1 GRUNDFOS INSTRUCTIONS CR Monitoring Installation and operating instructions
2 Declaration of Conformity We Grundfos declare under our sole responsibility that the product CR Monitor, to which this declaration relates, is in conformity with these Council directives on the approximation of the laws of the EC member states: Machinery Directive (98/37/EC). Standard used: EN 809: Low Voltage Directive (2006/95/EC). Standards used: EN : 2002 and EN : EMC Directive (2004/108/EC). Standards used: EN and EN Declaration of Conformity We Grundfos declare under our sole responsibility that the product CR Monitor, to which this declaration relates, is in conformity with these Council directives on the approximation of the laws of the EC member states: Machinery Directive (98/37/EC). Standard used: EN 809: Low Voltage Directive (2006/95/EC). Standards used: EN : 2002 and EN : EMC Directive (2004/108/EC). Standards used: EN and EN Konformitätserklärung Wir, Grundfos, erklären in alleiniger Verantwortung, dass das Produkt CR Monitor, auf das sich diese Erklärung bezieht, mit den folgenden Richtlinien des Rates zur Angleichung der Rechtsvorschriften der EU-Mitgliedsstaaten übereinstimmt: Maschinenrichtlinie (98/37/EG). Norm, die verwendet wurde: EN 809: Niederspannungsrichtlinie (2006/95/EG). Normen, die verwendet wurden: EN : 2002 und EN : EMV-Richtlinie (2004/108/EG). Normen, die verwendet wurden: EN und EN Bjerringbro, 1st November 2008 Jan Strandgaard Technical Director 2
3 CR Monitoring Installation and operating instructions 4 Montage- und Betriebsanleitung 39 Monterings- og driftsinstruktion 77 3
4 CONTENTS Page 1. Symbols used in this document 4 2. Scope of this manual 4 3. Quick start-up 5 4. Product description Primary functions Cavitation monitoring Graphical display Symbols used in the display Efficiency monitoring 6 5. Nameplate 7 6. Software label 7 7. Type key 7 8. Installation Mechanical installation The pump CR Monitor Connection to system Sensors Schematic system overview Terminal block in CR Monitor EMC-correct installation Electrical connection Control panel Display Buttons and indicator lights Start-up Setting of efficiency and cavitation monitoring Learning Forms of learning Pump in open loop (active learning) Pump with constant discharge pressure Passive learning Functions Functions tree Overview Status (1) System status (1.1) Q/H curve (1.2) Q/P curve (1.3) Efficiency curve (1.4) Cavitation curve (1.5) Measurements (1.6) Q/time histogram (1.7) Historical data (1.8) Alarm (2) Alarm status (2) Current alarms (2.1) Alarm log (2.2) Limits (3) Fault handling (3.1) Sensor measurements (3.1.1) Example: Fault handling, flow measurement ( ) Monitoring functions (3.1.2) Example: Fault handling, efficiency ( ) Monitoring filters (3.1.3) Pump and IO 351 (3.1.4) Other fault handling (3.1.5) General settings (3.1.6) Maintenance (3.2) Status display data (3.3) Installation (4) CR Monitor settings (4.1) Learning (4.1.1) Cavitation (4.1.2) Maintenance (4.1.3) Input/output settings (4.2) Digital inputs (4.2.1) Analog inputs (4.2.2) Analog inputs and measured values ( ) Digital outputs (4.2.3) Analog outputs (4.2.4) Basic settings, CU 351 (4.3) Display language (4.3.1) Units (4.3.2) Date and time (4.3.3) Password (4.3.4) Ethernet (4.3.5) GENIbus number (4.3.6) Software status (4.3.7) Data communication Ethernet GENIbus Maintenance CU Taking the CR Monitor out of operation Technical data Ambient temperature Air humidity Enclosure class Supported pumps Supported motors Liquid temperature Cable lengths Electrical data Fault finding Disposal 38 Warning Prior to installation, read these installation and operating instructions. Installation and operation must comply with local regulations and accepted codes of good practice. 1. Symbols used in this document Caution Note Warning If these safety instructions are not observed, it may result in personal injury! If these safety instructions are not observed, it may result in malfunction or damage to the equipment! Notes or instructions that make the job easier and ensure safe operation. 2. Scope of this manual These installation and operating instructions apply to Grundfos CR Monitor control cabinets. Subcomponents in the control cabinet are only described in these instructions when they are important for the operation of the CR Monitor. Further documentation supplied with the CR Monitor: Pump type Documentation CRE, CR with CR CUE Wiring diagram x x CU 351 x x IO 351 x x LiqTec x x MP 204 x - CIU 150 x * x * CIU 200 x * x * CIU 250 x * x * * Documentation is supplied if the component is selected (option). 4
5 3. Quick start-up This manual describes the installation, setting and operation of the CR Monitor. The product offers many functions and settings, and the manual may therefore seem comprehensive. For a detailed description of the functions and settings of the CR Monitor, please see the individual sections in this manual. For a quick start-up, see the sections below. Installation Position of control cabinet - section 8.1.2, page 8. Installation and connection of sensors - section 8.2, page 8. Electrical connection - section 8.4, page 11. Start-up As a minimum, the signal and measuring range of the analog inputs must be set. See section , page 29. The pump can be started, and the duty point will be shown in the display. For further settings of efficiency and cavitation monitoring, see section 10.1, page 13. Fault finding The service instructions contain a complete list of fault indications with fault cause, explanation and remedy. They can be downloaded from WebCAPS (www.grundfos.com > International website > WebCAPS). 4. Product description The CR Monitor consists of a control cabinet with all necessary components such as main switch, contactors and IO modules connected to a common terminal block. 