Unipower HPL110/220 Manual del propietario
HPL110A
Digital Power Monitor
Installation and Operation
True Motor Power
Monitor with...
•High Trip Alarm
•Low Trip Alarm
•Digital Display
•Start and Trip
Delay Timers
Typical
Applications
•Pumps
•Fans
•Conveyors
•Crushers and mixers
•Broken belt detection
Unipower®
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Contents
1System Overview 3
2Functional Description 4
3Typical Applications 7
4System Configuration 8
5Electrical Installation: 10
3-Phase Power Connection
1-Phase Power Connection
Alarm Relay States
Alarm Integration
Reset Function
6Specifications: 13
Technical Specifications
DIP Switches
7Mechanical Installation 14
HPL110A
Current Transformer
8Programming 16
9Troubleshooting 19
10 Set-Up Log Sheet 20
! WARNING: Dangerous voltages are present in motor control
panels; INSTALLATION MUST BE CARRIED OUT BY QUALIFIED
PERSONNEL.
!WARNING: Improper installation or programming can cause
damage to the unit and/or result in ineffective protection and/or
nuisance tripping.
System Overview
The Unipower HPL110A advanced digital
power monitor is a member of the
Unipower family of “Intelligent Power-
Control Units” designed for protection and
control of motor driven mechanical systems.
The HPL110A measures true power
consumption of 3-phase AC motors
(single phase versions also available) and
displays consumption as a percentage of
selected power range. Power consumption
(kW) is calculated from the formula:
P = Ö3 x U x I x cos j
The display shows power in units of %kW which represent the percentage
of full load power range for the unit.
Control functions comprise two independent and programmable trip functions:
Low Power Alarm - for example, to stop a pump in the event of dry-running, and
High Power Alarm - for example, to stop a feeder when blocked.
The alarm functions activate a single alarm relay which may be used to control the motor
being monitored; i.e. to trip a shut-down in the event of either a high or low power alarm.
The HPL110A may be configured to monitor any size motor either with the internal current
transformer for applications up to 8A or with an external CT for applications above 8A.
The HPL110A provides consistent sensitivity across the complete motor load range
making it ideal for low trip applications where amp meters are ineffective. In addition,
the HPL110A measurement principle allows it to be used on non-sine shaped loads such
as Variable Frequency Drives.
The digital design of the HPL110A including 3-key programming, 3 digit display, Max/Min
Peak Hold, Program Lock and Power Down Alarm Block functions make it very easy to use.
3
1
Functional Description
The Unipower HPL110A may be used either for monitoring applications - to protect
process equipment - or for control applications - to control secondary process functions.
Monitoring Example for Machinery Protection
A typical Power vs. Time graph for the HPL110A is shown in Figure 2.1 with the Y-axis
showing power P in units of %kW and the X-axis showing time.
At time 0, mains power is turned on, the HPL110A unit is energized and the alarm
relay changes state to the “on” condition.
At time 1, the motor is turned on and the load immediately surges due to the starting
current inrush before settling to a steady value at time 4.5.
At time 8, this example shows power rising above the L1 Max. Limit which triggers an
alarm resulting in the motor being switched off at time 9.5.
A continuation is shown starting at time 20 where the motor load drops such that it
falls below the L2 Min Limit at time 22. An alarm is again triggered after the delay
timer expires resulting in the motor again being shut down at time 23.
0%
Max. Limit
L1
100%
P (%)
Ts
t
Tr1
Power On
Relay On
5%
Motor On
0 1 2 3 4 5 6 7 8 9 20 21 22 23
P = f (t)
Min. Limit
L2
Tr2
4
2
Figure 2.1
The HPL110A functions in these examples are as follows:
P - Power %kW: The display shows true power in units of % of full scale for the
HPL110A as installed.
Ts - Start Delay Timer: Ts is used to delay the start of active monitoring until after
the start surge is completed.
The HPL110A assumes that the motor is OFF when measured load - %kW - is
below 5% full scale. The Ts timer starts when the load reaches 5% and
monitoring is disabled for the duration of the Ts period. Ts is programmable
in the range 0.1 to 99.9 seconds.
On conclusion of the Ts period, monitoring becomes active.
If P drops below 5%, monitoring is immediately disabled and a new Ts period
will start as soon as load again reaches 5%.
L1 - Max. Limit: Max. alarm limit programmable in the range 5% to 100% / OFF
and used in conjunction with the Tr1 Reaction Timer. A Max. Limit alarm is tripped
if P exceeds L1 for a period Tr1.
