BELT COUPLED MOTOR GENERATOR SETS

GENERAL USERS MANUAL

MOTOR GENERATOR SETS

WARNING DO NOT LIFT THE UNIT WITH LIFTING EYE BOLTS ON GENERATOR AND MOTOR. USE 2 DIAMETER HOLES PROVIDED IN THE BASE

DANGER

HIGH VOLTAGE CAUTION - CONNECT EQUIPMENT GROUND TO GROUND STUD AND INSULATE LEAD TERMINALS BEFORE STARTING THE GENERATOR. FAILURE TO COMPLY MAY RESULT IN ELECTRICAL SHOCK AND DAMAGE TO THE UNIT

TABLE OF CONTENTS

BELT COUPLED MOTOR-GENERATOR SETS GENERAL INSTRUCTIONS TENSIONING GUIDE FOR V-BELT DRIVES BASIC TROUBLE SHOOTING FOR BELT COUPLED MOTOR GENERATOR SETS BASIC TROUBLE SHOOTING FOR V-BELTS AND DRIVES MOTOR MANUAL GENERATOR MANUAL VOLTAGE REGULATOR MANUAL OUTPUT CIRCUIT BREAKER MANUAL OUTPUT METER PACKAGE MANUAL

BELT COUPLED MOTOR-GENERATOR SETS GENERAL INSTRUCTIONS

1.0 Georator Motor Generator (MG) Sets are inspected and fully tested at the factory before shipping. Tests specifically conducted are: 1.1 Examination of both motor and generator for general operation, vibration and noise. 1.2 Check of the output voltage of the generator, and the setting of voltage regulator adjustments to the required output voltage. 1.3 Check of the output frequency of the generator at no load. If the frequency is not within standard limits called for in the specifications, pulleys are turned (machined) to provide the correct frequency output. The unit will then be re-tested. 1.4 Motor starter operation is checked. Overload relay is tested. 1.5 Meters are checked for general operation, and calibrated if necessary. 1.6 Tripping function of the circuit breaker is checked using the test button. Users should follow national, local, and site codes for wiring, protection, and installation. No holes are punched in either Motor Starter enclosure or Generator connection box for electrical connections. The user should place these holes where most convenient for the installation. In selecting a location for the Motor-Generator Set, consideration should be given to environment and ventilation. Do not obstruct air flow for air intake and exhaust of the motor, generator, and pulleys & belts, or coupling. Allow a distance of at least 3 feet around the perimeter of the unit. Restricted ventilation will cause a motor-generator to operate at higher than desired temperature. Dirt, dust, chemicals, snow, oil, grass, weeds, etc., all can clog passages of an open frame motor. Georator uses open drip proof motors and generators, with drip covers, as a standard. Open drip proof construction is intended for use indoors where the atmosphere is relatively clean, dry and non-corrosive. According to the NEMA MG-2 publication, a drip proof machine is an open machine in which the ventilating openings are so constructed that successful operation is not interfered with when drops of liquid or solid particles strike or enter the enclosure at any angle from 0 to 15 degrees, downward from the vertical. Optional weather protection enclosures may be provided for outdoor installation. See paragraph 12, below, for a description of optional enclosures.

