Troubleshooting with ABS XJ Service Data Kit
Contents
1. 3 Motor Current L2 10 53A 10 15A 10 28A I5 Power Factor 1 00 Ei Heat Zink Temp 39 9 C liz Motor Temperature 57 2 C E Ground Fault Resistance 309kohm Oo Oil Resistance Leakage 999kohm Marker Time 13 20 hh mm DARK GREEN Oil resistance here on top of diagram 999 kOhm RED Ground fault resistance approximately 300 kOhm 1200 min r Motor Parameters Nominal Voltage 400 0V 50Hz Nominal Current 15 80A Nominal Power Factor 0 85 2014 06 23 SULZER 2 1 Water in Oil Oil resistance or water in motor housing e Oil resistance is mostly a high value 800 999 kOhm where 999 kOhm is the maximum measurement shown in these diagrams e Oil resistance values below 10 kOhm is too low and seals and oil have to be changed do also check winding status 2014 06 23 p 25 SULZER 2 1 Water in Oil Moisture sensor location in XJ pumps f water entered at top of sensor in motor house resistance will drop quick e f water enter through primary seal it will mix with oil and the resistance can drop less distinct value can jump up and down for a while 2014 06 23 SULZER 2 1 Water in Oil Example of oil resistance that drops quickly showing water in motor housing SULZER AquaTronic V1 6 Select Language Units Pump Information m Select Signal to Show n Voltage L1 L2 I voltage L2 L3 E voltage L3 L1 E Motor2. change to next slide 2014 06 23 SULZER Aqualronic Display Tab 5 1 Crash log data from 10 last alarms SULZER AquaTronic 1 6 EB x Select Language Units Pump Information Latest Run Log History Log Crash Log Service Voltage L1 L2 406 0 m Current L1 9 14 A E Power Factor 0 91 E Ground Fault Res 551 kohm w voltage L2 L3 405 0 V n Current L2 9 224 E Heat Sink Temp 109 9 C m Select Signal to Show Voltage L3 L1 406 9 E CurrentL3 9 024 8 Motor Temp 113 5 C 560kohm OO T Tooo T T T ae onc sron crasnogiz NN AAT E i va Voltage Voltage Voltage Motor Current Motor Current Motor Current Hest Sink Motor Ground Fault ma L2 L3 L3 L1 L3 L3 L3 Temperature Temperature Resistanse Time Y v v 4 4 4 as 2G kohm Ip Me min 405 5 404 6 406 5 9 06 9 18 8 98 110 0 113 5 544 8 Iz lmin 405 7 404 8 406 7 9 10 9 18 9 02 110 0 113 5 542 bv 2min 406 0 405 0 406 9 9 14 9 22 9 02 109 9 113 5 551 e Mv 3min 406 2 405 3 406 9 9 18 9 30 9 06 109 9 113 5 550 gec 4min 406 0 405 0 406 7 9 14 9 22 9 02 109 9 113 5 538 E 5min 406 7 405 5 407 6 9 22 9 34 9 14 109 8 113 5 534 pt Suin 406 9 406 0 407 6 9 26 9 30 9 14 109 8 113 4 538 fa Vt Mmi 406 7 405 7 407 6 9 18 9 22 9 02 109 7 113 4 535 Snin 47 2 406 0 407 9 9 22 9 30 9 10 109 7 113 4 531 fi Ver 9min 406 405 3 406 9 9 18 9 30 9 06 109 9 113 5 550 Iv Max Value Jax Value Max Value Max Value Max Value Max Value Max Value Max Value
3. Ground Fault Res 544 kohm a Voltage L2 L3 404 6 V m Current L2 9 184 E Heat Sink Temp 110 0 C Select Signal to Show E Voltage L3 L1 406 5 V n CurrentL3 8 98A E Motor Temp 113 5 C 410 0V 10 004 120 0 C I IV voltage L1 L2 max Value E I voltage L2 L3 I voltage L3 L1 B V Current L1 Max Value v 8 Current L2 E Current L3 B Powerractor dies IE Facies ari of time winding B T motor Temp naxvalie s have been 100 E I Ground Fault Res max value 7 1 08 400 0V Z min Imin 9 004 100 0 C m Show Crash Log Motor Parameters Show Table PUMP SETTINGS ON Nominal Voltage 400 0 50Hz lt lt Crash Log 12 gt gt FAULT REASON Heatsink Over Temperature Nominal Current 10 304 Nominal Power Factor 0 85 405 04 9 504 110 0 C In this case 75 96 If winding temperature exceeds 140 it will also show in crash log 2014 06 23 p 38 SULZER 2 4 High Temperature in Winding 2 5 High Temperature in Electronics e High temperature in windings and electronics can be caused by e High load during long period of time high SG Specific Gravity of pump media or friction in impeller turning e Bad cooling if XJS pumps are running long time with low water level below stator housing it often results in high temperature in electronics this is measured at the aluminium base plate for th
