Summary of Contents for C.S.L. VARIVAC 2006 B
- Page 2 Varivac™ Installation Manual Contents 1. General Information 2. Varivac Mounting and wiring 3. Transducer Mounting and wiring 4. Set up and Automatic Motor Tuning (AMA) 5. Vacuum Level Adjustment 6. Idle Speed Adjustment 7. Common Errors 8. Terms & Conditions 9.
- Page 3 starts. Although all Varivacs have booster fans fitted, cooling is very rarely an issue and covers are available to blank the fan off if moisture is the greater problem.
- Page 4 CABLING AND MOTOR The Varivac is designed to be permanently wired on a dedicated circuit with protection according to the controller Specification sheet current ratings. Cables to the electric motor must be screened, minimum size 4 X 2.5mm, CBS type preferred. The Cable between the Varivac and transducer is to be of minimum 0.2mm 2 core screened and not to be run parallel with heavy current carrying cables.
- Page 5 Mounting and Wiring Single Pump & Motor Combination This system consists of one motor with one or more vacuum pumps attached. 1. Generally mount the Varivac adjacent the vacuum pump. 2. Re-use the existing isolator normally at this point. 3. Remove power factor capacitor if connected (Varivac does this function). 4.
- Page 6 Tandem Pump & Motor Combination This system consist generally of two motors wired separately each with one or more vacuum pumps attached. These motors may be of different sizes, this does not matter ! 1. Generally mount the Varivac adjacent the switchboard. 2.
- Page 7 Twin Pump & Motor Combination This system is not normally used unless the plant has a huge vacuum over-capacity, it consists generally of two motors wired separately each with one or more vacuum pumps attached. These motors may be of different sizes, this does not matter! 1.
- Page 8 Transducer Installation General; mount the transducer as close to the action as possible, the sensing face is VERY sensitive and easily damaged, be very careful with it. Only mount the transducer in the Vacuum Interceptor when no other option is practical – it will still work well but in high vacuum loss situations the vacuum at the cups will be lower than at the transducer sensing face due to friction losses in the plant pipe work.
- Page 9 Rotary Dairy – mount as close as possible to the gland, in the installation photos below the tee moves the transducer out of direct air flow – this is good. There is often a spare outlet in the gland this is a good point to mount the transducer – beware of the transducer being accidentally knocked by operators or moving pipe work.
- Page 10 Do not mount the transducer ever like the following picture This is Very Bad !!!! – all kinds of stability problems !!! – too close to the vacuum pump and welded directly into a very small main air line.
- Page 11 Set Up and Automatic Motor Tuning Programming To make program changes press “Menu” to start, make the changes and press “Display” to end. Access this entire line by pushing the Hertz “Display” button Shows Kilowatts being used, can use the “+”...
- Page 12 1. After all connections are made, turn the “Test/Off/Auto” switch to “Off” and power up the Varivac 2. Check Vacuum Pump Motor direction(s) by briefly turning the “Test/Off/Auto” switch to “Auto” and then “Off” again. Turn the power completely off to the Varivac to inter-change motor phases and change at the Varivac motor output (singles) or the appropriate motor circuit breaker (Tandems).
- Page 13 Vacuum Level Adjustment Setting the air regulator or air regulators. There are two types of air regulators remote sensing and standard types, remote sensing types have a long pipe attached to the air regulator and attached to the sensor within the air line or close to the gland in rotary sheds.
- Page 14 Try opening clusters until the controller is unable to hold the vacuum level, close again quickly to test whether the original Air Regulator(s) will pull in, if they do, adjust the regulator in “Test” to a higher level. When the pump has reached maximum speed (pre programmed to 55Hz) with a number of clusters open, verify the kilowatt draw shown on the display against the name plate data.
- Page 15 Idle Speed adjustment Water Ring Vacuum Pumps. Start up the varivac in “AUTO” and get the plant up to vacuum with the selector in “Milk” and then open one cluster. Close the cluster and listen to the pump, the vacuum level may rise slightly at this point, this is normal.
- Page 16 Maximum speed is set at 55 Hz, by opening clusters until the top speed is reached (this can be seen on the top of the screen by pressing the “Display” button). The speed can be raised until the kilowatt reading is approximately 15% above the nameplate rating. If doing this with a two pump &...
- Page 17 Trouble Shooting RUNNING FIRST TIME FAULTS Drive won’t start. Remote start not wired properly, drive in local stop after performing ama, overloads tripped (tandem models only). Cause/Remedy: check to see if overloads tripped (tandem models only) reset if necessary and set them to the correct current rating for the motors. Check to see if remote start is wired correctly by placing a wire link between terminal 3 and 4 of the remote start terminals.
- Page 18 Cause/Remedy: check that drive is switching setups by switching the milk wash switch when in auto. If drive is not switching setups need to go into parameter 4 and select multi setup. Common Error Messages. WARNING/ALARM 4 Phase fault (MAIN PHASE LOSS). A phase is missing on the supply side or the mains voltage imbalance is too high.
- Page 19 back on, “RESET” and then “START” may need to be pressed on the control panel on the Danfoss Drive. ALARM 14 Earth fault (EARTH FAULT). There is a discharge from the output phases to earth, either in the cable between the frequency converter and the motor or in the motor itself.
- Page 20 Corkill Systems Limited - TERMS AND CONDITIONS OF SALE GENERAL All quotations, orders and contracts for the sale or supply of goods or services by Corkill Systems Limited shall unless, otherwise agreed in writing, be subject to the following terms and conditions: 1.
- Page 21 VARIVAC Installation Data Sheet Customer Name..............Installation Date........Postal Address............................Delivery Address............................ Phone ........Fax......... Mobile..........Email........Purchased from..................---------------------------------------------------------------------------------------------------------------------------- Installer Business Name........................Installer Technician Name........................Postal Address............................Delivery Address............................ Phone ........Fax......... Mobile..........Email........----------------------------------------------------------------------------------------------------------------------------- VARIVAC Model #......Serial #............VLT Model....Manufacture Date......Program..........Software Version....
- Page 23 3 phase mains supply 3 core +earth tps variva c 3 core + earth emc/cbs flex Tandem system only transducer Main airline Motor 2 Vacuum pump 2 Interceptor motor Vacuum pump receiver san- itary can spare vacuum port in gland CORKILL SYSTEMS Ltd 2 King St, PO Box 16 OPUNAKE, TARANAKI.
- Page 25 RELAY #4 “FAN” TO TERMINAL #4 ON DANFOSS DRIVE 230V FAN BLACK 0.5 APPL WIRE 2A FUSE 2A FUSE 400V/230V/50VA TRANSFORMER 2A FUSE DANFOSS DRIVE DANFOSS DRIVE 2.5MM BUILDING WIRE 4 - 7KW VA- RIVAC TERMINAL BLOCK IN CABINET PKZM LINE PKZM = white...
- Page 26 RELAY #4 “FAN” TO TERMINAL #4 ON DANFOSS DRIVE 230V FAN BLACK 0.5 APPL WIRE 2A FUSE 2A FUSE 400V/230V/50VA TRANSFORMER 2A FUSE DANFOSS DRIVE DANFOSS DRIVE 2.5MM BUILDING WIRE 4 - 7KW VARIVAC ONLY TERMINAL BLOCK IN CABINET V W E LINE MOTOR CORKILL SYSTEMS Ltd...
- Page 27 DIN CONNECTORS 3 4 5 6 7...