2.0

3.0

4.0

Ambient temperature of the air surrounding the MG Set should not exceed 40C (104F), for standard rated motors and generators. De-rating may be necessary if the ambient temperature exceeds 40C. Consult Georator engineering for recommendations. For estimated values of heat generated by the MG set under full-load conditions (BTU/hr) please consult Georator engineering. Eyebolts or lifting lugs on the motor or the generator are intended only for lifting the motor or generator. These lifting provisions should never be used to handle the entire MG Set. Please use the holes provided in the base for lifting the entire assembly. The MG Set base should be mounted on level, solid foundation. Georator recommends using the 4 mounting holes in the base for mounting the base directly on a rigid foundation. If these holes are used, 5/8 bolts will be required for mounting. For mounting the unit on a concrete foundation , anchored bolts can be used with a maximum nut torque of approx. 30 lb-ft. Anchored bolts can pull loose if the concrete is overstressed by too much bolt tension. If grouting is used, always check for cracks and gaps. All rotating parts such as couplings, pulleys, and unused shaft extensions are guarded in accordance with ANSIB15.1. Welded steel guards are provided on all MG sets. Belt guard screens are welded in the front end of the belt guards for ventilation and should not be obstructed. Excessive Vibration may be the result of: 8.1 Un-even mounting surface. 8.2 Non rigid mounting surface, or loose mounting bolt(s). 8.3 For coupled-in-line units, coupling misalignment. 8.4 Belt tension and alignment (please refer to the belt tensioning and maintenance section of the service manual). 8.5 Inherent vibration in either motor or generator, or both. This vibration may occur as a result of worn bearings, or an unbalanced rotor. 8.6 For belted units, improper balance on the either, or both, sheaves. Audible Noise: Belted motor-generator sets are typically louder than coupled-inline motor-generator sets. Indoor installation sites requires consideration for the noise level that the set is likely to produce. As far as speech interference is concerned, maximum levels recommended for offices are 60-65 dB. For belted units, an estimate for Georators MG sets sound pressure level is dB 75-85 dB at 3 feet. This level may vary under given operating and environment conditions and is expected to be maximum when the MG set is operating under full load condition, and near a corner with poor sound absorbing reflective surfaces. It will be even higher than the above levels with abnormal vibration conditions caused by loose belts. A rigid sealed enclosure, with baffles, reduces noise levels typically by 15-25 dB. Although typical sound attenuating enclosures offered by Georator are not sealed at the bottom, careful design of the enclosure, baffles, and

5.0

6.0

7.0

8.0

9.0

inclusion of acoustical absorbing materials substantially reduce the audible noise of the MG by typically 25-30 dB at 3 feet. 10.0 Electrical Considerations: 10.1 Apply the correct input voltage to the Motor Starter terminals. Motors may operate within 10% of their nameplate; however performance characteristics will differ from nameplate data. Maximum frequency variation may not exceed 5% rated frequency. Good electrical systems and operating practice limit the voltage at the motor under load to not more than 5% of nameplate. Also note that starting motors at lower input voltages will reduce the starting torque, thereby prolonging the acceleration time of the motor from stand still (locked rotor) to rated speed. With MG Sets, the motor is already started under some load, which is the generators inertia. For full voltage starting, the maximum allowable time for small frame motors (up to 286T) is 10 seconds, for medium frames (324T-326T) is 15 seconds, and for large frames (364T449T) is 15 seconds. 10.2 To prevent nuisance tripping when starting the unit, ensure that an appropriately sized circuit breaker is used with the instantaneous trip set at least at 800% of the Full Load Amp of the motor (per NEC Table 430152). Typical locked rotor current (for across the line start) can be as high as 600% to 800% of full load motor amps (FLA). Georator offers reduced voltage motor starters as a standard for units using 125 HP motors and above. Part winding motor starters can reduce the starting current by 50%, whereas Wye/Delta motor starters can reduce starting current down to 33% of the normal starting current. Solid-State Soft Starters can significantly reduce the starting current of the motor to a controlled level usually selected by the user in the range of 25% - 55% of the motor full load current. 10.3 All motors used on Georator MG sets confirm with the EPACT mandate requirements for high efficiency induction motors. 10.4 Check input voltage periodically. Voltage imbalances cause temperature rise in the motor. A 3.5% voltage imbalance will typically cause 25% temperature rise in the motor. 10.5 The Neutral wire on the Generator side is provided for most wiring configurations for three phase Wye, and single phase Delta or Zig-Zag connections. The Neutral wire if provided is not tied to the ground potential in the factory. User to follow the installation requirements and codes pertaining to grounding. Except in the case of MG Sets designed for special testing requirements with complete isolation of Input and Output, the structural steel base is electrically bonded to the motor and generator frames through the mounting bolts of each, thus confirming to NEC Article 250-104 (d). Other applicable standards for grounding are: 10.5.1 NEC, Article 430, Part L on grounding of motors. 10.5.2 NEC, Article 445-1 on grounding of generators. 10.5.3 NEC, Article 250 for general information on grounding.