4. Resistance H Oil Resistance Leakage SULZER Comparison Real Time Start Stop AquaTronic start stop at external start stop action xi END Start sequence in Voltage L1 L2 399 1V fa Motor Current L1 4 914 Il Power Factor 0 74 ia Ground Fault Resistance is Voltage L2 L3 400 34 Motor Current L2 4 998 fj Heat Zink Temp 33 9 C if Oil Resistance Leakage 999kohm Voltage L3 L1 399 34 Motor Current L2 5 114 Motor Temperature 39 3 C ja e fai E p Marker Time 0 23 bi Motor Parameters Nominal voltage Nominal Current Nominal Power Factor Run period Stop 2014 06 23 4 004 4 00 50 min 45 min 40 min 35 min 30 min 25 min 20 min 15 min 10 min 5 min min Run period normal power Stop period is not B Heatsink Temperature MEET d DE S h owi n g as E B Motor Temperature AquaTronic has A no power T Amperage from test of pump with external starter 3 starts hour 0 85 6 5 4 period 00 00 00 10 00 20 00 30 00 40 00 50 01 00 01 10 01 20 01 30 01 40 SULZER Another way to see if the pump has been standing or running is often to select motor temperature As you can see below the motor is slowly warming up during run period and then the temperature suddenly drops down This sudden drop is an indication of time passing w
5. 0V Motor Current L1 3 70A Power Factor 0 57 Ground Fault Resistance 468kohm r Select Signal to Show E 3 O E w n isi Voltage L2 L3 396 7V E Motor CurrentL2 3 784 I Heat Zink Temp 45 89C LH Oil Resistance Leakage 999kohm Voltage L3 L1 397 7V Motor Current L2 3 704 Motor Temperature 59 5 C I IV voltage L2 L3 ti i E B ii Marker Time 2 30 hh mm iu T voltage L3 L1 E J Motor Current L1 E IV Motor Current L2 I Motor Current L3 Power Factor E Heatsink Temperature 7 Motor Temperature Ground Fault Resistance IV Oil Resistance Leakage 375 0 6 504 500k 340 07 2 004 Ok 200 min 195 min 190 min 185 min 180 min 175 min 170 min 165 min 160 min 155 min 150 min r Motor Parameters Select Scale Nominal Voltage 400 04 50Hz lt lt gt gt 5 min x Marker On Nominal Current 4 90A Nominal Power Factor 0 86 2014 06 23 p 30 SULZER 2 2 Ground Fault Current or Ground Fault Resistance e Ground fault current measurement can also be measured ground fault resistance shall be stable if measurement is rising moisture is entering in winding and motor needs dry out and if that do not help winding needs to be changed e Ground fault current measurement above 30 mA is too much or ground fault resistance below 100 kOhm 2014 06 23 p 31 SULZER 2 2 Ground Fault Current or Ground Fault Resistance
6. 2 min Value E Voltage L2 L3 E F votage 341 Current much above nominal but Ihesus ew have not reached peak amperage E F careret due to fast appearance 57 508 E j M Current L3 E Power Factor Max value v 8 Heat Sink Temp Max Value v 8 Motor Temp max Value Ground Fault Res max Value 52 00A J 9 min 8 min 7 min 6 rhin rnin 4 thin 3 min Z min Imin r Show Crash Log pee Parameters Show Table lt Marker gt PUMP SETTINGS ON Nominal Voltage 400 0 50Hz lt lt crash Log 4 za FAULT REASON otor Over Current Nominal Current 10 30A Nominal Power Factor 0 85 You can move through Fault reason can be the stored crash logs checked here CERBERUS RISE here 2014 06 23 p 41 SULZER 2 6 This shows start sequent of a direct started XJ 50ND s 5 i d E 2 s E i Startstrom L2 Full start sequence is done in about 0 1 seconds T 1 Pook AMS Measurement in AquaTronic cannot keep the measuring speed like this and the read out will show average values PRES Lhe sl cee m LEER Pees LESE EHE ERE HLTELELEEEEEEEEEEEEEEEEEIIEHHIRH H HEEEEELELELELTTTETLLILTT L 1 1 1 ss mmm 1 1 1 h o 1 1 IS 1 I I amp a EEE A Rx cx cad CIC
7. 4 Power Factor 1 00 Ground Fault Resistance 360kohm r Select Signal to Show E E E E Voltage L2 L3 391 5V Motor Current L2 11 384 Heat Zink Temi 15 6 C Oil Resistance Leakage 24kohm voltage L1 L2 E i 3 a E H tener Voltage L3 L1 393 Motor CurrentL2 12 12A Motor Temperature 36 7 C Marker Time 15 51 hh mm IV voltage L2 L3 8 E Voltage L3 L1 ao v ieee 44 00 v Md DE Max a mq cE measured wre value Measured mee 999kOhm value 24kOhm E Motor Temperature pct dens arae seal have B M Ground Faut Resistance TT started to leak drops to below Im IV Oil Resistance Leakage i a C E haree i 1200 min 1120 min 1040 min 960 min 880 min 800 min 720 min 640 min 560 min 480 min 400 min LN IESE EN DEA Ee EA I ee Re 400 0V i 44 00A 1000k Further down in time value m Motor Parameters Select Scale Nominal Voltage 400 0 50Hz 8mn v Marker Off Nominal Current 15 804 Nominal Power Factor 0 85 2014 06 23 p 28 SULZER 2 1 Water in Oil Continues from earlier graph down to 0 min showing oil resistance that dropping down below 10 kOhm showing water in oil Water in oil measurement can drop quickly or jump up and down for a time before getting a low figure SULZER AquaTronic V1 6 Select Language Units Pump Information r Select Sign