4.1 Primary functions The CR Monitor is designed for monitoring one pump and makes it possible for the operator to set limits for warnings and alarms. This offers the operator these possibilities: To detect if the pump efficiency is reduced. To detect if pump is about to cavitate. Detect if the pump is running outside the normal duty range. To plan pump maintenance in order to prevent unplanned downtime. The CR Monitor furthermore offers the operator these possibilities: monitoring of operation and protection of equipment bus communication with for instance a SCADA system data collection, monitoring and setting via internet. 4.2 Cavitation monitoring The cavitation monitoring does not depend on learning the pump's operating characteristic. The CR Monitor calculates the actual NPSH value by measuring the actual inlet pressure and temperature and compares the values with the NPSH data of the pump. Note The NPSH value calculated applies only to clean and degassed water. NPSH, Net Positive Suction Head NPSH R (required NPSH) states how big the absolute pressure must be at the pump inlet to prevent cavitation. The NPSH R depends on the flow rate and the water vapour pressure at a given temperature. NPSH A (available NPSH) is the pressure that is available at the pump inlet. The curve in the display (fig. 2) shows NPSH R. It is usually advisable to add a safety margin of 0.5 m to NPSH R to ensure that the pump does not cavitate. The duty point shown in the display is NPSH A. In order to prevent cavitation, NPSH A must be greater than NPSH R. m NPSH A NPSH R Fig. 1 CR Monitor control cabinet The control cabinet is designed for mounting on a wall or pedestal. GrA7120 Fig. 2 NPSH curve m 3 /h TM Caution The CR Monitor can only be used for the motor size and type for which it has been configured. Contact Grundfos if the CR Monitor is to be used for another motor! 5
6 4.3 Graphical display The CR Monitor has a graphical display showing the actual duty point in relation to an operating characteristic learned (flow rate, pressure, efficiency and power) and the distance to the cavitation curve of the pump. If the learning has been finished and the duty point then moves outside the range learned, the CR Monitor will give a warning, "Outside the range learned". See fig. 5. bar bar bar The pump is ok 100 % speed m 3 /h Operating characteristic learned TM Fig. 5 Operation outside the range learned 4.4 Symbols used in the display m 3 /h The CR Monitor shows the operational status of the pump with three symbols: The pump is running within the range learned. TM Fig. 3 Note The pump efficiency is reduced Example of graphical display The CR Monitor requires stable measured data in order to able to learn the operating characteristic of the pump. The lower curve in fig. 3 could also show a changed duty point with no stable measured data yet. When there are stable measured data, the CR Monitor will show the new curve corresponding to the new duty point. During operating, the CR Monitor will show the actual pump duty point in relation to the parts of the pump's operating characteristic where learning has taken place. bar Actual duty point Complete learning 100 % speed 100 % speed m 3 /h m 3 /h TM TM ! X The duty point has exceeded a set warning limit. Maintenance can be planned in good time. The duty point is outside the range learned. The CR Monitor lets the pump continue to run in case of warnings. The duty point has exceeded a set alarm limit. The operator decides whether the CR Monitor is to stop the pump or whether it is to continue to run. 4.5 Efficiency monitoring The function is based on a mathematical model of the pump and motor. On the basis of this model, the CR Monitor can evaluate if the relation between the hydraulic power transferred to the liquid (P hyd ) and the input power from mains (P 1 ) corresponds to the operating characteristic learned. The CR Monitor calculates the total efficiency as the relation between hydraulic power and input power(η tot = P hyd /P 1 ). The CR Monitor then compares the actual measured data and efficiency to the data and efficiency learned. A reduced efficiency is typically caused by wear or clogging of the hydraulic system of the pump. Note The friction in the motor bearings may increase after relubrication and thus reduce the efficiency for a short period. The CR Monitor cannot show the cause of the increased loss, but the operator of the pump will be able to fault-find and prepare maintenance of the pump before an unintended stoppage occurs. bar m 3 /h TM Partial learning Fig. 4 Complete and partial learning 6
7 5. Nameplate The nameplate of the CR Monitor is on the inside of the cabinet door. Type: Prod.-Nr.: Options: 1 Equipment Nr.: Commission: Main supply: In: 7 P.C. YYWW: Main Pumps: 3 Auxiliary Pumps: Ambient Temperature P I Switch- Number kw mm max mode I IP Software label The software label is on the back of the CU 351 controller. Fig. 7 Software label Pos. Description 1 Flow data - No of GSC file 2 Motor data - No of GSC file 3 Pump data - No of GSC file 4 Software version - No of software version Note CR Monitor Flow data Motor data 1 2 Software version: 4 Pump data 3 A GSC file (Grundfos Standard Configuration) is a configuration file. TM Made in P Type key Fig. 6 Nameplate Pos. Description 1 Type designation 2 Product number 3 Options 4 Internal serial number 5 Sales order No/production order No 6 Supply voltage [V] 7 Rated current [A] 8 Operating range for ambient temperature [ C] 9 Year-week code 10 Enclosure class 11 Number of pumps 12 Motor power [kw] 13 Min. current limit 14 Max. current limit 15 Starting method (not stated for CRE and CR with CUE) 16 Country of origin 17 Production department 18 CE-mark TM Example CR Monitor 2.2 kw DOL 3x400V 50-60Hz PE IP54 Type designation CR Monitor (MG and Siemens) or CRE Monitor (MGE and CUE) Motor size and starting method (not stated for CRE and CR with CUE) Supply voltage Mains frequency Separate PE conductor Enclosure class 7