11.0

Optional Accessories: Several control and protection accessories are provided with the MG sets. Below is a description of each. Other devices may also be provided to facilitate special testing or operational requirements. Consult with Georator Application Engineers. 11.1 Motor Starters: Starters used are generally Enclosed, Full Voltage, Magnetic, Non-Reversing, with IEC Rated contacts. Non-combination (without Input Circuit Breakers) starters are offered as a standard. Enclosures are NEMA1 Type. Combination Motor Starters and different type enclosures, e.g., dust tight, can also be provided. All starters are supplied with motor overload Class 10 protection. This protection is a solid state relay with wide selection of motor current and manual trip reset. Door mounted Start/Stop push buttons are also provided. Additional auxiliary contacts, and/or power control transformers can also be made available for control purposes. Reduced voltage starters are the general offering for large motors. 11.2 Circuit Breakers: Breakers are Thermal-Magnetic Trip, Molded Case, 2 or 3 pole Common Trip circuit breakers. A molded circuit breaker is one that is assembled as an integral unit in a supportive and enclosing housing of insulating material. The circuit breakers offered by Georator are provided for the output (generator) and are wired to the generator terminals and mounted on the generator connection box. They are supplied complete with line and load terminals, and in the case of FD Frames (250 Amp frames) and above the Breaker is UL listed for reverse feed applications. For FD Frames and up, an adjustable magnetic trip unit is provided. In addition to providing short circuit protection (through the magnetic trip unit), and an overload protection (through the thermal trip unit), the circuit breakers are often used, as convenient switches, to apply the Load to the Generator terminals. Several accessories and modifications may optionally be provided with the circuit breakers such as Shunt trip devices, under-voltage release, and auxiliary switches. For Safety and Installation Instructions, the user should consult the appropriate section of the service manual. For general information on application and performance refer to NEMA Standards Publications AB 1 and AB 3. For Guidelines for Inspection and preventive maintenance consult NEMA AB 4. 11.3 Power Monitor: The power monitor is a solid-state digital triple display multi-function power monitoring system. The power monitor simultaneously displays every metered electrical power function including: 11.3.1 11.3.2 11.3.3 11.3.4 Volts, Amps, Frequency, KW or KVA

The Meter is featured with a large bright digital display and a smart keypad for programming and calibration. The meter can also be supplied with digital communications interface port such as RS232 or RS485 that allows it to interface with other equipment and allow remote monitoring of the MG operation. Full details on the power monitors features and functions, calibration, and service can be found in the service manual. 12.0 Optional Enclosures: These notes pertain to weather as well as sound attenuating enclosures. 12.1 The enclosure is constructed in aluminum, and is provided with: 12.1.1 Access Door for belts (or couplings) service 12.1.2 Circulating fan 12.1.3 Thermostat switch 12.1.4 Access for circuit breaker, voltage adjustment, power monitoring, and input and output wiring. 12.2 Access for input and output wiring is normally provided through input and output connection boxes to which electrical connections are made by the user. Connections from the motor (or motor starter) to the input box, and from the generator (or output circuit breaker) to the output box are made by Georator. 12.3 The enclosures are either mounted (bolted) on the MG steel base, or are drop over type. The latter will be supplied as a separate item and final electrical connection for the fan and thermostat switch is carried out by the user.

TENSIONING GUIDE FOR V-BELT DRIVES

Although belts are tensioned properly before shipment, loosening may occur during the first weeks of operation. Tension should be checked after the first 24 to 40 hours of operation. Ideal tension is the tension at which the belt will not slip under peak load conditions. However, note that over tensioning shortens belt and bearing life. Avoid the use of belt dressing as this will damage the belts and lead to premature failure. While an educated thumb may be acceptable for ordinary drives, we recommend the use of a tension gauge which measures the pounds force required to deflect the belt a specified distance. Vendors such as TB Woods provided detailed data on upper and lower limits for tension as a function of belt size and length and should be used for precise data. (see: http://www.tbwoods.com/index.php for their free downloads). General data is shown below: Belt Type BX BX CX CX D 3VX 5VX 5VX 5VX 8V Smaller Sheave Dia. 4.4 5.6 5.8 8.6 7.0 9.0 9.5 16.0 12.0 16.0 4.02 6.9 4.4 6.7 7.1 10.9 11.8 16.0 12.5 17.0 Used Belt, lbs. force 7.1 7.3 14.7 15.9 21.2 5.3 8.8 14.8 17.1 26.8 New Belt, lbs force 10.5 10.9 21.8 23.5 31.3 7.9 13.2 22.1 25.5 39.9