8. Current L1 E Motor Current L2 I Motor Current L3 n Power Factor E Heatsink Temperature I Motor Temperature n IV Ground Fault Resistance E IV Oil Resistance Leakage Latest Run Log History Log Crash Log Service Ix Marker Values sd Voltage L1 L2 388 4V 5 Motor Current L1 Voltage L2 L3 387 7V I5 Motor Current L2 392 9V m Voltage L3 L1 si Motor Current L2 11 834 n Power Factor 1 00 E Ground Fault Resistance 346kohm 10 914 n Heat Zink Temp 15 8 C o Oil Resistance Leakage 30kohm 11 974 a Motor Temperature 35 8 C i Marker Time 14 35 hh mm Max measured Min measured value 30 kOhm value 999 kOhm 500k 925 min 920 min 915 min 910 min Motor Parameters Nominal Voltage 400 0V 50Hz Nominal Current 15 804 Nominal Power Factor 0 85 905 min lt lt 900 min 895 min 890 min 885 min 880 min 875 min Marker On Select Scale cc smn s 2014 06 23 OF Quit Apply Help p 27 SULZER 2 1 Water in Oil Example on oil resistance that drops showing water in oil Water in oil measurement can drop quickly or jump up and down for a time before getting a low figure SULZER AquaTronic V1 6 x Select Language Units Pump Information Latest Run Log History Log Crash Log Service r Marker Values Voltage L1 L2 388 4V Motor Current L1 10 91
9. Ground fault resistance is OK even if it jumps up and down as below Be aware of scale This sample max value is 551 kOhm and minimum is 531 kOhm It is normal that resistance change with heat in winding SULZER AquaTronic V1 6 i x Select Language Units Pump Information Latest Run Log History Log Crash Log Service E Voltage L1 L2 406 0 V P Current L1 9 14A E Power Factor 0 91 ia Ground Fault Res 551 kohm E Volagel2 L3 405 0V Current L2 9 22 4 E Heat Sink Temp 109 9 C Select Signal to Show E Voltage L3 L1 406 9 V 1 Current L3 9 02 Motor Temp 113 5 9C EON 410 0 i 10 004 Iv Voltage L1 L2 Max value Value m 120 0 C r7 votage v2 13 ll voltage L3 L1 E v Current Lt max Value B Current L2 405 0V 545kohm 9 50 B rn current i3 110 09C I Power Factor Max Value B IV Heat Sink Temp Max Value B v Motor Temp Max Value v i I V Ground Fault Res Max vale v 530kohm 400 0V 9 min 8 min 7 min 6 rhin 5 min 4 min 3 min 2 min Imin Onin 9 00A 100 0 C Show Crash Log Motor Parameters Show Table PUMP SETTINGS ON Nominal Voltage 400 0 50Hz lt lt Crash Log 12 gt gt FAULT REASON Heatsink Over Temperature Nominal Current 10 30A Nominal Power Factor 0 85 9 Quit Apply Help 2014 06 23 p 32 SULZER 2 2 Ground Fault Current or Ground Fault
10. L2 362 6V am Motor Current L1 40 114 Power Factor 1 00 r Select Signal to Show Voltage L2 L3 369 9V Motor Current L2 43 394 Heat Zink Tem 54 9 F E v Voltage L1 L2 is E E i i Voltage L3 L1 371 3V 5 Motor Current L2 42 06A m Motor Temperature 70 3 F a C voltage L2 L3 E Ground Fault Resistance i Oil Resistance Leakage Marker Time 4kohm 00 00 hh mm n voltage L3 L1 E Motor Current L1 E Motor Current L2 E Motor Current L3 E Power Factor m Heatsink Temperature Graphs shows voltage L1 E I E Motor Temperature L2 C Ground Fault Resistance E Oil Resistance Leakage 15 nin 20 nin 25 nin 30 min 35 nin 40 min 45 nin 50 min r Motor Parameters 400 0V 50Hz 15 804 0 85 Nominal Voltage To activate marker click button or double click Nominal Current Nominal Power Factor diagram area 2014 06 23 10 nin Select Scale 5 min SULZER AquaTronic 1 6 Select Language Units Pump Information Latest Run Log History Log Crash Log Service Select Signal to Show H voltage L1 L2 B Voltage L2 L3 n Voltage L3 L1 o Power Factor v Motor Current L1 D v Motor Current L2 Graphs shows motor E IV Motor Current L3 current x3 o I Ground Fault
11. LALN A A A ALA AR AR BPLWARLEAPATLPAPAFLBWAP ISLS BT 327 941 314 X134 31 10 31 310131 314 3 VIY Y vuvilvuupvuulv vi HLEELLEEEEEELEELEEEEEEEEE ee _ LL L L fhm tenet ty tt rrrEEEEEEEELEHLELELELLLLLI HL TTLEELEEELELLEEEEEEEEEEFEE EEG LITERA ILLU T onduy 4 e p 42 SULZER 2 Worn Hydraulics e If hydraulics get heavily worn the power input gets low and pumps that are set on Power save mode off on could experience problems as power can be the same as normal snoring and pump will stop as soon as it have started e Worn hydraulics can also cause flow to be reduced as far as no water is cooling pump which can cause overheating problems 2014 06 23 SULZER service Check This part is made to speed up normal service If these initial tests do not show bad signs we can assume pump to be OK 1 No fault counters 2 Earth current below 30 mA or Ground fault resistance above 100 kOhm 3 Oil resistance values above 10 kOhm Run pump and check head against shut of valve 5 Adjust wear ring if needed according to service manual p Pump is then ready for new operation 2014 06 23 p 44