8 8. Installation Warning Installation and operation must comply with local regulations and accepted codes of good practice. Before installation, check that the specifications of the CR Monitor correspond to the order. no visible parts have been damaged Schematic system overview There are two pump types: Mains-operated CR pumps. The motor is supplied with current through the CR Monitor control cabinet. CRE pumps and CR pumps supplied by a CUE. The motor has separate power supply. CR 8.1 Mechanical installation This section describes the mechanical installation of the CR Monitor control cabinet and also provides general advice about how to position sensors in order to achieve stable measured values. A standard configuration of system connections in the control cabinet will be described with reference to the configuration of sensors and signals via the menus in the CU 351. AO DO DI A AI Communication The pump Install the pump according to the installation and operating instructions supplied with the pump CR Monitor Location Note Note Due to radio noise, the CR Monitor must not be installed in residential areas (first environment). The CR Monitor is not designed for outdoor installation and must not be exposed to direct sunlight. 8.2 Connection to system Sensors The CR Monitor requires correct measured values for giving an accurate indication of the pump status. It is therefore important to position and install sensors according to the guidelines of the manufacturer. General requirements In a system with a diaphragm tank, sensors must not be installed after the tank. The sensors must always be correctly sized for the range they are to measure. If the sensor is too small, it will be saturated. If it is too big, the solution of the sensor signal will be too poor. In the case of sensors where is it possible to set a damping of the measured value, the damping should be as low as possible. In the case of cavitation monitoring, the sensor for inlet pressure must measure absolute pressure. It must be as close to the pump inlet as possible (max. 30 cm). The table below shows what sensor types can be used for cavitation and efficiency monitoring: Sensor type Monitoring Inlet/discharge pressure Cavitation Efficiency Absolute/absolute x x Relative/relative * - x Differential pressure sensor - x * Requires that the inlet pressure is always positive. Fig. 8 CRE Fig. 9 CR Monitor with a CR pump CR Monitor with a CRE pump In the case of CR with a CUE, pos. B and C from the CR Monitor in fig. 9 must be connected to the CUE. Note 4 TT AO DO DI 4 TT 1 2 PT PT A B C AI 1 2 PT PT The CRE and CUE must be set to automatic resetting of alarms. 3 FT 5 Communication 3 FT 5 TM TM Pos. Analog input/ output Description 1 AI1 (CU 351) Inlet pressure 2 AI2 (CU 351) Discharge pressure 3 AI3 (CU 351) Flow rate 4 AI1 (IO 351) Temperature 5 AI2 (IO 351) Optional sensor - AO4 (CU 351) (Optional) Display Analog inputs (4.2.2) Analog outputs (4.2.4) 8
9 Digital input/ output DI1 (CU 351) DI2 (CU 351) * DI3 (CU 351) DO1 (CU 351) DO2 (CU 351) ** DO4 (IO 351) DO5 (IO 351) Description External fault The pump is running (Y/D) Resetting of alarm Relay, alarm Relay, alarm stop Relay, warning Relay, ready Display Digital inputs (4.2.1) Digital outputs (4.2.3) * The digital input must be configured in the case of a CR pump. ** The output is only connected to the terminal block in the case of a CRE pump, but it must also be configured in the case of a CR pump. Pos. Liqtec Description A LiqTec Dry-running protection Pos. Communication Description - GENIbus (external) Bus communication B GENIbus (internal) * Start/stop signal to CRE or CUE C LiqTec * Stop signal to CRE or CUE - Ethernet Webserver (RJ45 plug) * Only CRE Terminal block in CR Monitor The components of the CR Monitor are connected to a common terminal block at the bottom of the control cabinet. Components and signal transmitters mentioned in section 8.2 Connection to system must be connected to the terminal block. Note The web server must be connected directly to the CU 351 via a cable with an RJ45 plug. See the installation and operating instructions of the CU 351 supplied with the control cabinet. For connection of SMS box (if selected), see separate manual. Terminal block The terminal block is divided into groups as shown below. X0 X1 X10 X11 X14 X15 TM Fig. 10 Terminal block in CR Monitor Pump X0 X1 X10 X11 X14 X15 CR x x x x x x CRE CR with CUE x - x x x x Connection Make sure to keep unused cable entries closed in order to maintain the IP class of the control cabinet. Cables for sensors, signal transmitters and communication must be connected to the terminal block and configured via the menus in the CU 351. The table below shows an overview of terminals and refers to displays where configuration is carried out. 9
10 Group Pump type Description Terminal Value Comments PE1 Power supply to control cabinet and motor. PE2 CR Power supply L1 400 V X0 L2 400 V L3 400 V CRE CR with CUE Power supply L1 400 V Power supply to control cabinet. L2 400 V The motor has separate power supply. CR (DOL) Motor connection U1 400 V Starting method: Direct-on-line starting V1 400 V W1 400 V U1 400 V Starting method: Star-delta starting X1 V1 400 V CR (Y/D) Motor connection W1 V2 400 V 400 V W2 400 V U2 400 V AI1 (CU 351) PE1 Sensor for inlet pressure (section , page 29). Supply V * Input signal: 0-20 ma, 4-20 ma, 0-10 V. ** Only 3-wire sensor. AI1 51 Input signal * GND 52 GND ** X10 CR, CRE AI2 (CU 351) PE2 Sensor for discharge pressure (section , page 29). Supply V * Input signal: 0-20 ma, 4-20 ma, 0-10 V. ** Only 3-wire sensor. AI2 54 Input signal * GND 55 GND ** AI3 (CU 351) PE3 Flow sensor (section , page 29). AI3 57 GND ** The flow sensor has separate power supply. * Input signal: 0-20 ma, 4-20 ma, 0-10 V. GND 58 Input signal * ** Only 3-wire sensor. GENIbus (external) RS-485 A SCADA. RS-485 Y MODBUS, PROFIBUS, GSM-module RS-485 B CR, CRE DI1 (CU 351) DI3 (CU 351) DI1 10 GND 11 DI1 13 GND V / 5 ma pulldown External fault (section , page 29). Possibility to send external stop signal to the CR Monitor. 24 V / 5 ma pulldown Resetting of alarm (section , page 29). Possibility to reset an alarm in the CR Monitor externally. X11 DO1 (CU 351) (C) 70 Relay, alarm (section , page 30). (NO) * 71 DO1 is always activated in case of alarms. * Optional, but normally (NC) is selected. (NC) * 72 DO2 (CU 351) (C) 73 Relay, alarm stop (section , page 30). (NO) * 74 To be connected to the start/stop input of the motor or CUE. DO2 is only activated if the function has been selected. (NC) * 75 * Optional, but normally (NO) is selected. CRE CR with CUE GENIbus (internal) RS-485 A1 To be connected to the CRE/CUE. RS-485 Y1 To be screened. RS-485 B1 LiqTec (Run) 91 To be connected to the digital input of CRE/CUE. (C) 92 To be set via R100 or PC Tool to "External fault". (AL) 93 10
