IWAKI Pump Driver Model FD
Transcription
IWAKI Pump Driver Model FD
( )Country codes IWAKI CO.,LTD. 6-6 Kanda-Sudacho 2-chome Chiyoda-ku Tokyo 101-8558 Japan TEL:(81)3 3254 2935 FAX:3 3252 8892 Australia Austria Belgium China China China China Denmark Finland France Germany Holland Hong Kong Indonesia IWAKI Pumps Australia Pty. Ltd. IWAKI EUROPE GmbH IWAKI Belgium n.v. IWAKI Pumps (Shanghai) Co., Ltd. IWAKI Pumps (Guandong) Co., Ltd. GFTZ IWAKI Engineering & Trading (Guangzhou) GFTZ IWAKI Engineering & Trading (Beijing) IWAKI Nordic A/S IWAKI Suomi Oy IWAKI France S.A. IWAKI EUROPE GmbH IWAKI EUROPE NL Branch IWAKI Pumps Co., Ltd. IWAKI Singapore (Indonesia Branch) TEL : (61)2 9899 2411 TEL : (49)2154 9254 0 TEL : (32)1367 0200 TEL : (86)21 6272 7502 TEL : (86)750 3866228 TEL : (86)20 8435 0603 TEL : (86)10 6442 7713 TEL : (45)48 24 2345 TEL : (358)9 2745810 TEL : (33)1 69 63 33 70 TEL : (49)2154 9254 0 TEL : (31)547 293 160 TEL : (852)2 607 1168 TEL : (62)21 690 6606 FAX : 2 9899 2421 FAX : 2154 9254 48 FAX : 1367 2030 FAX : 21 6272 6929 FAX : 750 3866278 FAX : 20 8435 9181 FAX : 10 6442 7712 FAX : 48 24 2346 FAX : 9 2742715 FAX : 1 64 49 92 73 FAX : 2154 9254 48 FAX : 547 292 332 FAX : 2 607 1000 FAX : 21 690 6612 Italy Korea Malaysia Norway Singapore Spain Sweden Switzerland Taiwan Taiwan Thailand U.K. U.S.A. Vietnam IWAKI Italia S.R.L. IWAKI Korea Co.,Ltd. IWAKIm Sdn. Bhd. IWAKI Norge AS IWAKI Singapore Pte. Ltd. IWAKI Iberica Pumps, S.A. IWAKI Sverige AB IWAKI (Schweiz) AG IWAKI Pumps Taiwan Co., Ltd. IWAKI Pumps Taiwan (Hsin-chu) Co., Ltd. IWAKI (Thailand) Co.,Ltd. IWAKI Pumps (UK) LTD. IWAKI AMERICA Inc. IWAKI pumps Vietnam Co.,Ltd. TEL : (39)0444 371115 TEL : (82)2 2630 4800 TEL : (60)3 7803 8807 TEL : (47)23 38 49 00 TEL : (65)6316 2028 TEL : (34)943 630030 TEL : (46)8 511 72900 TEL : (41)26 674 9300 TEL : (886)2 8227 6900 TEL : (886)3 573 5797 TEL : (66)2 322 2471 TEL : (44)1743 231363 TEL : (1)508 429 1440 TEL : (84)613 933456 FAX : 0444 335350 FAX : 2 2630 4801 FAX : 3 7803 4800 FAX : 23 38 49 01 FAX : 6316 3221 FAX : 943 628799 FAX : 8 511 72922 FAX : 26 674 9302 FAX : 2 8227 6818 FAX : (886)3 573 5798 FAX : 2 322 2477 FAX : 1743 366507 FAX : 508 429 1386 FAX : 613 933399 T467-2 '12/10 IWAKI Pump Driver Model FD-3 Instruction Manual Read this instruction manual before use of product Thank you for selecting IWAKI pump driver model FD-3. This driver is designed to drive IWAKI pneumatic-driven bellows pump FS series. Please read this instruction manual before the use of driver and always keep this manual near the product so that it can be referred whenever it is needed. CONTENTS 1. Safety instruction..............................................................................Page 1 · 2 2. Unpacking and inspection............................................................................... 3 3. Outline of product...................................................................................... 3 · 4 4. Names of parts............................................................................................... 5 5. Specifications................................................................................................. 6 6. Dimension....................................................................................................... 7 7. Mounting......................................................................................................... 8 8. Electrical wiring........................................................................................ 9 - 11 9. Air piping........................................................................................................11 10. Preparation for operation......................................................................11 · 12 11. Operation.................................................................................................... 