12. Max Value Dv PE Show Crash L The data for the signal you EZEN lt lt Crash Log 12 gt gt Faurtreason Heal have chosen is shown Nominal Power Factor 0 6 2014 06 23 p 15 SULZER AquaTronic Display Tab 6 Service and data upgrade SULZER quaTronic 1 5 DEMO VERSION xj Select Language Units Pump Information Latest Run Log History Log Crash Log Service UPGRADE FIRMWARE DRAIN PLIMP 64 r Current Firmware Version Version 21 l I 9 Type Option 5516A Soft Start S pare part i st O r Wo rks h O p r oe Version loaded Tm File manual for pump in pdf TypelOption Open Firmware File smf For Upgrade Download Firmware to Drain Pump Open Spare Part List Open Workshop Manual Open Service Log Open Service log and change to next slide o j o ww e 2014 06 23 p 16 SULZER AquaTronic Display Tab 6 2 Service and data upgrade SULZER auaTronic V1 5 DEMO VERSION Select Language Units Pump Info Thi S i S h OW the service log looks and it can be used for service notes e i Service UPGRADE FIRMWARE DRAIN PUMP P 38 L0G Notepad File Edit Format View Help 2012 06 26 11 01 55 Log File created Service Log Drain Pump X3525D 38 2012 06 26 11 01 55 Open Service Log Total Number of starts 24 Total Run Time 1322 29 hh mm Total Power
13. Resistance Example on ground fault resistance that drops showing moisture in winding SULZER AquaTronic V1 6 Select Language Units Pump Information m Select Signal to Show mir a E voltage L2 L3 Voltage L3 L1 E Motor Current L1 EI Motor Current L2 E Motor Current L3 Im Power Factor gH E Heatsink Temperature E Motor Temperature Im I Ground Fault Resistance ie Oil Resistance Leakage Latest Run Log HistoryLog Crashlog Service r Motor Parameters Nominal Voltage 400 0V 50Hz Mominal Current 15 804 Nominal Power Factor 0 85 Marker Values S Voltage L1 L2 387 5 B Motor Current L1 11 364 el Power Factor 1 00 xl Ground Fault Resistance 342kohm IN Voltage L2 L3 387 2V m MotorCurrentL2 10 554 El Heat Zink Temp 15 7 C F Oil Resistance Leakage 97kohm m Voltage L3 L1 392 2V a Motor Current L2 11 674 I Motor Temperature 35 5 C Marker Time 13 14 hh mm i SM 100 kOhm V 190k 190k je Ok Ok 800 min 720 min 640 min 560 min 480 min 400 min 320 min 240 min 160 min 80 min 0 nin Select Scale aw 80 min Marker Off 2014 06 23 Ok Quit Apply Help p 33 SULZER 2 3 Shortage Between Phases in Winding This will show as phase unbalance and or motor overload e Shortage between phases is normally caused by voltage surges or spikes that come from pow
14. SULZER Troubleshooting with Service Data Kit Information of how pump run data is stored in AquaTronic and can be used in service checks and trouble shooting DANGER Always check that the pump is A disconnected from the electric power supply before connecting it to the computer AquaTronic communication cable with standard USB contact PC with Windows XP or later Adobe Reader a 2014 06 23 SULZER Ltd 2014 2014 06 23 SULZER Troubleshooting with Service Data Kit This information contains two parts The first is describing how the AquaTronic device is working and how you can make readouts from the device with XJ Service data kit pages 1 17 The second is showing how possible faults on XJ Submersible dewatering pumps can show in XJ Service data kit readouts pages 18 44 p 2 SULZER Start of Service Diagnostic Software Removable Disk G A ini o x File Edit View Favorites Tools Help ae oe F Back d p Search lc Folders Address e Gl Go Name Size Type Date Modified File and Folder Tasks A O Aqualog File Folder 2012 06 27 13 11 Make fold PUMPINFO File Folder 2012 06 27 13 10 g Ma nee A AQUATRON ICO 4KB Icon 2006 06 06 06 06 a incid this Folder to the AquaTronic exe 2319KB Application 2012 02 28 11 37 B PROGRAM TXT 1KB Text Document 2006 06 06 06 06 E Share this Folder Scher Doe i When connecting computer send with pump t