11 Group Pump type Description Terminal Value Comments X14 CR, CRE AO4 (IO 351) AI1 (IO 351) AI2 (IO 351) DO4 (IO 351) DO5 (IO 351) 8.3 EMC-correct installation In order to ensure an EMC-correct installation, these guidelines for communication and signal cables must be followed: Leave the screen of the cable as close to the connecting terminals as possible. Fix the screen with a cable clamp. GND 17 Optional analog sensor. Output signal: AO V (section , page 31). Supply V Temperature sensor (section , page 29). GND 55 GND ** * Input signal: 0-20 ma, 4-20 ma, 0-10 V. ** Only 3-wire sensor. AI1 57 Input signal * Supply V Optional sensor (section , page 29). GND 55 GND ** * Input signal: 0-20 ma, 4-20 ma, 0-10 V. ** Only 3-wire sensor. AI2 60 Input signal * (NO) 82 Relay, warning (section , page 30). (C) 83 DO4 is always activated in case of warnings. (NO) 84 Relay, ready (section , page 30). (C) 85 The pump is running without a warning or an alarm. Brown/ To be connected to the LiqTec sensor of the pump. 1 black X15 CR, CRE LiqTec Blue 2 White 3 - CR, CRE Webserver Ethernet - To be connected directly to the CU 351 (RJ45). TM Fig. 11 Example of stripped cable with screen Connect the screen of communication and signal cables to frame at both ends. Screws for frame connections must always be tightened whether a cable is fitted or not. 8.4 Electrical connection Warning The electrical connection should be carried out by an authorised person in accordance with local regulations and the wiring diagram. The electrical installation must comply with enclosure class IP54. Make sure that the CR Monitor is designed for the electricity supply on which is will be used. Check that the conductor cross-section corresponds to the specifications in the wiring diagram. 11
12 9. Control panel The control panel in the front plate of the control cabinet consists of a display, a number of buttons and two indicator lights. The control panel offers these possibilities: to monitor the operating status of the pump to set the indication of pump status to set parameters for alarm to see the alarm log (history) to start/stop a new learning to set intervals for relubrication or replacement of motor bearings to configure inputs and outputs. 9.1 Display The display (pos. 1, fig. 12) of the CU 351 show the menu with status and settings. D A B Fig. 12 Control panel Legend Pos. Symbols Description Display 4 Goes up in a list Goes to the next column in the menu structure Opens a help text for the display in question 5 Goes down in a list 6 Increases a value 7 Reduces a value 8 Goes one display back in the menu 9 Goes back to menu Status Indicator Indicator 1 CU 351 TM Starts the setting of a value or activates the value light, operation (green) light, fault (red) 13 Changes the contrast of the display Fig. 13 Display design Menu line The menu line (A) shows the four main menus: Status Alarm Limits Installation Monitoring the operating status of the pump Alarm log for fault finding Setting of limits for fault handling Start/stop of learning, configuration of inputs and outputs, various system settings Top line The upper line (B) shows the following: number and title of the display (to the left) the menu selected (to the left) the symbol in case of alarm (to the right) the symbol if the service language has been selected (to the right). Graphical illustration The graphical display depends on the position in the menu structure: In displays with status indication, the status is shown in the upper half and menu elements in the lower half. In displays for setting and configuration of functions, each element is listed, and it is possible to set values and/or select and deselect functions. If not all elements can be shown in the display, the symbols and will be shown to the right in the scrollbar. Go up and down in a list with [ ] and [ ]. Lower line The bottom line (C) shows the following: the text "CR Monitor" during normal operation (to the left) the text "Learning started" during learning (flashing to the left) date and time (to the right). C 12
13 9.2 Buttons and indicator lights The buttons (pos. 2 to 10, fig. 12) of the CU 351 are active when they are lit. [>] (pos. 2) Goes to the next column in the menu structure. If the button is pressed while menu Installation is highlighted, you go to menu Status, etc. [?] (pos. 3) Opens a help text for the display in question. Close the help text with [esc]. [ ] and [ ] (pos. 4 and 5) Goes up and down in a list. A text can be selected when it is in a frame. [+] and [ ] (pos. 6 and 7) Increases or reduces a value. Activate the value with [ok]. [esc] (pos. 8) Goes one display back in the menu. If a value has been changed and [esc] is pressed, the new value will not be saved. Further information, see section [ok] (pos. 10), page 13. If [ok] is pressed before [esc], the new value will be saved. Further information, see section [ok] (pos. 10) below. [home] (pos. 9) Goes back to menu Status. The menu item shown last in menu Status will appear. [ok] (pos. 10) Is the enter button and used for starting the setting of a value. If a value has been changed and [ok] is pressed, the new value will be activated. Indicator lights (pos. 11 and 12) The control panel has a green and a red indicator light. The green indicator light is on when the pump is running. In the case of CRE and CR with a CUE, the green indicator light will be flashing if the pump has been set to stop. The red indicator light is on if there is an alarm or a warning. The fault can be identified from the alarm list. See section 14.2 Current alarms (2.1). Contrast (pos. 13) Changes the contrast of the display. 