Tr1 - Reaction Timer: Used in conjunction with the L1 Max. Limit and programmable
in the range 0.0 to 99.9 seconds. Tr1 is time for which the P must remain above
the L1 Max. Limit before an alarm is declared. If P falls below the L1 during the
Tr1 timer period, the timer is re-set to zero.
Note: if Tr1 is set to 0.0 seconds, actual reaction time will be one cycle or approx.
16 msec. at 60Hz and 20 msec. at 50Hz
L2 - Min. Limit: Min. alarm limit programmable in the range OFF / 5% to 100% and
used in conjunction with the Tr2 Reaction Timer. A Min. Limit alarm is tripped
when P remains below the L2 Min. Limit for a period of time Tr2.
Tr2 - Reaction Timer: Used in conjunction with the L2 Min. Limit and programmable
in the range 0.0 to 99.9 seconds. Tr2 is time for which the P must remain below
the L2 Min. Limit before an alarm is declared.
D - Max. Level: If the D up arrow key is depressed while the HPL110A is in monitor
mode, the display will show the maximum load - in %kW - experienced since
the last Ts.
Ñ - Min. Level: If the Ñ down arrow key is depressed while the HPL110A is in monitor
mode, the display will show the minimum load - in %kW - experienced since the
last Ts.
5
Control Example
While monitoring for machinery protection is the primary application for the HPL110A,
it is also suitable for simple two-point control regulation applications by using the
Hysteresis function included in the unit.
A possible control example might be where the HPL110A is monitoring the power
consumed to mix a slurry and the relay output is used to add liquid if the slurry becomes
too viscous.
This is shown graphically in Figure 2.2. Power surges when the motor is switched
on and the Ts function inhibits monitoring until the motor settles at time 2.5.
Once Ts is completed, the high power alarm becomes active and a hysteresis band
(programmable) is shown under this alarm level. At time 5, the mixing power rises
above the L1 Max. Limit and, after the Tr1 trip delay times out, the alarm is activated
and the relay switches.
In this example, the relay controls the addition of liquid to the slurry and the power
gradually drops as liquid is added until at time 7, it has fallen below the hysteresis
band for the L1 Max. Limit. At this point, the alarm relay is automatically reset and
the addition of liquid is stopped.
Typical applications include the continuous control of mixing, crushing and grinding
processes. Hysteresis is also available on the L2 Min. limit in the same manner
(not shown).
Max. Limit
L1
100%
P (%)
Ts
t
Tr1
Power On
Relay On
0 1 2 3 4 5 6 7
P = f (t)
5%
6Figure 2.2
Typical Applications
Seal-less Centrifugal Pumps
These “positive pressure” pumps have a power curve which is proportional to flow rate.
Power monitoring using the HPL110A, therefore, is very effective for ensuring the pump
is running within the design minimum and maximum flow limits.
This is particularly true of seal-less pumps where dry-running can quickly result in damage
or failure of the pump and containment system.
These situations are very effectively detected by the HPL110A as “low power” alarms and,
being a true power monitor, the HPL110A is far more effective at detecting under-
power situations than a current sensing relay.
Positive Displacement Pumps
In the case of positive displacement pumps, flow rate is constant but excessive outlet
restriction results in high pressure and high power. The HPL110A provides a simple,
non-intrusive monitoring function which can be effectively used to protect against
dead-heading.
Again, dry-running is detrimental to the pump and results in a low power condition
which is also effectively monitored for with the HPL110A.
Belt Breakage
The HPL110A can be used to immediately detect a low power conditions resulting
from transmission chain or belt breakage and is far more sensitive to such "low power"
conditions than a simple current sensor.
The HPL110A helps avoid the damage which is easily generated when part of a
production line is malfunctioning.
Feeder Blockage
The HPL110A can be used to immediately generate a max. kW alarm when a feeder
mechanism is jammed or overloaded. Such applications would include belt or screw
feeders, conveyors, etc. In many cases, the HPL110A can replace mechanical shear
pins and are easier to set.
Many Other Applications exist including: Fans, Mixers, Crushers, Grinders, etc.
7
3
System Configuration
The Unipower HPL110A measures voltage in all three legs of the 3-phase supply (or one
leg and neutral for single phase versions) and current in one leg. The HPL110A has an
internal current transformer with a measurement range of 8 Amps.
In configuring the HPL110A for a particular application, the voltage rating of the unit
must match the mains supply being used and the effective current measured by the unit
must be within its internal 8 Amp capacity.