15. Units Pump Information Latest Run Log History Log Crash Log Service Marker Values Voltage L1 L2 397 4V Motor Current L1 8 094 Power Factor 0 73 Ground Fault Resistance 604kohm Select Signal to Show E HE lii lis C IV voltage L1 L2 oO voltage L2 L3 B Voltage L3 L1 D v Motor Current L1 jE Motor Current L2 E Motor Current L3 E Power Factor E IV Heatsink Temperature B 1 Motor Temperature Read of value for temperature E Ground Fault Resistance a t d O t te d i n e Im oil Resistance Leakage Du Voltage L2 L3 397 2 E Motor Current L2 8 374 fa Heat Zink Temp 107 5 C ni Oil Resistance Leakage 999kohm a Voltage L3 L1 398 4V Tel Motor Current L2 IB Motor Temperature 106 8 C Marker Time 14 58 hh mm Temperature gra 1200 min 1120 min 1040 min 960 min 880 min 800 min 720 min 640 min 560 min 480 min 400 min Motor Parameters Select Scale Nominal voltage 400 0 50Hz us 8o min x Marker Off In this case temperature is very close to cut out temperature and we check this at crash log 2014 06 23 p 37 SULZER 2 5 High Temperature in Electronics Crash log 12 SULZER AquaTronic 1 6 E X Select Language Units Pump Information Latest Run Log History Log Crash Log Service E Voltage Li L2 405 5 V n Current L1 9 06 4 Power Factor 0 91 E
16. al to Show IV voltage L1 L2 3 v voltage L2 L3 I voltage L3 L1 E IV Motor Current L1 0 Iv mir E Power Factor 2 Heatsink Temperature E Motor Temperature IV Ground Fault Resistance v Oil Resistance Leakage Max measured value 999 kOhm Latest Run Log HistoryLog Crashlog Service Marker Values E voltage L1 L2 E voltage L2 L3 E Voltage L3 L1 384 1V E Motor Current L1 11 36A 5 Power Factor 1 00 i Ground Fault Resistance 185kohm 384 4V E Motor Current L2 11 074 Bi Heat Zink Temp 15 8 C Fi Oil Resistance Leakage 10kohm 388 2V r1 Motor CurrentL2 11 76A E Motor Temperature 35 1 C Marker Time 4 56 hh mm Measured value 24 kOhm seal time value drops to below has started to leak Motor Parameters Nominal Power Factor 0 85 Nominal Voltage 400 0V 50Hz Nominal Current 15 80A 2014 06 23 720 min 10 kOhm 640 min 560 min 480 min 400 min 320 min 240 min 160 nin Select Scale 80 min Marker Off SULZER 2 1 Water in Oil Example on oil resistance showing drops in measurement that are not for real it is just a function of start current no fault SULZER AquaTronic V1 6 A x Select Language Units Pump Information Latest Run Log History Log Crash Log Service Marker Values Voltage L1 L2 397
17. an also be read from history log SULZER AquaTronic 1 6 E Select Language Units Pump Information Latest Run Log r Select Signal to Show C Voltage L1 L2 C voltage L2 L3 voltage L3 L1 C Motor Current L1 Motor Current L2 Motor Current L3 C Power Factor C Heat Sink Temp Motor Temp C Fault Counters r Select Max Min Average max Value Min Value Average Value Motor Parameters Nominal Voltage Nominal Current Nominal Power Factor 160 C 152 C loss 136 C 128 C 120 C giles 104 C 96 C 88 C 80 C CSAS 64 C 56 C 48 C 40 C 32 C 24 C 16 C 8 C arc 8 C 400 0V 50Hz HistoryLog CrashLog Service L DEED aes a I H o In this case 75 96 I i of time winding o have been 100 B o E 108 0 10 95 20 9 309 40 9i 50 60 70 805 90 100 4 r Running Parameters I Power On Time 280 50 hh min Total No Faults 30 elect Scale procents z Total Run Time 275 45 hh min Total No Starts 64 If winding temperature exceeds 140 it will also 2014 06 23 show in crash log o Lx Que Apply Help p 36 SULZER 2 5 High Temperature in Electronics Direct started AquaTronic will cut out at temperatures exceeding 110 C Soft start AquaTronic will cut out at temperatures exceeding 80 C SULZER AquaTronic V1 6 1 x Select Language
18. ct Signal to Show gt 20 0 00 a you want to show 00 C Voltage L1 L2 ex 0 00 9 C Voltage L2 L3 14 0 00 Voltage L3 L1 12 0 00 10 0 00 C Motor CurrentL1 43 0005 C Motor Current L2 2696 0 58 C Motor Current L3 4 5303 9 C PowerFactor 2 27 05 400V 12 18 C HeatSink Temp 2 7 08 C Motor Temp 4 0 07 Fault Counters 6 0 00 Select max min or 000 m 0 00 12 average value 000 Select Max Min Average 14 0 00 C Max Value 16 0 00 C Min Value 18 0 00 Average Value 20 0 00 lt 22 0 0 0 10 20 30 40 50 60 70 80 90 100 Motor Parameters Running Parameters alent Seal I Nominal Voltage 400 0V 50Hz Power On Time 357 20 hh min Total No Faults 3 Poceni E Nominal Current 11 30A Total Run Time 96 39 hh min f Nominal Power Factor 0 80 Total No Starts 97 Information running Set x scale i time and faults 2014 06 23 p 11 SULZER AquaTronic Display Tab 4 1 History log fault counters SUPAwamoru mp A m me WO X n A Select Language Units Pump Information LatestRunLog History Log CrashLog Service x occurred will show C Heatsink OverTemp Select Signal to Show Na 0 Na 0 C Voltage L1 L2 Na 0 C Voltage L2 L3 Na 0 C Voltage L3 L1 Na 0 Na 0 E spi E Parameter Error If you select Fau It 0 otor Current L2 i nt Supply Volt Fail 2 C Motor Current L3 Na COU nters and 0 C Power Factor iB am