1. Press the button. 2. Adjust the contrast with [+] and [ ]. Backlight If the buttons are not touched for 15 minutes, the backlight of the display will be dimmed and the display shown last in menu Status will appear. Press any button to reactivate the backlight. 10. Start-up When the basic mechanical, electrical and hydraulic installation as described in section 8.1 Mechanical installation and 8.2 Connection to system have been carried out, then switch on the electricity supply, and wait for the first display to appear. Display language, measuring units, date and time are set in display 4.3. See section 16.3, page Setting of efficiency and cavitation monitoring 1. Analog sensors Setting of analog sensors (display 4.2.2, section , page 29). Sensors required for efficiency monitoring: Inlet and discharge pressure, flow rate. Sensors required for cavitation monitoring: Inlet pressure, flow rate and temperature. 2. Cavitation monitoring Setting of cavitation monitoring (display 4.1.2, section , page 28). Safety margin for NPSH R (cavitation limit). Liquid temperature monitoring via sensor. 3. Limits for sensor values Setting of warning and alarm limits for sensor values (display 3.1.1, section , page 23). Warning and alarm limits for each sensor. 4. Limits for monitoring functions Setting of warning and alarm limits for efficiency and cavitation monitoring (display 3.1.2, section , page 24). Warning and alarm limits for each function. 5. Learning Learning of operating characteristic (display 4.1.1, section , page 27) Start/stop of a new learning. Selection between active and passive learning. 11. Learning Learning of the operating characteristic of the pump is an essential part of the start-up of the CR Monitor. As it is reference for efficiency monitoring, learning must take place when the pump is running faultlessly under normal operating conditions. Consider these items before starting a learning: The pump must be running faultlessly. Measured data from flow and pressure sensors must be stable. Pump, motor and pumped liquid must have reached normal operating temperature. The pumped liquid must be the same during learning as during normal operation. Newly relubricated motor bearings may increase the power loss and must therefore have run for a while before starting a learning. Learning is carried out by letting the pump run at various duty points. To achieve sufficient learning, a duty point must be stable for about ten seconds. The algorithms of the CR Monitor can then calculate the operating characteristic of the pump between duty points learned. Caution Note Learning must be carried out within the permissible limits for pump and application! The pump must not cavitate when learning. 13
14 11.1 Forms of learning The CR Monitor can only monitor the operation in the ranges where learning has been carried out. When the learning has been finished, the CR Monitor will give a warning if the pump duty point moves outside the range learned. It is possible to resume learning if the pump is still running faultlessly. There are two forms of learning: active and passive learning. Active learning: The duty point is adjusted manually in the permissible pump duty range during learning. Passive learning: Learning takes place during normal pump operation and with a set learning time. In order to achieve the best possible monitoring, it is advisable to carry out an active learning in the expected duty range. Learning should not be carried out in ranges for which the system is not sized. The next sections describe active learning with pump in uncontrolled operating mode (open loop) and the considerations to make in the case of constant pressure operation. Learning is started and stopped in display Learning (4.1.1). See page Pump in open loop (active learning) The following procedure is based on the possibility of adjusting the discharge pressure of the pump (throttling). 1. Select "Start learning" under "Learning management". The display in fig. 14 will appear, and the text "Learning started" will flash in the lower menu line. bar Fig. 15 Active learning - open loop (extreme ends for learning) 6. Adjust the discharge pressure to achieve learning at duty points at suitable intervals (pos. 3 to 5, fig. 16) between the two ends of the curve. The number of necessary duty point, and thus the distance between the points, may vary, but the CR Monitor must be able to draw the operating characteristic of the pump between the two points. bar bar % speed m 3 /h 100 % speed m 3 /h 100 % speed m 3 /h TM TM TM Fig. 16 Active learning - open loop (point for learning) Steps 7 and 8 apply to speed-controlled pumps (CRE and CR with CUE): 7. Reduce the speed to a minimum to obtain a new duty point. See pos. 6, fig. 17. A new curve will be shown in the display. 8. Repeat step 7, but at an intermediate speed. See pos. 7, fig. 17. Fig. 14 Learning started 2. Go to display Q/H curve (1.2). See section Start the pump. A cross indicating the actual duty point of the pump will appear in the display. In the case of CRE and CR pumps with a CUE, set the motor to run at max. speed. 4. Adjust the discharge pressure so that the pump delivers a min. flow rate at a max. discharge pressure. See pos. 1, fig. 15. Caution The flow rate must be larger than 10 % of the nominal flow rate to prevent the liquid temperature in the pump from rising. bar bar 6 ~ 25 % speed m 3 /h TM Adjust the discharge pressure so that the pump delivers a max. flow rate at a min. discharge pressure. See pos. 2, fig. 15. Note The pump must not cavitate. It may be necessary to reduce the flow rate. ~ 65 % speed 7 m 3 /h TM Fig. 17 Active learning in open loop (variable speed) 14