12 12. Troubleshooting.......................................................................................... 13 1. Safety Instructions For the Safe and Correct Handling of the Pump Driver ●"Safety Instruction" section deals with important details about handling of the product. Before use, read this section carefully for the prevention of personal injury or property damage. ●Observe the instructions accompanied with "WARNING" or "CAUTION" in this manual. These instructions are very important for protecting users from dangerous situations. ●The symbols on this instruction manual have the following meanings: WARNING Nonobservance or misapplication of “Warning” sections could lead to a serious accident which may result in death. CAUTION Nonobservance or misapplication of “Caution” sections could lead to personal injury or property damage. Types of Symbols Indicates that “Warning” or “Caution” must be exercised. Inside this triangle, a concrete and practical image provided as a warning or caution message is depicted. Indicates a prohibited action or procedure. Inside or near this circle, a concrete and practical image of the activity to be avoided is depicted. Indicates an important action or procedure which must be performed or carried out without fail. Failure to follow the instructions herein can lead to malfunction or damage to the product. Export restrictions Technical information contained in this instruction manual might be treated as controlled technology in your countries, due to agreements in international regime for export control. Please be reminded that export license/permission could be required when this manual is provided, due to export control regulations of your country. -1- Warning ●Confirmation For safety, confirm that no person is found near to pump when pump system is started. ●For specified application only The use of driver in any other applications than specified one may cause human injury or damage of the driver. Use the driver strictly in accordance with the specifications and its application range. ●No remodeling Never remodel a driver. Otherwise, a serious accident may result. IWAKI will not be responsible for any accident or damage of any kind which is caused by the remodeling of the driver without obtaining permission or instructions from IWAKI. Caution Prohibited No Remodeling Caution ●Qualified operators only The operation, maintenance and repair of this product must be done by the person who has enough knowledge and operation of the product. The person who has little knowledge of the product must not operate nor handle the product. ●Specified power source only Do not operate the driver by other power source voltage than 24VDC. Non observance may result in damage or fire. ●Limited operating site and storage Do not install or store the driver in the following places: Places where a flammable gas is generated. Places where corrosive gas is generated. ●Precautions for wiring of proximity-switches Wrong wiring of proximity switches may result in burned switches and damaged circuit board. -2- Prohibited Prohibited Prohibited Caution 2. Unpacking and inspection After unpacking, check the following points before installation. (1) The model indicated on the front panel is the same as your ordered model. (2) The driver or any part of it are not damaged, or hardware and bolts are not loosened during transportation. (3) Accessories are not missing. Standard accessories: • Connector for CN-1 - CN7 (1 for each) Total 7 pcs. • Contact for above One set Ask IWAKI or dealer if any abnormality is found. 