TECHNICAL SERVICE MANUAL
Contents
1. injury or death failure to follow the instruction may result in serious injury DORNING indicated instruction may cause damage Legend g or death to pump and or other equipment BEFORE opening any liquid chamber pumping WARNING INSTALL pressure gauges sensors next to the chamber reservoir relief valve adjusting cap fitting pump suction and discharge connections to monitor etc be sure that pressures e Any pressure in the chamber has been completely vented through the suction or discharge lines or other appropriate openings or connections USE extreme caution when lifting the pump Suitable lifting devices should be used when appropriate Lifting e The pump drive system means motor turbine eyes installed on the pump must be used only to lift engine etc has been locked out or otherwise WARNING the pump not the pump with drive and or base plate been made non operational so that it cannot be If the pump is mounted on a base plate the base plate started while work is being done on the pump must be used for all lifting purposes If slings are used for lifting they must be safely and securely attached For weight of the pump alone which does not include the drive and or base plate refer to the Viking Pump product catalog i gt e You know what material the pump has been handling have obtained a material safety data sheet MSDS for the material and understand and follow all precautions appropriate for the s2. relay common and also reset a i common N Alarm relay is normally closed N C C O Alarm relay is normally open L1 Motor voltage phase L1 Motor voltage phase L2 N for single phase motors Motor voltage phase L3 N for single phase motors 1 Note Terminals 1 and 2 S1 S2 carry Line voltage 2 N Must be connected to terminal 11 and 13 single phase SECTION TSM 750 ISSUE B PAGE 7 OF 8 TECHNICAL SERVICE MANUAL DISMANTLING AND DISPOSAL The housing is made of recyclable plastic PC ABS and the circuit board contains small amounts of tin and lead When disposing the parts must be handled and recycled in accordance with local regulations EU EUROPEAN UNION SPECIFICATIONS EMC EN 50081 1 EN 50081 2 EN 50082 1 EN 61000 6 2 Electrical safety IEC 947 5 1 Rated insulated voltage 690 V Rated impulse withstand voltage 4000V Pollution degree 2 Terminals 5 6 7 and 8 are basic insulated from the line US SPECIFICATIONS FCC Federal Communications Commission This equipment has been tested and found to comply with the limits for a class A digital device pursuant to the Part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual may caus
3. the factory setting no 0 13 Confirm chosen value 0 by pressing PAR nD adi Da The above parameters are necessary to set for safe functioning Note that Rated Power for the motor must be set before Auto Set CAUTION Positive displacement pumps require some form of over pressure protection to be placed in the discharge line in conjunction with the Power Load Monitor Pressure spikes created by sudden discharge line blockage may cause serious pump damage Hints Change the load on the machine to find out if appropriate load limit margin is set correctly You can also reduce the margin by one or more steps to find out at what level the machine will trip See figure 6 Set Reset e g start delay response delay trip margin etc if necessary see table 2 If the alarm level is difficult to set simply perform an Auto Set when the motor is stopped Then start the machine run at normal load and perform an Auto Set again If a wrong value is unintentionally set simply set a new value If the value is not confirmed by pressing PAR the new value is not accepted time out after 30 seconds SECTION TSM 750 ISSUE B PAGE 6 OF 8 FACTORY PARAMETER VALUE SETTING NOTE RATED POWER a 1 2 s 32 64 See Table 3 e e I alae alan ee ee current O T Ber 1 overload seconds 0 50ms START DELAY 01248163264 2 Start delay in seconds of rated power sensitivity Fig 6 AUTO SET Auto
4. CIDENTAL INDIRECT CONSEQUENTIAL OR PUNITIVE DAMAGES OF ANY KIND INCLUDING BUT NOT LIMITED TO LOST OR UNREALIZED SALES REVENUES PROFITS INCOME COST SAVINGS OR BUSINESS LOST OR UNREALIZED CONTRACTS LOSS OF GOODWILL DAMAGE TO REPUTATION LOSS OF PROPERTY LOSS OF INFORMATION OR DATA LOSS OF PRODUCTION DOWNTIME OR INCREASED COSTS IN CONNECTION WITH ANY PRODUCT EVEN IF VIKING HAS BEEN ADVISED OR PLACED ON NOTICE OF THE POSSIBILITY OF SUCH DAMAGES AND NOTWITHSTANDING THE FAILURE OF ANY ESSENTIAL PURPOSE OF ANY PRODUCT THIS WARRANTY IS AND SHALL BE VIKING S SOLE AND EXCLUSIVE WARRANTY AND SHALL BE IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO ALL WARRANTIES OF MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE AND NON INFRINGEMENT ALL OF WHICH OTHER WARRANTIES ARE EXPRESSLY EXCLUDED See complete warranty at www vikingopump com All rights reserved 3 2013 Viking Pump Inc