15 9. The learning is complete and can be stopped in display Learning (4.1.1) by selecting "Stop learning". A display will be shown for ended learning, and the text "Learning started" will disappear from the lower menu line. Press [ok] Pump with constant discharge pressure Pumps set to delivering a constant discharge pressure will adjust the speed in relation to the flow rate. See fig. 18 ("SP" = setpoint). At 100 % speed, an increase of the flow rate will cause a lower pressure. The CR Monitor will only show the curve learned at the speed which can deliver the constant pressure at the flow rate required. bar SP 100 % speed 65 % speed 25 % speed Fig. 18 Constant pressure - complete learning m 3 /h TM Passive learning Passive learning should only be carried out if active learning is not possible. The CR Monitor will only carry out learning in the range where the pump runs during normal operation. When the learning has been finished, the CR Monitor will give a warning if the pump duty point moves outside the range learned. Note Passive learning can be expanded with a new duty range by recalling saved learning sets and resume the learning as described below. 1. Select "Learning time-out" under "Learning management", and set the desired learning time. Set the time-out so that all variations of the operating characteristic is included in the learning. 2. Select "Start learning". The display in fig. 14 will appear, and the text "Learning started" will flash in the lower menu line. 3. The CR Monitor will carry out a continuous learning. It is therefore important to make sure that the pump is running faultlessly while learning takes place. When learning has ended (either by time-out or manual stop), a display will be shown for ended learning, and the text "Learning started" will disappear from the lower menu line. The best learning in constant pressure systems is achieved if learning can be carried out in open loop as described above. If this is not possible, the second best solution is to carry out learning at minimum two discharge pressures. See fig. 19 (SP1 and SP2). bar SP2 SP1 m 3 /h Fig. 19 Constant pressure - learning at two setpoints TM This way, the operating characteristic is drawn between the two setpoints. This still provides a good basis for reliable efficiency monitoring. If it is only possible to carry out learning at one constant discharge pressure, the CR Monitor will only learn a limited part of the operating characteristic. See fig. 20. bar SP m 3 /h Fig. 20 Constant pressure - learning at one setpoint TM If the CR Monitor has only learned in one setpoint, it cannot give a direct warning/alarm if the efficiency is reduced. Instead, the CR Monitor will give the warning "Outside the range learned". It is then possible to evaluate if the duty point is outside the range learned, or if the warning is actually caused by reduced efficiency. 15
16 12. Functions The CR Monitor has four main menus: 1. Status The Status menu shows the operating status of the system and pump as well as historical data. Note: No settings can be made in this menu. 2. Alarm The Alarm menu gives an overview of alarms and warnings. Alarms and warnings can be reset in this menu. 3. Limits In menu Limits, the following settings can be made: Limits for warning and alarm and the reaction of the CR Monitor in case of fault. Intervals for maintenance of motor bearings. Values to be shown in the status display. 4. Installation In menu Installation, it is possible to set various functions: Starting and stopping learning. Saving, recalling and deleting learning sets. Setting of cavitation measurement. Configuration of digital and analog inputs and outputs. Selection of service language, display language and units. Setting of date and time, password, ethernet connection, GENIbus number and software status Functions tree 1. Status 1.1 System status 1.2 Q/H curve 1.3 Q/P curve 1.4 Efficiency curve 1.5 Cavitation curve 1.6 Measurements 1.7 Q/time histogram 1.8 Historical data 2. Alarm 2.1 Current alarms 2.2 Alarm log 3. Limits 3.1 Fault handling Sensor measurements Fault handling, flow measurement Fault handling, inlet pressure measurement Fault handling, discharge pressure measurement Fault handling, diff. pressure measurement Fault handling, power measurement Fault handling, speed measurement Fault handling, motor voltage measurement Fault handling, liquid temperature measurement Fault handling, optional-sensor measurement Monitoring functions Fault handling, efficiency Fault handling, Q/H Other fault handling Fault handling, cavitation Monitoring filters Pump and IO Other fault handling General settings 3.2 Maintenance 3.3 Status display data 16
17 4. Installation 4.1 CR Monitor settings Learning Save learning set Recall learning set Cavitation Maintenance 4.2 Input/output settings Digital inputs DI1... DI3 (CU 351), [10, 12, 14] DI1... DI9 (IO 351), [ ] Analog inputs AI1... AI3 (CU 351), [51, 54, 57] Analog inputs and measured values AI1, AI2 (IO 351), [57, 60] Analog inputs and measured values Digital outputs (1-2) DO1, DO2 (CU 351), [71, 74] (3-9) DO2... DO7 (IO 351), [ ] Analog outputs 4.3 Basic settings, CU Display language Units Pressure Differential pressure Head Level Flow rate Temperature Power Date and time Password Ethernet GENIbus number Software status 17