4.1 VOLTAGE MATCHING:
From Table 4.1, ensure that the rated voltage for the HPL110A unit matches the mains
voltage being used.
For single phase applications, an isolation transformer must always be used with a
secondary voltage of 24V.
Note: The display full scale for the HPL110A is based on the nominal voltage of the unit;
e.g. when using a nominal 220V unit at 208V, the display range will read 95% at full load
(208/220 in %).
4.2 CURRENT MATCHING:
From the motor name plate, note the full load current in Amps. If full load amperage for
the motor is 8 amps or less, an external current transformer is not required.
If the full load current is greater than 8 amps, then an external N/1 or N/5 current
transformer must be used.
Refer to Table 4.2 for the appropriate selection of current transformer and current range
setting for the HPL110A.
The HF3A current transformers specified in this table are low voltage, through-primary
devices offered as accessories for the HPL110A product line; equivalent devices from other
manufacturers may be substituted at user’s discretion.
8
Catalog Number Phase Use for 50/60 Hz Mains Voltages
HPL110/220 3-Phase 208/220/230/240 VAC
HPL110/380 3-Phase 380/415 VAC
HPL110/460 3-Phase 460/480 VAC
HPL110/575 3-Phase 575/600 VAC
HPL110A/S24 1-Phase 110/120 and 208/220/230/240 VAC
Figure 4.1
4
Note: The two ranges given for full load ratings of 15 and 25 Amps require two primary
wraps of the current transformer whereas all other ranges require a single through primary.
Figure 4.3 shows the HF3A current transformers with a single through primary hook-up
and with two primary wraps. When taking multiple primary wraps on the HF3A current
transformers, ensure that the wraps are wound to the sides and not across the top or
bottom of the current transformer.
9
Figure 4.2
Full Load Current Ratio Primary HPL110 Range Effective Range
Amps Transformer Primary : Secondary Turns Setting Amps
1 Internal 1 : 1 1 1 1
3 Internal 1 : 1 1 3 3
5 Internal 1 : 1 1 5 5
8 Internal 1 : 1 1 8 8
10 HF3A,050/5 50 : 5 1 1 10
15 HF3A,050/5 50 : 5 2 3 15
25 HF3A,050/5 50 : 5 2 5 25
30 HF3A,050/5 50 : 5 1 3 30
50 HF3A,050/5 50 : 5 1 5 50
75 HF3A,075/5 75 : 5 1 5 75
100 HF3A,100/5 100 : 5 1 5 100
150 HF3A,150/5 150 : 5 1 5 150
Figure 4.3
Installation - Electrical
5.1 3-PHASE HOOK-UP
The HPL110A should be connected directly in front of the motor starter unit and
downstream of the motor fuses and/or isolation breaker as shown in Figure 5.1.
An external current transformer with a secondary rating of 1 or 5 amps must be used
if the rated full load motor current is in excess of 8 amps. Figure 5.1 shows correct
installation using the internal current transformer (<8A), and using an external current
transformer (>8A).
For correct readings, the current measurement must always be made on the L3 leg of the
3-phase supply. The direction of the current measurement, however, is not important.
Power-Down Alarm Blocking: When the motor is turned off, power drops to zero and
a Min. Limit Alarm will be triggered if L2 is active. Figure 5.1 shows an auxiliary normally
closed contact on the motor starter being used to short S2 to Gnd when the motor is off.
This activates the S2 inhibit function which inhibits alarm functions and prevents a Min.
Limit alarm on power down.
An alternative method of achieving the same result is available using the Min. Alarm
Block function explained in Section 8.8; the S2 Inhibit solution described above is
preferred and safer.
Soft Starts and Frequency Inverters:: When using the HPL110A with a soft start or
a motor driven by a frequency inverter, the HPL110A connections must be made directly
in front of these devices.
10
5
L1
L2
L3
M
3~ In < 8 Amp.
Example internal converter
Only if min. limit used
Motor
Fuses
Motor
Fuses
Aut. Reset
Ext. Reset
Aut. Reset
Ext. Reset
M
3~ In > 8 Amp.
Only if min. limit used
Example external converter
11
10
NC
NC
NC
9
C
NO
HPL110A
12
13
PE 14
S1 15
S2
1 L1
3 L2
5 L3
7 k
8 l GND 17
NC 18
16
K
11
10
NC
NC
NC
9
C
NO
HPL110A
12
13
PE 14
S1 15
S2
1 L1
3 L2
5 L3
7 k
8 l GND 17
NC 18
16
K
P1
P2
S1
S2
Figure 5.1
Este manual sirve para los siguientes modelos
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