5. Electronic copies of the most current TSM issue can be found on the Viking Pump website at www vikingpump com TECHNICAL SERVICE MANUAL MOTOR SHAFT OUTPUT POWER MEASUREMENT CONTENTS Introduction noa ao om aoe we me oe SO Schr oh a ee 1 Viking Part Numbers 2 20050 1 Safety Information a eee eee 2 WING e os e oe ewe ERE HO ho ee eh ee A 3 Transformer Selection 0 0042 ee eee 4 ODSA e a6 a4 Ges Meee OP RS oO ES 5 LED amp eee be ee hee ea eee hae ee oe he 5 Auto Set gk ge em eek oe we PR ee 5 Programming 2 a6 x2 e he oe Ee RES ee ew we 5 Setup and First Start 5 EXAMP cweeeed cagex dais Be eb eee we 5 Technical Data 2 000 eee eee 7 Dimensions 2 1 ee a 7 Parameters 2 1 a a a a a 7 Terminals a a a a a 7 Parameter List ooa a a a a a a a 7 Dismantle and Disposal 8 Wanani 52 BRE DGD Re Oh REE 8 INTRODUCTION This instruction manual describes the installation and operation of the Power Load Monitor Its function is to supervise induction motor driven equipment and provide alarms or motor shutdown when abnormal conditions are detected If the machine s normal load level is exceeded the internal relay change state and the alarm LED turns red The output relay contact can be used for alarm indication and or machine shutdown The unit is intended for price sensitive applications that only demand non
6. Pressure relief valves cannot be used to control pump Pp PP BEFORE operating the pump be sure that e Itis clean and free from debris Pip PPP WARNING all valves in the suction and discharge pipelines flow or regulate discharge pressure For additional are fully opened information refer to Viking Pump s Technical Service e All piping connected to the pump is fully supported ngs TSM 000 and Engineering Service Bulletin and correctly aligned with the pump e Pump rotation is correct for the desired direction of flow THE PUMP must be installed in a matter that allows safe access for routine maintenance and for inspection during operation to check for leakage and monitor WARNING pump operation SECTION TSM 750 ISSUE B PAGE 2 OF 8 WIRING This wiring example shows how the Power Load Monitor can be used to control the starting and stopping circuit of the motor Other wiring configurations are possible The current transformer must be placed in the same phase that is connected to terminal 9 phase L1 For single phase connection refer to Figure 2 for the alternate single phase connection To complete the remaining wiring refer to Figure 1 DANGER The monitor must be installed by qualified personal e Always disconnect lockout and tag out supply circuits prior to installing The installation must comply with standard and local regulations Study this manual thoroughly before installing and using the Power L
7. afe handling of the material DO NOT attempt to dismantle a pressure relief valve that has not had the spring pressure relieved or is BEFORE operating the pump be sure all drive guards mounted on a pump that is operating are in place AVOID contact with hot areas of the pump and or drive Certain operating conditions temperature control devices jackets heat tracing etc improper installation improper operation and improper maintenance can all cause high temperatures on the pump and or drive DO NOT operate pump if the suction or discharge piping is not connected DO NOT place fingers into the pumping chamber or its connection ports or into any part of the drive train if there is any possibility of the pump shafts being rotated i THE PUMP must be provided with pressure protection This may be provided through a relief valve mounted DO NOT exceed the pumps rated pressure speed and directly on the pump an in line pressure relief valve temperature or change the system duty parameters WARNING a torque limiting device or a rupture disk If pump from those the pump was originally supplied without rotation may be reversed during operation pressure WARNING confirming its suitability for the new service protection must be provided on both sides of pump Relief valve adjusting screw caps must always point towards suction side of the pump If pump rotation is reversed position of the relief valve must be changed