18 12.2 Overview In the next sections, displays and functions will be described in the order they appear in the menus. Section Display and No See page 13. Status (1) System status (1.1) Q/H curve (1.2) Q/P curve (1.3) Efficiency curve (1.4) Cavitation curve (1.5) Measurements (1.6) Q/time histogram (1.7) Historical data (1.8) Alarm (2) Alarm status (2) Current alarms (2.1) Alarm log (2.2) Limits (3) Fault handling (3.1) Sensor measurements (3.1.1) Example: Fault handling, flow measurement ( ) Monitoring functions (3.1.2) Example: Fault handling, efficiency ( ) Monitoring filters (3.1.3) Pump and IO 351 (3.1.4) Other fault handling (3.1.5) General settings (3.1.6) Maintenance (3.2) Status display data (3.3) Installation (4) CR Monitor settings (4.1) Learning (4.1.1) Cavitation (4.1.2) Maintenance (4.1.3) Input/output settings (4.2) Digital inputs (4.2.1) Analog inputs (4.2.2) Digital outputs (4.2.3) Analog outputs (4.2.4) Basic settings, CU 351 (4.3) Display language (4.3.1) Units (4.3.2) Date and time (4.3.3) Password (4.3.4) Ethernet (4.3.5) GENIbus number (4.3.6) Software status (4.3.7) 34 18
19 13. Status (1) No settings can be made in this menu. If the buttons of the control panel have not been touched for 15 minutes, the display will return to the display shown last in menu Status Q/H curve (1.2) 13.1 System status (1.1) When the CR Monitor is switched on, this display will be shown. C A B D Fig. 22 Q/H curve Fig. 21 System status Description The operating status of the pump in relation to the operating characteristic learned is shown by means of text (A) and relevant graphics (B) at the top of the display. There is this connection between text and graphics: E Description This status display shows the duty point of the pump at the actual speed in relation to a operating characteristic learned. During normal operation, this point will be somewhere on the curve learned. If the point is under the curve, this may indicate a fault or changed operating conditions. For setting of warning and alarm limits for the operating characteristic learned, see section Monitoring functions (3.1.2) Q/P curve (1.3) CR Monitor status Graphical symbol (B) Normal operation Warning Alarm! X Note If a fault has occurred, the symbol will be shown to the right of the upper line (C). The symbol will be shown in all displays as long as the fault exists. For information about fault cause, see section 14.2 Current alarms (2.1) and 14.3 Alarm log (2.2). It is possible to show up to five status values (D). See section 15.4 Status display data (3.3). The lower display half (E) shows these data: actual duty point for pressure, power, efficiency and cavitation margin in relation to the flow rate of the duty point learned measured values of various operating parameters histogram of the operating pattern of the pump statistics for the CU 351 and the pump as well as intervals for relubrication and replacement of motor bearings. Fig. 23 Q/P curve Description This status display shows the motor input power (P1) at the actual duty point. The point will be shown together with the operating characteristic learned. During normal operation, this point will be somewhere on the curve learned. If the point is above the curve, this may indicate a fault or changed operating conditions. For setting of warning and alarm limits for the operating characteristic learned, see section Monitoring functions (3.1.2). 19
20 13.4 Efficiency curve (1.4) 13.6 Measurements (1.6) Fig. 24 Efficiency curve Description This status display shows the total pump efficiency at the actual duty point. The point will be shown together with the operating characteristic saved. During normal operation, this point will be somewhere on the curve learned. If the point is under the curve, this may indicate a fault or changed operating conditions. For setting of warning and alarm limits for the operating characteristic learned, see section Monitoring functions (3.1.2). Fig. 26 Measurements Description This display shows actual and calculated values of pump performance and operating conditions Q/time histogram (1.7) 13.5 Cavitation curve (1.5) Fig. 27 Q/time histogram Fig. 25 Cavitation curve Description This status display shows the NPSH A value of the pump at the actual duty point. The point will be shown in relation to the cavitation curve of the pump (NPSH R ) under the actual operating conditions. In order to prevent cavitation, the duty point must be above the curve. Note The NPSH value calculated applies only to clean water. The actual distance between the inlet pressure and the cavitation curve can be read in the next display, Measurements (1.6). For setting of warning and alarm limits for cavitation monitoring, see section Monitoring functions (3.1.2). Sizing of correct pump size as to cavitation is described in the data booklet "CR, CRI, CRN, CRE, CRIE, CRNE". Description This status display shows a histogram of the various flow ranges where the pump has been running. The histogram shows an accumulated duty time (y-axis) at various flow rates (x-axis). For speed-controlled pumps, every flow range may be divided into several grey tones. The grey tones show at which speeds the pump has been running at the various flow rates. The table below shows the connection between grey tone, motor frequency and speed. (Motor slip is not included.) Grey tone Motor frequency, f m [Hz] Speed [min -1 ] 0 < f m < f m < f m f m >
21 13.8 Historical data (1.8) 14.2 Current alarms (2.1) Fig. 28 Historical data Description This status display shows various statistical data of the pump and the CUE Alarm (2) Menu Alarm gives an overview of alarms and warnings. In this menu, it is possible to reset alarms and to read the alarm log Alarm status (2) Fig. 29 Alarm status Fig. 30 Current alarms Description This display shows warnings caused by faults that still exist. alarms caused by faults that still exist. alarms caused by faults that have disappeared, but the alarm requires manual resetting. All warnings and alarms with automatic resetting are automatically removed from the display when the fault has disappeared. Alarms requiring manual resetting are reset in this display by pressing [ok]. An alarm cannot be reset until the fault cause has disappeared. For every warning or alarm, the following is shown: Whether it is a warning or an alarm. Where the fault occurred. Sensor