3. Outline of product FD-3 is pump driver for IWAKI pneumatic drive pump FS series. It receives start/stop or stroke signals from cleaning or other equipment and controls pump operation by controlling solenoid valve to switch over supply air to pump. Main functions and features 1) Manual setting of pump stroke rate. 2) Stroke rate control by external stroke signal. 3) Constant flow rate can be kept regardless the change of load put on pump. 4) Start and stop of pump by external signal. 5) Leak alarm output and emergency stop of pump. 6) Timer alarm output in the event of pump stop. 7) Electro-pneumatic regulator system is employed to always keep bellows differential pressure to minimum. Note: M odel EV2500-008 made by CKD is exclusively usable as electro-pneumatic regulator (Optional accessory). 8) Flow rate and life of filter can be controlled. (Option) Explanation of operation 1. Manual operation (MANU) 1) Pump starts if start switch is positioned at MANU. 2) When L (left) side sensor input is ON, solenoid valve output becomes ON. L sensor input becomes OFF instantly, but solenoid valve operation output is kept at ON. 3) After R (right) side sensor input becomes ON, solenoid valve output becomes OFF. 4) When L sensor input becomes ON once again, solenoid valve operation output becomes ON. 5) Pump operation continues by repeating above procedures 2) to 4). 2. Automatic operation (AUTO) 1) Pump operates automatically if start switch is set at AUTO. 2) Pump stops and starts by external contact signal. 3) Stroke rate can be automatically controlled by external stroke signal. -3- 3. Constant stroke speed (See Fig. 1) Pump stroke speed is always kept constant regardless of the change of discharge pressure of pump. In Fig. 1, time which is needed from to (operation timing of sensor R & L) is measured according to the moving average of four times to control output air pressure of electro-magnetic regulator, thus stroke speed is kept constant. Sensor L Sensor R Solenoid valve function output Fig. 1 4. Leak alarm This function is to activate alarm signal and to stop pump operation if liquid leaks inside the pump. Alarm signal is given if electrodes between C1 and C2 or between D1 and D2 of R and L side bellows are conducted by liquid leakage. 5. Time alarm (See Fig. 2.) This function is to give the signal if pump stops or stroke speed lowers abnormally because of any reason. Output to solenoid is kept on operating condition. Time setting (0 - 60 sec.) of stroke speed at which alarm is given is done by timer dial. Alarm is activated when any stroke time of t1, t2 or t3 gets longer than preset time t 0. If all of t1, t2 and t3 get shorter than t 0, it automatically resets and pump starts to run normally. Sensor L Sensor R Time-up alarm t1 t2 t0 Fig. 2 -4- t3 t0 t0 4. Names of parts Start switch : To switch over MANU - AUTO. Stroke rate setting dial : To set stroke rate by percent of full stroke. Timer dial : To set max. stroke time in second at which alarm signal is given. Connector CN1 : Alarm output (for leak alarm and timer alarm) Connector CN2 : Output signal to operate solenoid valve Connector CN3 : Power source 24VDC Connector CN4 : Leak sensor/Proximity switch Connector CN5 : External start signal Connector CN6 : Electro-pneumatic regulator output signal Connector CN7 : External stroke signal Mfg. No. : Manufacturing No. PUMP DRIVER 40 MODEL 60 20 20 40 50 10 80 100 AUTO 0 FD-3 30 STOP MANU SPEED(%) 60 0 TIMER(SEC) IWAKI CN1 CN2 CN3 CN4 CN5 CN6 Fig. 3 -5- CN7 5. Specifications General specifications Input specifications Power supply 24VDC ± 10% (Capacity: more than 0.5A) Power consumption 12VA Ambient temperature 0 - 55ºC Ambient humidity 5 - 95%RH (Non-condensing) Proximity sensor A Input resistance 4.7kohm (Pull-up to 24V) Negative logic action Input voltage "L" 0 - 3V, "H" 5 - 30V Sensor power 24VDC 20mA Input resistance 4.7kohm (Pull-up to 24V) Negative logic action Input voltage "L" 0 - 3V, "H" 5 - 30V Sensor power 24VDC 20mA Inter-electrode voltage 5VDC ± 5% Operating resistance Detection at 0 - 15kohm. No detection at 25kohm or higher. Setting range 0-30 sec.: ±10% of full scale Proximity sensor B Electrode Timer 30-60 sec.: ±15% of full scale External start signal AUTO operation Relay contact External stroke rate change signal Input resistance 0 - 100% changeable by 0 - 5kohm input External stroke rate change signal AUTO operation Relay contact ON: by external signal OFF: by dial on panel Pump max. stroke rate setting change-over Output specifications Control specifications Pump operation output 4 steps selection by dip switch on board (180, 200, 220 & 240spm) Output type NPN open collector output Output load voltage 24VDC ±10% Load current 0.75A max. Withstand voltage 35V Residual voltage 1.5V or below Leak alarm output Output type Relay contact output 30VDC, 5A Timer alarm output Output type Relay contact output 30VDC, 5A Electro-pneumatic regulator control signal output Output signal Analog signal 0 - 10VDC, 50mA Resolution 8 bit D/A converter Stroke rate change external output voltage Output voltage 4VDC Pump models to be controlled FS series Range of control speed 0~100% of specified max. stroke -6- 6. Dimensions 6-1. Driver CN1 CN2 CN3 CN4 CN5 CN6 CN7 120 116.2 115 40 PUMP DRIVER 40 20 60 50 MODEL 60 100 AUTO STOP MANU 4- F 4.5 50 10 80 0 FD-3 20 30 40 60 0 TIMER(SEC) SPEED(%) IWAKI 120 130 Fig. 4 52 6-2. Electro-pneumatic regulator Model EV2500-008 made by CKD Note that the electro-pneumatic regulator is optional accessory. M12, 4-pin connector Zero span adjusting window (9) 50 72 PUSHOPEN PT1/4, EXH. OUT 22.5 SUP 3-Rc1/4 Fig. 5 -7- 7. Mounting Mounting to instrument board 1) Cut out the panel board for mounting hole of 41 × 125mm. See Fig. 6. 2) Drill holes for mounting screws. 3) Insert the driver through the panel cutout and fix it with M4 screws. 4) The depth of the controller is 120mm. Keep installation space deep enough. 125 +0.5 0 41+0.5 0 50 ±0.2 120 ±0.2 4- F4.5 Fig. 6 -8- -9- CN4 CN3 CN2 CN1 3 2 1 Sensors R and L are the positions seen from pump suction port side. GND 8 Sensor R input 7 DC24V output 6 GND 5 Sensor L input 4 DC24V output 3 GND 2 Leak sensor input 1 GND 2 DC24V 1 DC24V output SV output COM 4 Time-up alarm 3 COM 2 Leak alarm 1 DC24V power source SV D1 C1 Electrode C2 Electrode D2 FS pump R EV2500 Fig. 7 Wiring & Air Piping Diagram L Equipment : air piping : signal 5 GND 4 E-EXT input 3 VR GND 2 VR CENTER 1 VR Vref(4V) 3 GND 2 DC0~10V output 1 DC24V output 2 GND CN7 CN6 CN5 1 External start input 8. Electrical wiring Fig. 7 shows basic wiring diagram between driver, pump and other devices. Referring to the diagram and operating manual of the pump, follow the procedures described below to correctly connect wires. 1) Connection of 24VDC power source with FD-3 • Prepare 24VDC power source (capacity more than 0.5A) • Connect power source "+" to 1P of CN3 and "-" to 2P of CN3. 2) Connection of FD-3 with pump Wiring is done for proximity switches (pump stroke detection) and leak sensor only. • Connect cords (red, white, black) which come from proximity sensor R (right side seen from suction port side) to 6P, 7P and 8P of CN4 respectively. • Connect cords (red, white, black) which come from proximity sensor L (left side seen from suction port side) to 3P, 4P and 5P of CN4 respectively. • Electrodes of pump D1, D2 and C1, C2 are respectively connected in parallel to 1P, 2P of CN4 as shown in Fig. 7. 3) Connection of FD-3 with solenoid valve Connect 3P of CN2 to "+", and 1P to "-" of solenoid valve. Note that solenoid valve is optional accessory. 