 8. With 0 Parameter shown on the display press the button until 8 Parameter is displayed. 9. Press Enter once to accept the change. 10. Press # once to return to P97 U1 I/P srce. 11. Press the button once until P98 U1 I/P Mask is shown at the top of the display. 12.
  • Page 157 Programming 17. Press the button once so that P99 U1 O/P Dest is shown at the top of the display. 18. Press Enter to select P99 U1 O/P Dest. 19. With 0 Parameter shown on the display press the button until 52 Parameter is displayed.
  • Page 158 Programming This page is left intentionally blank. page 5-47 FD8420 issue02_F...

  • Page 159: Using The K3 Relay To Indicate A Stall (Applies To Plus Units Only)

    Programming 5.5.3 Using the K3 relay to indicate a Stall (applies to plus units only). Here the user is shown how to output the unit’s stall signal. This might be used by a customer to monitor a motor’s stall status. 1.
  • Page 160 Programming 7. Check that 9 Parameter is showing - if it isn’t press the button until it is displayed. 8. Press Enter once to apply any changes and the display will flash once to confirm the changes have been accepted. 9.

  • Page 161: Selecting Optimising With Programmable Input 1

    Programming 5.5.4 Selecting Optimising with Programmable Input 1. This example programs the S1 input to turn the Optimising function Off and On. When the specified voltage is applied and removed to and from the S1 input, the energy optimising function is turned Off and On ( note the inverse action - apply voltage = Optimising Off). 1.
  • Page 162 Programming 9. With Map To on the top line of the display press the button once until Bit Number is displayed. 10. Press Enter once to select Bit Number. 11. Press the Optimise button four times so that the cursor moves to bit 4. 12.

  • Page 163: Selecting A 'Kick' Start With Programmable Input 3, (Applies To Plus Units Only)

    Programming 5.5.5 Selecting a ‘Kick’ Start with Programmable Input 3, (applies to plus units only). If the start-up characteristics of the load vary, i.e. ‘sticky’ and non-sticky, the user will be able to use the input to select a kick start for a ‘sticky’ load. 1.
  • Page 164 Programming 10. With Map To on the top line of the display press button once until Bit Number is displayed. 11. Press Enter once to select Bit Number. 12. Press the button once to change the bit state of the LSB to one (1). 13.

  • Page 165: Selecting A Parameter Group With Programmable Input 2, (Applies To Plus Units Only)

    Programming 5.5.6 Selecting a Parameter Group with Programmable Input 2, (applies to plus units only). The user will be able to choose between two pre-programmed parameter groups, using the second programmable input. These parameter groups will have been pre-programmed by user to suit different load conditions.
  • Page 166 Programming 10. With Map To on the top line of the display press the button once until Bit Number is displayed. 11. Press Enter once to select Bit Number. 12. Press the Optimise button six times so the cursor is displayed on bit 6. 13.

  • Page 167: Using The K3 Relay To Indicate The Main Contactor Status, (Applies To Plus Units Only)

    Programming 5.5.7 Using the K3 relay to indicate the Main Contactor status, (applies to plus units only). 1. With Stopped and Ready shown on the display press the Enter button once. 2. With Applications shown on the top line of the display press the button until Outputs is shown at the top of the display.
  • Page 168 Programming 7. Press the buttons until 52 Parameter is displayed on the bottom line of the display. 8. Press the Enter button once to apply the change. The display will flash once to confirm the change has been accepted. 9. Press # once to return to Map From. 10.

  • Page 169: Using The 4-20Ma Input To Monitor A Level, (Applies To Plus Units Only)

    Programming 5.5.8 Using the 4-20mA input to monitor a level, (applies to plus units only). The unit can monitor the voltage level of the 4-20mA input and can be programmed to set a bit when that input level reaches a certain value. This bit can then be used to energise a relay, for example the K3 relay.
  • Page 170 Programming 5. Press the Enter button. 6. Scroll down with the button until Set Level is on the top line. 7. Press the Enter button. 8. Using the buttons set the level at which the unit is required to switch over from a zero (0) to a one (1).
  • Page 171 Programming 19. Press the button until Bit Number is on the top line of the display. 20. Press the Enter button once to select Bit Number. 21. With the cursor on the LSB, press the button once to change the bit value to zero (0).