8. complex protection against under or overload for motors up to 50A Your shipment should contain the following items e Power Load Monitor e Current transformer e Instruction manual Check carefully that the Power Load Monitor complies with the motor s input voltage and that the current transformer rating is as stated on the delivery packaging and that the contents have not been damaged in shipping SECTION TSM 750 PAGE 1 OF 8 POWER LOAD MONITOR ISSUE B Power Load Monitor VIKING PART NUMBER RATED MOTOR CURRENT A 2 E90 012 999 00 0 4 10 0 2 E90 013 999 00 10 1 25 0 2 E90 014 999 00 26 50 1ER i wih 4 1 T u l i Shipment Contents CORPORATION VIKING PUMP INC e A Unit of IDEX Corporation Cedar Falls IA 50613 USA SAFETY INFORMATION AND INSTRUCTIONS IMPROPER INSTALLATION OPERATION OR MAINTENANCE OF PUMP MAY CAUSE SERIOUS INJURY OR DEATH AND OR RESULT IN DAMAGE TO PUMP AND OR OTHER EQUIPMENT VIKING S WARRANTY DOES NOT COVER FAILURE DUE TO IMPROPER INSTALLATION OPERATION OR MAINTENANCE THIS INFORMATION MUST BE FULLY READ BEFORE BEGINNING INSTALLATION OPERATION OR MAINTENANCE OF PUMP AND MUST BE KEPT WITH PUMP PUMP MUST BE INSTALLED OPERATED AND MAINTAINED ONLY BY SUITABLY TRAINED AND QUALIFIED PERSONS THE FOLLOWING SAFETY INSTRUCTIONS MUST BE FOLLOWED AND ADHERED TO AT ALL TIMES ae Warning In addition to possible serious Symbol Paner E FAETO ONON Me naea eg
9. d liquid is flowing under normal conditions to the pump before beginning to set the Power Load Monitor for normal operating conditions SET UP AND FIRST START 1 Switch on the supply voltage Power LED turns green 2 Press PAR once LED AUTO SET turns green 3 Keep pressing PAR until the desired parameter is selected e g RATED POWER see table 2 and 3 4 Press VAL Factory set value or earlier set value flashes e g 64 5 Keep pressing VAL until desired value is displayed 0 64 6 Confirm chosen value by pressing PAR 7 Press PAR again and repeat steps 3 to 6 for all parameters except for AUTO SET See tables 2 3 and fig 6 for possible value setting for each of the eight parameters 8 Start and run motor system at normal load conditions also wait until the START DELAY has expired Hint Short circuit the output relay during the set up this prevents the equipment from stopping unintentionally see Caution in section Wiring 9 Press PAR once LED AUTO SET turns green 10 Press and hold VAL for 3 seconds at normal machine load The Auto Set load level is automatically set and the LED is switched off 11 Set re set e g start delay response delay margin etc if necessary see table 2 3 and figure 6 Relay Output Terminal 6 7 and 8 output relay Reset Input Terminal 5 and 6 are used for external reset and selection of latched unlatched YY iat g T p Powe
10. e harmful interference in which case the user will be required to correct the interference at their own expense CANADA SPECIFICATIONS DOC Department of communications This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus as set out in the Canadian interference Causing Equipment Regulations Le pr sent appareil num rique n ement pas de bruits radio lectriques d passant les limites applicables aux appareils num riques de la Classe A prestite dans le R egelement sur le brouillage radio lectrique edict du Canada ce CORPORATION POWER LOAD MONITOR MOTOR SHAFT OUTPUT POWER MEASUREMENT VIKING PUMP INC A Unit of IDEX Corporation Cedar Falls IA 50613 USA SECTION TSM 750 PAGE 8 OF 8 ISSUE B VIKING PUMP CORPORATION WARRANTY Viking warrants all products manufactured by it to be free from defects in workmanship or material for a period of one 1 year from date of startup provided that in no event shall this warranty extend more than eighteen 18 months from the date of shipment from Viking The warranty period for Universal Seal series pumps ONLY Universal Seal models listed below is three 3 years from date of startup provided that in no event shall this warranty extend more than forty two 42 months from the date of shipment from Viking UNDER NO CIRCUMSTANCES SHALL VIKING BE LIABLE UNDER THIS WARRANTY OR OTHERWISE FOR SPECIAL IN
11. ed motor current 12 A e Select 10 1 12 5 from the first column in table 1 and choose 2 E90 013 999 00 with two 2 primary windings sg MLTR Note Maximum length of CTM cable is 39 inches 1 m gt hi aan Ma F FIGURE 4 Example CTM 025 With 2 Windings For 12 A Motor Note Iwinding 3windings Normally the appropriate current transformer will have 2o been ordered and shipped with the Power Load Monitor check that this is the case contact the supplier if in doubt Note The transformer connection and orientation are not polarity FIGURE 5 sensitive Example 1 And 3 Windings SECTION TSM 750 ISSUE B PAGE 4 OF 8 OPERATION LED e A constant green LED indicates a parameter type e A flashing green LED indicates a value Under normal system operation the eight LED s are all off see table 2 Any LED s illuminated will be automatically switched off 30 seconds after the last key press AUTO SET The alarm load level is automatically set by the Auto Set function see Programming The value for a parameter e g seconds kW HP or margin can only be set as 0 1 2 4 8 16 32 or 64 Select closest value PROGRAMMING Set up the monitor as below CAUTION Make sure that all safety measures have been taken before switching on the supply voltage and starting the motor machine in order to avoid personal injury lines are that suction and discharge Verify connected and tight valves are open an