4) Connection of FD-3 with electro-pneumatic regulator • Use electro-pneumatic regulator model EV2500-008 made by CKD. Note that regulator is optional accessory. • Use connector model XS2C-D422 made by OMRON. Note that connector is optional accessory. • Use 4-wires shield cable for wiring (0.3mm 2, ø5.9) Refer to following table for connection. Electro-pneumatic regulator EV2500-008 Connector XS2C-D422 Driver connector CN6 1P 24VDC 1P 1P 24VDC output 2P Monitor output 2P - 3P Common 3P 3P GND 4P Control signal 4P 2P 0 - 10VDC output Note: shield wire is connected to 3P (GND) of CN6. 5) Wiring of FD-3 with other equipment • Alarm output wiring 1P and 2P of CN1 are leak alarm output. 3P and 4P are time alarm output. • Wiring of external start/stop signal Connect relay contact inside equipment to 1P and 2P of CN5. • Wiring of external stroke rate change signal As shown on Fig. 8, variable resistor of resistance 5kohm is connected to 1P, 2P and 3P of CN7. If analog signal is employed , wiring is made according to Fig. 9. - 10 - CN7 Your own system Your own system Variable 1VR Vref (4V) resistance 2VR CENTER 5kΩ 3VR GND DC0~4V 3VR GND 4E-EXT input Contact point 5GND 5GND Fig. 9 Fig. 8 2VR CENTER GND 4E-EXT input Contact point CN7 1VR Vref (4V) Note: If contact points 4 and 5 are connected, the external signal has priority over the set value by dial. Stroke rate can be adjusted from 0% to 100% by input signal 0-5kohm or DC0-4V. Wrong wiring causes damaged IC or board inside driver and built-in sensor or proximity switch. Sufficient attention must be paid when wiring is done. Also after wiring is completed, check it with wiring diagram. In case flammable liquid is handled, standard proximity switch can not be used. Please ask IWAKI for explosion-proof proximity switch. Also, leak sensor can not be used because spark may happen. 9. Air piping Refer to operating instruction of IWAKI pneumatic bellows pump FS series as well respective instruction of solenoid valve and electro-pneumatic regulator etc. As shown in Fig. 7, piping is done in order of pump - solenoid valve - electro-pneumatic regulator - manual regulator. 10. Preparation for operation 1) Setting of dip switch Set dip switch (SW1, SW2) which is located inside driver according to max. stroke rate of used FS pump. Refer to following table and Fig. 10. Max. stroke rate of used pump 180 spm 200 spm 220 spm 240 spm SW1 OFF ON OFF ON SW2 OFF OFF ON ON Note: When shipped from factory, SW1 and 2 are set for 220 spm. Model Max. FS-15 FS-30 FS-60 stroke rate 240 spm 220 spm 200 spm - 11 - Fig. 10 2) Confirm that wiring and air piping are correctly done between equipment, FD-3 driver, pump, solenoid valve, electro-pneumatic regulator and manual regulator. 3) Set supply air to electro-pneumatic regulator at specified pressure by adjusting manual regulator. Specified air pressure depends on used pump. Refer to operating manual of FS pump. 4) Set stroke rate dial and timer dial at desiring values. If dial is set based on liquid circulating capacity, calculate to get the stroke number according to circulating capacity (discharge capacity). Note: Pump does not start unless speed setting dial is set at 10% or more. 11. Operation 1) Manual operation To start: Set the start switch at MANU position. To stop: Set the start switch at STOP position and reduce the pressure of manual regulator to zero. 2) Automatic operation To start: Turn ON the contact signal from equipment. To stop: Turn OFF the contact signal. - 12 - 12. Troubleshooting Trouble Pump does not start. Pump starts but soon stops Fixed stroke rate control can not be performed. (Set stroke is not maintained) Leak alarm is activated. Timer alarm is activated. Causes Countermeasures * Power is not supplied. Check that the power switch is on. * Faulty wiring Sensor L and R is wired in reverse. Faulty wiring of three leads of sensor. Disconnected sensor lead. Faulty wiring to solenoid valve. Faulty