  • Page 172: Using The Dc Input To Set A Parameter's Value, (Applies To Plus Units Only)

    Programming 5.5.9 Using the DC input to set a parameter’s value, (applies to plus units only). In this example the Start Time (P12) is adjusted by means of the 0-10v DC Programmable Input. The following instructions describe how to program the input for this type of application.

  • Page 173: Mapping The Load Current To Analogue Output 2, (Applies To Plus Units Only)

    Programming 5.5.10 Mapping the Load Current to Analogue Output 2, (applies to plus units only). In this example the user will be able to take some real-time information from the unit and transfer it to the outside world in the from of an analogue signal. 1.

  • Page 174: Mapping Programmable Input 2 To The User Trip, (Applies To Plus Units Only)

    Programming 5.5.11 Mapping Programmable Input 2 to the User Trip, (applies to plus units only). This example shows the user how to program the QFE to accept a trip input from an external source. 1. With Stopped and ready shown on the display press the Enter button once. 2.
  • Page 175 Programming 10. With Map To on the top line of the display press the button once until Bit Number is displayed on the top line. 11. Press the Enter button once to select Bit Number. 12. Press the Optimise button three times so the cursor key moves to bit three. 13.

  • Page 176: Definitions

    Programming 5.6.1 Definitions Auxiliary Function Card An optional expansion card that extends the functionality of the QFE. See the Electrical Installation Manual, sections 2.5.4, 2.7.2 and 2.7.4. Dwell This is the period between Top of Ramp and Run which is designed to give unstable loads a chance to settle down.
  • Page 177 Programming 5.6.1 continued Static Static as in static loads. This term refers to loads with no moving parts, so induction motors, linear motors etc... are non static loads. An example of a static load would be a resistor bank. Top of Ramp This is the point at which the soft starter reaches maximum output voltage.
  • Page 178 F A I R F O R D E L E C T R O N I C S Soft Starters and Energy Optimising Soft Starters Technical Data for 5MC Based Soft Starters Modbus Protocol Manual FD5100 issue07...
  • Page 179 This document may not be reproduced, in full or in part, without written permission. Enquiries about copyright of Fairford Electronics deliverables should be made to Fairford Electronics, Coombe Works, Derby Road, Kingsbridge, Devon TQ7 1JL.
  • Page 180 Modbus The Modbus Protocol Overview ....................5 Quick Start ....................5 Specification .................... 6 Function 03 - Read holding registers ............7 Function 05 - Preset Single Coil .............. 7 Function 06 - Preset Single Register ............8 Function 07 - Exception status ..............8 continued ....................
  • Page 181 Modbus FD510007 page 6-4...

  • Page 182: The Modbus Protocol

    Modbus The Modbus Protocol Overview The 5MC has built in serial communications this has been changed from Version 55 onwards to be a compatible subset of the widely recognised Modbus RTU protocol (slave). The serial communications is accessible from the keypad connector or with an additional interface card (RS485) the 5MC may be connected to a PC or suitable PLC network.

  • Page 183: Specification

    Modbus Specification Refer to Modicon Modbus Protocol Reference Guide PI-MBUS-300 for full protocol specification. Baud rate is 9600. 8 data bits, no parity, 1 stop (default) or 8 data bits, no parity, two stop bits. Modbus timeout is 3.5 character times, the in message timeout is also 3.5 character times unlike the standard which is 1.5 character times.
  • Page 184 Modbus Function 03 - Read holding registers Starter 01 PNU 01, 02 This function is used to read a group of up to eight parameters from the 5MC. The allowable address range for this function is 0-127 for working parameters and 1000 – 1127 for offline eerom parameters.
  • Page 185 Modbus Function 06 - Preset Single Register Starter 01 PNU 12, Data 09 This function is used to set the value of a single parameter. It differs from the modbus protocol in that only the data Lo byte of the query is written to the parameter address. The data Hi byte is ignored.