19. d into stator windings can also cause high current readings High voltage can also give high amperage causing trip out e Next page shows motor protection trip curve 2014 06 23 p 19 SULZER Motor Current Protection Cut Out Curves 10000 1000 100 10 Time s 0 1 0 01 0 001 When pump is running tripping is set to 1 2 x Inominal if this occurs for mor than 100 seconds Softstart Direct on Line For Softstarted pumps the current in start sequence shall not excide 3 75 x Inominal or pump will trip except shorter periods than 0 01 seconds At locked rotor pump will stop after aprox 10 seconds Long time over load shown as Fallen M protector Pumpcan run with 54 overload in 60 seconds before tripping For Direct on line started pumps the current in start sequence shall not excide 11 5 x Inominal or pump will trip except shorter periods than 0 01 seconds At locked rotor pump will stop after 1 2 seconds Short time over load shown as Motor over current 10 Current x nominal 2014 06 23 p 20 SULZER 1 2 Voltage Unbalance Phase Failure e Voltage unbalance is a fault caused by incoming power An unbalanced voltage will give a result in unbalance in amperage AquaTronic will cut out for an amperage unbalance that exceed 20 e At phase failure AquaTronic cuts out immediately without delay 2014 06 23 p 21 2014 06 23 SULZER 1 3 L
20. e AquaTronic unit used as heat sink Too hot water is pumped A maximum temperature for pumped water is 40 C 2014 06 23 SULZER 2 6 Locked Rotor 1 Rotor is locked at start e Aqualronic unit is made to try to restart the pumps 3 times then try to kick backwards once and then forwards 3 times It repeats this for 3 times and then stops with looked rotor e This will show as Fallen motor protector on direct started pumps and Start time out on Soft started pumps 2 Rotor gets blocked wile running e Ondirect started pumps this will cause the motor protector to cut according to cut out curve page 20 this will take 1 2 seconds e On Soft started pumps current will run up to start current for motor witch normally is 7 8 times nominal This is over the accepted limit for Thyristors and AquaTronic units are made to cut of as soon as possible 0 001 0 01 of a second 2014 06 23 p 40 SULZER 2 6 Locked Rotor Locked rotor at start with AquaTronic DS pump In this case a XJ 50ND Nominal amperage 10 3 A Start current 92 A SULZER AquaTronic V1 6 x Select Language Units Pump Information Latest Run Log History Log E Log Service FE Volageli L2 377 7 V ES Current L1 56 96 E Power Factor 1 00 E Ground Fault Res 0 kohm E Voltage L2 L3 385 3 V Current L2 62 554 H Heat Sink Temp 30 3 C Select Signal to Show I Volagel3 L1 383 9V E Current L3 52 69 4 E Motor Temp 36 0 C 63 004 voltage L1 L
21. er supply It can also appear due to bad insulation of winding or wear of parts in winding 2014 06 23 p 34 Select Language Units Pump Information r Select Signal to Show IV Voltage L1 L2 a voltage L2 L3 n voltage L3 L1 p v Motor Current L1 I Motor Current L2 E Motor Current L3 Im Power Factor fa Heatsink Temperature fa v Motor Temperature Im Ground Fault Resistance B Oil Resistance Leakage SULZER 2 4 High Temperature in Winding AquaTronic will cut out at temperatures exceeding 140 C Latest Run Log History Log Crash Log Service Marker Values E Voltage L1 L2 398 1V E Motor Current L1 8 214 E voltage L2 L3 398 1V ia Motor Current L2 8 494 399 34 8 294 8 Voltage L3 L1 Motor Current L2 E Power Factor 0 78 IS Ground Fault Resistance 600kohm E Heat Zink Temp 107 4 C ie Oil Resistance Leakage 999kohm m Motor Temperature 107 2 C Marker Time 15 13 hh mm Read of value for temperature at dotted line 1200 min 1120 min 1040 min 960 min 880 min Motor Parameters Nominal Voltage 400 0V 50Hz Nominal Current 10 304 Nominal Power Factor 0 90 lt lt gt gt 560 min 800 min 720 min 640 min 480 min 400 min Select Scale 80 min Marker OFF Le Quit Apply Help 2014 06 23 p 35 SULZER 2 4 High Temperature in Winding C