type (flow rate, pressure, etc.), external fault, communication fault, etc. In the case of input-related faults, the identity of the input is shown. What the fault cause is, followed by a fault code in parentheses. When the fault occurred: Date and time. When the fault disappeared: Date and time. If the fault still exists, date and time will be shown as The latest warning/alarm is shown at the top of the display. If an SMS box for the CR Monitor has been selected, fault messages can be sent by SMS. Description A fault in the system or an exceeded limit value can cause an alarm or a warning in the CR Monitor. Besides the fault indication via the relay for alarm/warning and the read indicator light on the CU 351, an alarm can be set to activating a relay for alarm stop. This is done in menu Limits. A warning only causes a fault indication. The two submenus show warnings or alarms together with a fault code. The service instructions of the CR Monitor include a complete fault-finding table with all fault codes and a description of fault, cause and remedy. 21
22 14.3 Alarm log (2.2) The alarm log can store up to 24 warning and alarms Fault handling (3.1) The menu is divided into six submenus: Sensor measurements Monitoring functions Monitoring filters Pump and IO 351 Other fault handling General settings. Fig. 31 Alarm log Description For every warning or alarm, the following is shown: Whether it is a warning or an alarm. Where the fault occurred. Flow sensor, external fault, communication fault, etc. In the case of input-related faults, the identity of the input is shown. What the fault cause is, followed by a fault code in parentheses. When the fault occurred: Date and time. When the fault disappeared: Date and time. If the fault still exists, date and time will be shown as The latest warning/alarm is shown at the top of the display. 15. Limits (3) In menu Limits, one of the submenus can be selected: Fault handling Maintenance Status display data. Fig. 33 Fault handling Description Display "Sensor measurements" makes it possible to set warning and alarm limits for each sensor/measuring point and to set how the CR Monitor is to react. "Monitoring functions" makes it possible to set limits for warning and alarm if the duty point moves outside the range learned. "Monitoring filters" makes it possible to set how long measured data may be unstable before a warning is given. It is also possible to set whether the CR Monitor is to send an SMS and/or if measured data are unstable, and if the duty point is outside the range learned. "Pump and IO 351" makes it possible to set how the CR Monitor is to react to warnings and alarms from the pump, IO 351 and sensor faults. "Other fault handling" makes it possible to set how CR Monitor is to react to external faults and faults in the electronic components. "General settings" makes it possible to set how the CR Monitor is to react if the number of restarts is too high. Fig. 32 Limits Description "Fault handling" makes it possible to set how the CR Monitor is to react if a sensor value exceeds a set warning and/or alarm limit or the pump moves outside the range learned. "Maintenance" shows when it is time to relubricate or replace motor bearings. "Status display data" makes it possible to select what values are to be shown in display Status (1). 22
23 } Sensor measurements (3.1.1) It is possible to set min. and max. warning and alarm limits for each of the sensors below as well as how the CR Monitor is to react to faults. Description Note If the value for warning or alarm limits is changed, the function will be selected automatically. The setting of min. and max. warning or alarm limits can be illustrated this way: [ma] [ma] [V] } TM Fig. 34 Sensor measurements Description The submenus for each sensor has the same structure. In the next section, the possible settings for fault handling in connection with flow measurement will be described as a general example Example: Fault handling, flow measurement ( ) The menu offers these possibilities of handling an exceeded limit. Selection and setting of min. and max. alarm limits and the reaction of the CR Monitor. Selection and setting of min. and max. warning limits. Possibility of sending warnings and alarms as SMS (only with optional module) and/or . (To be set via PC Tool.) Fig. 36 Min. and max. limits 1 Normal duty range 2 Max. warning limit 3 Max. alarm limit 4 Min. warning limit 5 Min. alarm limit Example of limits for flow rate: bar m 3 /h TM Fig. 37 Flow limits on a Q/H curve Fig. 35 Fault handling, flow measurement The CR Monitor comes with a hysteresis band for each limit. The purpose is to prevent repeated warnings/alarms caused by small variations of sensor values close to a limit. (The hysteresis band can be changed via PC Tool.) If an alarm limit is exceeded, the CR Monitor can be set to give an alarm and stop the pump, if required. It is generally advisable to let the pump continue to run in case of alarm. If "Stop in case of alarm" has been selected, the pump must be started manually or set to "Auto restart". When the sensor value is within the normal range again (the alarm disappears), the CR Monitor will try to restart the pump after a set time delay. For setting of time delay, see section General settings (3.1.6). Indication in "Alarm status" (2) Warnings and alarms in connection with sensor measurements will be shown this way in 14.2 Current alarms (2.1) and 14.3 Alarm log (2.2): Warning An exceeded warning limit will be shown in Current alarms (2.1) and saved in Alarm log (2.2). The icon will be shown to the right of the upper line. If the sensor value comes within the normal range again, the warning will disappear from Current alarms (2.1). The icon will disappear. A warning indicating that the maintenance interval has been exceeded must be reset when maintenance has been carried out (section 15.3 Maintenance (3.2)). 23
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