12. oad Monitor Pay special attention to this section and the parts marked CAUTION or DANGER Should questions or uncertainties arise please contact your authorized Viking distributor Note Removing or breaking the seal on the housing will invalidate the warranty CAUTION If the START STOP is connected according to figure 1 it is recommended that terminals 6 and 7 be by passed during settings After the settings are completed the by pass must be taken out LATCHED OR UN LATCHED ALARM Un Latched Auto Reset when voltage supplied to terminal 5 and 6 Latched Alarm when terminal 5 and 6 opened not connected CT Max E FIGURE 1 Standard Wiring Three Phase Motors CTh 1 jE FIGURE 2 Single Phase Wiring Example fl Maa pih WEE FIGURE 3 Wiring Example For Latched Or Un Latched Alarm SECTION TSM 750 ISSUE B PAGE 3 OF 8 CURRENT TRANSFORMER SELECTION FOR MOTORS UP TO 50A CURRENT TRANSFORMERS 1 Check the rated motor current on the motor plate 2 Compare this value with the Rated Motor Current in table 1 3 From table 1 select the appropriate numbers of windings for the current transformer a RATED MOTOR CURRENT A owo e f SoSo o e o o E a a asso Od OT a S orms gt o ooo esso o TABLE 1 Current Transformer And Number Of Primary Windings DANGER Li Terminals 1 and 2 s1 s2 carry line voltage L3 CT Mixxx 2 windings EXAMPLE Rat
13. r Alarm Abares The Power Alarm a LED indicates TET green at power on and at normal Current Input Terminal 1 and 2 Current Transformer CTM 010 025 or 050 Max 50 A motor oD load Red at alarm PAR VAL Parameter Value setting change LED light constant green pressing Pressing VAL key when green LED is flashing PAR key when increases value A parameter is changed value is displayed confirmed by pressing PAR Reset Reset a latched alarm by pressing both PAR and VAL at the same time for 3 seconds Motor Terminals Terminal 9 L1 11 L2 and 13 L3 for supply and motor voltage input SECTION TSM 750 ISSUE B PAGE 5 OF 8 EXAMPLE PUMP WITH OVERLOAD PROTECTION Pump with overload protection motor 11 kW fig 6 1 Check output power on motor plate and see table 3 11 kW Rated Motor Power 6 1 12 setting 8 Switch on the supply voltage Power LED green Press PAR once LED AUTO SET turns green Keep pressing PAR until RATED POWER is selected 5 Press VAL Value 64 flashes factory setting 6 Set recommended value according to table 3 Keep pressing VAL until chosen value 8 flashes 7 Confirm chosen value by pressing PAR 8 Press PAR again and select MAX 9 Press VAL Choose the factory setting MAX Overload Protection 1 10 Confirm chosen value 1 by pressing PAR 11 Press PAR again and select RELAY INVERTED 12 Press VAL Choose
14. set load level VAL key must be is automatically set pressed when LED if VAL key is parameter AUTOSET pressed for 3 is lit LED bar is seconds switched off when Autoset level is set TABLE 2 Parameters and Values SETTING RATED aa oo IN HP 12 1 24 24 1 48 48 1 75 TABLE 3 Setting or Rated Motor Power POWER Overload Alarm Level overload monitor Power at AUTO SET Auto set load level Margin Alarm Level underload monitor FIGURE 6 Alarm Level and Margin TECHNICAL DATA Dimensions 1 77 x 3 54 x4 53 45x90x115mm WxHxD FES on 35mm DIN rail 46277 5 65 oz 175g Supply Voltage 1x100 240 10 3x100 600 10 3x600 690 10 50 or 60 Hz Current Input Current Transformer CTM 010 025 or 050 max 50 A motor PO Start up Delay 1 64 seconds Response Delay 0 05 64 seconds Rel slay Output 5 A 240 VAC Resistive 1 5 A 240 VAC Pilot Duty AC12 Fuse Max 10 Terminal Wire Size Use 75 C copper CU wire only 0 2 4 0 mm single core AWG12 0 2 2 5 mm flexible core AWG14 Strip length 0 32 8mm Terminal Tightening 5 7 Ib in 0 56 0 79 Nm Torque l External RESET on Max 240VAC or 48 VDC TERMINALS PARAMETER LIST Current transformer input for CTM 010 SETTING SETTING SETTING 2 S2 Current transformer input Alarm Current 0 ae E 4 re a Reset input Latched or unlatched alarm Response Delay a ie 5 RES i selected via this input Stet Daley Alarm
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