22. hrough USB amp J My Network Places interface this box shall pop up Double click on icon AquaTronic exe to start program Details Y If this box do not show when connecting pump with the USB cable use your Explorer to find pump memory 2014 06 23 p 3 SULZER First View of AquaTronic Display Tab 2 Name plate data and firmware version SULZER AquaTronic V1 6 I Select Language Units Pump Information Latest Run Log History Log Crash Log Service Drain Pump Data Type XJ540D SIN 44 Volt Weight 41 0kg Amp Speed 2852 rim Pn 3 7 kw Efficiency 87 P1 4 3 kW Qmax 20 I s Power Factor 0 85 Hmax 23 5 m Name plate data shall be consistent to physical name plate on pump specially look on voltage frequency and amperage Firmware Version 21 Variant DOLI2A Direct Version shows software version within pump New firmware is available on server if you need update procedure is located on page service Ix 2014 06 23 SULZER AquaTronic Display Tab 1 Language and unit settings Select Language Units Pump Information Latest RunLog History Log Crash Log Service r Select Language r Select Units Select Date Format C Metric Units vYYY MM DD 2011 12 31 C Swedish CN US Units C DD MM YYYY 31 12 2011 English C MM DD YYYY 12 31 2011 C German C Italian Select units Select date format C F
23. ime current overload AquaTronic SS this is 3 5 times nominal start current is 3x nominal on AquaTronic DS this is set to 11x nominal start current is 7 9 x nominal 2014 06 23 p 13 SULZER Aqualronic Display Tab 5 Crash log data from 10 last alarms SULZER AquaTronic V1 5 DEMO VERSION X Select Language Units Pump Information Latest Run Log History Log Crash Log Service E Voltage L1 L2 N Current L1 E Power Factor E Ground Fault Res EH Voltagel2 L3 E Current L2 E Heat Sink Temp m Select Signal to Show E Volagel3 l1 Current L3 E Motor Temp 110kohm pu OY 2 004 PF 1 00 il IV Voltage L1 L2 max Value ill Voltage L2 L3 IN Voltage oi E v Current L1 Max Value E M Current L2 Ups I Current L3 jE IV Power Factor max Value E Heat Sink Temp Max Value v B Motor Temp max Value I IV Ground Fault Res max Value x Diam 0 0V 9 min 8 min 7 rin 6 min 5 min F thin 3 min Z min I min Omin 0 004 Show Table lt Marker gt r Show Crash Log Motor Parameters PUMP SETTINGS NO DATA Nominal Voltage 400 0V 50Hz Crash Log 1 Latest gt gt FAULT REASON NO DATA Nominal Current 15 808 Nominal Power Factor 0 85 To activate marker click button Click button Show table and or double click diagram area
24. ithout being measured recorded SULZER AquaTronic 1 6 E x e Select Lanquage Units Pump Information Latest Run Log History Log P u m p i S ru nn i n g r Marker Values Select Sal to Sh 3 Voltage L1 L2 3 and motor in Power Factor 0 74 Bm Ground Fault Resistance m Select Signal to Show rm NH us Voltage L2 L3 3 temperatu re IS Heat Zink Temp 35 0 C Oil Resistance oltage L1 i ei Stop period is not B VYotagerz 13 Bid slowly rising M nice cegs Mai pp showing as m j voltage L3 L1 AquaTronic has E v Motor Current L1 BH v Motor Current L2 1 p Suet a E v Motor Current L3 can see th at Im Power Factor temperature E Heatsink Temperature CU rve j u m ps o v Motor Temperature am C Groug Fault Resistance B OilResist Rce Leakage 4 00A 4 00A 20 0 C 20 0 C 50 min 45 min 40 min 35 min 30 min 25 min 20 min 15 min 10 min 5 min 0 min r Motor Parameters Select Scale Nominal Voltage 400 0V 50Hz E gt gt 5 min 7 Nominal Current 7 004 S e ect m oto r Nominal Power Factor 0 85 te m pe r at u re Quit Apply Help 2014 06 23 p 10 SULZER AquaTronic Display Tab 4 History log pump full life SULZER AquatTronic V1 7 g n Select Language Units Pump Information LatestRunLog History Log Crash Log Service Select the signal Sele
25. on Time 1322 38 hh mm Total No Faults 5 g down anny information you want g have been opened it creates a login of Starts and run time v C Open Firmware File smf For Upgrade 7 Download Firmware to Drain Pump Open Spare Part List Open Service Log Gancel Operation Open Workshop Manual 2014 06 23 p 17 2014 06 23 SULZER Faults that can occur in XJ submersible dewatering pumps Fault could be divided into two groups 1 Faults caused by outer conditions 1 2 3 4 High load Voltage unbalance Phase failure Low or high voltage Pumps are not pumping Faults caused by malfunction in pump or caused by outer conditions showing like faults in pump 1 TO ole Water in oil Water oil mixture in motor housing Water in motor housing Bad insulation in windings shortage to earth Shortage between phases in winding High temperature in winding High temperature in electronics Locked rotor Worn hydraulics SULZER 1 1 High Load High load 20 above nominal e High load can be a result of many different things Too much material in pumped media Power is direct proportionally to the weight of pump media SG 1 2 or more It will cause motor to draw too much current e Stuck material between impeller and upper diffuser lower diffuser or wear ring will make motor to run heavy and will also result in high current reading Oil that has penetrate