wiring to electro-pneumatic regulator. Faulty wiring of external start signal. Refer to item 8 "Electrical wiring" * Faulty air piping Supply air pressure is not added. Refer to item 9 "Air piping". * Malfunction of solenoid valve switching over. Inspect or replace solenoid valve. * Malfunction of pump. Inspect or replace pump. * Speed dial is set at 0-10%. Reset dial. * Speed setting level is too low, and supply air pressure becomes lower than pump's lowest driving air pressure. Increase speed setting value. * Load on pump discharge side is too low, and supply air pressure becomes lower than pump's lowest driving air pressure. Increase speed setting value. * Load on pump discharge side is too high, and supply air pressure has reached upper limit. (Setting was made beyond performance of pump) Reduce speed setting value. Replace filter which is likely to be clogged. * Driver's dip switch does not relate with specified max. stroke of pump. Correct dip switch setting. * Air pressure to electro-pneumatic regulator is not set correctly. Refer to item 9 "Air piping". * Electrodes inside pump are conducting. Broken bellows. Liquid splash on pump outside. Replace bellows or pump. Wipe off liquid which was splashed around electrodes. * Wiring between electrodes is short circuited. Correct short circuit. * Pump discharge pressure is increased. Check discharge condition. * Supply air pressure is lowered. Inspect and reset pressure. * Malfunction of pump. Inspect or replace pump. * Speed dial is set at 0-10%. Reset dial. - 13 - ( )Country codes IWAKI CO.,LTD. 6-6 Kanda-Sudacho 2-chome Chiyoda-ku Tokyo 101-8558 Japan TEL:(81)3 3254 2935 FAX:3 3252 8892 Australia Austria Belgium China China China China Denmark Finland France Germany Holland Hong Kong Indonesia IWAKI Pumps Australia Pty. Ltd. IWAKI EUROPE GmbH IWAKI Belgium n.v. IWAKI Pumps (Shanghai) Co., Ltd. IWAKI Pumps (Guandong) Co., Ltd. GFTZ IWAKI Engineering & Trading (Guangzhou) GFTZ IWAKI Engineering & Trading (Beijing) IWAKI Nordic A/S IWAKI Suomi Oy IWAKI France S.A. IWAKI EUROPE GmbH IWAKI EUROPE NL Branch IWAKI Pumps Co., Ltd. IWAKI Singapore (Indonesia Branch) TEL : (61)2 9899 2411 TEL : (49)2154 9254 0 TEL : (32)1367 0200 TEL : (86)21 6272 7502 TEL : (86)750 3866228 TEL : (86)20 8435 0603 TEL : (86)10 6442 7713 TEL : (45)48 24 2345 TEL : (358)9 2745810 TEL : (33)1 69 63 33 70 TEL : (49)2154 9254 0 TEL : (31)547 293 160 TEL : (852)2 607 1168 TEL : (62)21 690 6606 FAX : 2 9899 2421 FAX : 2154 9254 48 FAX : 1367 2030 FAX : 21 6272 6929 FAX : 750 3866278 FAX : 20 8435 9181 FAX : 10 6442 7712 FAX : 48 24 2346 FAX : 9 2742715 FAX : 1 64 49 92 73 FAX : 2154 9254 48 FAX : 547 292 332 FAX : 2 607 1000 FAX : 21 690 6612 Italy Korea Malaysia Norway Singapore Spain Sweden Switzerland Taiwan Taiwan Thailand U.K. U.S.A. Vietnam IWAKI Italia S.R.L. IWAKI Korea Co.,Ltd. IWAKIm Sdn. Bhd. IWAKI Norge AS IWAKI Singapore Pte. Ltd. IWAKI Iberica Pumps, S.A. IWAKI Sverige AB IWAKI (Schweiz) AG IWAKI Pumps Taiwan Co., Ltd. IWAKI Pumps Taiwan (Hsin-chu) Co., Ltd. IWAKI (Thailand) Co.,Ltd. IWAKI Pumps (UK) LTD. IWAKI AMERICA Inc. IWAKI pumps Vietnam Co.,Ltd. TEL : (39)0444 371115 TEL : (82)2 2630 4800 TEL : (60)3 7803 8807 TEL : (47)23 38 49 00 TEL : (65)6316 2028 TEL : (34)943 630030 TEL : (46)8 511 72900 TEL : (41)26 674 9300 TEL : (886)2 8227 6900 TEL : (886)3 573 5797 TEL : (66)2 322 2471 TEL : (44)1743 231363 TEL : (1)508 429 1440 TEL : (84)613 933456 FAX : 0444 335350 FAX : 2 2630 4801 FAX : 3 7803 4800 FAX : 23 38 49 01 FAX : 6316 3221 FAX : 943 628799 FAX : 8 511 72922 FAX : 26 674 9302 FAX : 2 8227 6818 FAX : (886)3 573 5798 FAX : 2 322 2477 FAX : 1743 366507 FAX : 508 429 1386 FAX : 613 933399 T467-2 '12/10 IWAKI Pump Driver Model FD-3 Instruction Manual Read this instruction manual before use of product