  • Page 186: Function 16 - Preset Multiple Registers

    Modbus continued Returned Exception Data t e l n i l n i l e l i Function 16 - Preset Multiple Registers Starter 01 PNU 10 - 13, Data undefined This function is used to set the values of multiple parameters. It differs from the modbus protocol in that since all parameters are bytes they are packed into the 16 bit register space lowest parameter number to hi byte then the next parameter in the low byte and so on up to 3 contiguous words (6 parameters) may be preset with one query.

  • Page 187: Returned Errors

    Modbus Returned Errors If there is a communication error in the query the 5MC does not reply. If the network communication is Ok but for some reason the 5MC cannot correctly execute the query then it will return an error reply. In an error reply the function byte is returned OR’ed with $80 and the following byte contains the error number.

  • Page 188: 5Mc Commands

    Modbus 6.10 5MC Commands The 5MC Modbus series software has a new mechanism for carrying out common functions or offline ones which take a long time and requires the 5MC to be off and disabled. Commands are now carried out by writing various values to a Command Register (parameter 124). For example writing a 1 to PNU124 using function 6 disables the starter Once a value has been written to This special register further Modbus queries will receive an error “slave busy”...
  • Page 189 Keypad or alternately through an external isolated Modbus network. Fairford Electronics • Innovation in Soft Start Technology Bristow House, Gillard Way, Lee Mill Industrial Estate, Ivybridge, PL21 9GG. United Kingdom Tel: +44 (0) 1752 894554 • Fax: +44 (0) 1752 897145 • Email: info@fairford.com •...
  • Page 190 Communications Technical Specification SD0008604 Fairford Electronics • Innovation in Soft Start Technology Bristow House, Gillard Way, Lee Mill Industrial Estate, Ivybridge, PL21 9GG. United Kingdom Tel: +44 (0) 1752 894554 • Fax: +44 (0) 1752 897145 • Email: info@fairford.com •...

  • Page 191: Starting

      Keypod Concept  SD0005304 Fairford Electronics • Innovation in Soft Start Technology Bristow House, Gillard Way, Lee Mill Industrial Estate, Ivybridge, PL21 9GG. United Kingdom Tel: +44 (0) 1752 894554 • Fax: +44 (0) 1752 897145 • Email: info@fairford.com • www.fairford.com...
  • Page 192 Comms card Comms card Network Network Start Fairford Electronics Limited, Bristow House, Lee Mill Industrial Estate, Ivybridge, Devon PL21 9GG, United Kingdom TEL: + 44 (0) 1752 894554 FAX: + 44 (0) 1752 897145 EMAIL: sales@fairford.co.uk WEB: www.fairford.co.uk Registered No.: 1559267 England...

  • Page 193: Important

    When the keypad selector switch is set to remote the local keypad is off. Local Fairford Electronics Limited, Bristow House, Lee Mill Industrial Estate, Ivybridge, Devon PL21 9GG, United Kingdom TEL: + 44 (0) 1752 894554 FAX: + 44 (0) 1752 897145 EMAIL: sales@fairford.co.uk...
  • Page 194 04/04/2011 AP9A00 Circuit board in fitted position on 5MC card APCB9A00X8 circuit board Fairford Electronics Limited, Bristow House, Lee Mill Industrial Estate, Ivybridge, Devon PL21 9GG, United Kingdom TEL: + 44 (0) 1752 894554 FAX: + 44 (0) 1752 897145 EMAIL: sales@fairford.co.uk...

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