26. ow or High Voltage 5 is normal voltage Pump shall perform as normal No high amperage or temperature problems Q H P as nominal 10 96 is possible without malfunction No temperature problems Q H P can go outside tolerance 20 pump will run without cut out May cause temperature stop of pump Q H P curves outside tolerance Low voltage lower Q H High voltage high power More than 20 AquaTronic will cut out SULZER 1 4 Pumps Are Not Pumping e On XJS pumps volute can be full of air witch causes the impeller to spin without gripping water enough to create pressure to start pumping This can be solved by tilting pump body and release air pocket e Pumps can also been worn so badly so no water discharge is possible 2014 06 23 p 23 SULZER AquaTronic V1 6 Select Language Units Pump Information r Select Signal to Show n voltage L1 L2 I v Voltage L2 L3 n Voltage L3 L1 E v Motor Current L1 E Motor Current L2 E Motor Current L3 Power Factor E Heatsink Temperature Motor Temperature IV Ground Fault Resistance E IV Oil Resistance Leakage 2 1 Water in Oil How to understand ground fault current or ground fault resistance and oil resistance Latest Run Log HistoryLog CrashLog Service SULZER Marker Values Voltage L1 L2 388 9V Motor Current L1 KE Voltage L2 L3 388 7V m Motor Current L2 390 1V E Voltage L3 L1
27. p 0 i Start Timeout Select scale to 0 C HeatSink Temp Motor OverTemp 0 C Motor Temp erOverCurrent m l n u tes t h e Fault Counters Cur Phase Inbalance 0 Input OverVoltage number of times 0 Input UnderVoltage 0 Input Phase Fault differe nt fault 1 Select Max Min Average Na 0 0 0 0 0 G Fallen M protector Na 5 Motor Parameters Running Parameters Que Des Nominal Voltage 400 0V 50Hz Power On Time 357 20 hh min Total No Faults 3 Nominal Current 11 30A Total Run Time 96 39 hh min Nominal Power Factor 0 80 Total No Starts 97 Quit 2014 06 23 p 12 SULZER History Log Fault Counters Understanding Parameter error Software has dropped set parameters very uncommon e Int supply volt fail AquaTronic internal voltage has failed e Start timeout More than 4 seconds on start with soft start Locked rotor e Motor over temp Motor NTC giving indication of temperature beyond 140 C Motor over current Motor current more than 20 over nominal amperage for more than 100 seconds Cur phase unbalance More than 20 96 difference between phase amperage Input over voltage Voltage more than 20 above nominal e Input under voltage Voltage more than 20 96 below nominal Input phase fault One phase is missing e Heatsink over temperature AquaTronic internal temperature above allowed AquaTronic SS 60 C AquaTronic DS 80 C Fallen M protector Short t
28. rensh z LZ Spanish Select language 2014 06 23 p 5 SULZER Aqua Ironic Memory e Processor in AquaTronic unit stores run data on an USB memory that you can reach when the pump is not energised e Aqualronic stores Last 20 hours running voltage x3 amperage x3 power factor AquaTronic temperature heat sink motor temperature ground fault current or ground fault resistance on older versions oil resistance water in oil History log where data is summed up during pumps lifetime same physical measures as above plus fault counters Crash log where 10 last minutes is stored before an alarm have been triggered 16 crashes can be stored Service manual spare part list and service log book 2014 06 23 p 6 2014 06 23 SULZER General Behaviour of XJ Service Data Kit AquaTronic unit do not have internal clock and cannot measure when out of power This may cause the graphs to make a jump One way to observe this non recording time is to look at motor temperature Motor temperature shall move slowly If motor temperature makes a jump you know that some time have elapsed p 7 AquaTronic Display Tab 3 Latest run log data from latest 1200 min SULZER AquaTronic V1 5 DEMO VERSION marker is Select Language Units Pump Information Latest Run Log History Log Crash Log Service SULZER Values for the point where the Marker Values mE Voltage L1
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