BASIC TROUBLE SHOOTING FOR BELT COUPLED MOTOR GENERATOR SETS

1. Check output voltage and output frequency. A. Output voltage is adjustable using voltage adjusting pot and screw driver voltage adjustment for voltage regulator. If there is no voltage adjustment, it is likely that the voltage regulator has failed. To check voltage regulator, remove leads F+ and F- from the voltage regulator and noting polarity, put a 12 V DC battery, battery charger or DC power supply across F+ and F- leads. Then turn the MG on and the output voltage at no load should be high and stable. If so, the voltage regulator is the only thing that doesnt work. Replace the regulator. If this is not the case, then a major generator problem exists that will need factory repair. 2. The output frequency should be within plus or minus 1 percent. A. If the no load output frequency is above 1%, check the input frequencywhere the output frequency will vary proportionally to the input frequency. B. If the loaded output frequency is low (below 1%), check input frequency for proportional relationship. If the input frequency is OK and the input voltage is OK, check for belt tensioning.

BASIC TROUBLE SHOOTING FOR V-BELTS AND DRIVES Problem

Short Belt Life

Probable Cause
Spin burns from belt slipping on drive sheave under a stalled load condition or when starting Gouges or extreme cover wear caused by belts rubbing on drive guards or other objects High ambient temperature

Trouble-Shoot
Tension belts

Eliminate obstruction or realign drive to provide clearance Use high-temperature belts Provide ventilation Shield belts Check for leaky bearings Clean belts and sheaves Replace sheaves Replace belts Tension belts Replace belts if damaged Replace sheaves Realign sheaves Tension drive Redesign & replace drive Revise centerline distance Provide drive guard (standard on Georator units) Follow installation instructions Eliminate overload Redesign drive Replace belts Tension drive Tension belts evenly

Belts turn over in grooves Belts Squeal

Grease or oil on belts

Worn sheaves Damaged cord section in belts Frayed or gouged belts Excessive vibration Worn sheaves Sheave misalignment High starting load Belts not tensioned properly Excessive overload Insufficient arc of contact Foreign material in drive Belts damaged during installation Shock or extreme overload

Belt Breakage

Excess Vibration

Damaged belt cord section Loose belts Belts improperly tensioned

MAGNAPLUS GENERATOR
280430 Frame Installation, Operation, and Maintenance Manual

Marathon Electric Mfg. Corp. A Subsidiary of Regal-Beloit Corp. P.O. Box 8003 Wausau, WI 54402-8003 Phone: (715) 675 3359 Fax: (715) 675 8026 www.marathonelectric.com

CONTENTS Safety Receiving and Storage Principles of Operation Installation Wiring Connections Operation Maintenance Testing Service Troubleshooting Specifications Parts List & Recommended Spare Parts

2 2 3-4 4-6 6-9 9 - 10 10 - 11 11 - 12 12 - 14 14 - 17 18 19 - 20

When in doubt, ask. Questions are much easier to handle than mistakes caused by a misunderstanding of the information presented in this manual.

RECEIVING AND STORAGE

RECEIVING AND STORAGE
Upon receipt of the generator, it is recommended that it be carefully examined for possible shipping damage. The generator was given to the freight carrier in good condition; thus, the carrier is responsible for the product from the factory dock to the destination. Any damage should be noted on the freight bill before accepting the shipment. Any claims for damage must be promptly filed with the delivering carrier.

SAFETY
PLEASE REMEMBER SAFETY FIRST. If you are not sure of the instructions or procedures contained herein, seek qualified help before continuing. This service manual emphasizes the safety precautions necessary during the installation, operation, and maintenance of your MagnaPLUS generator. Each section of this manual has caution and warning messages. These messages are for your safety, and the safety of the equipment involved. If any of these cautions or warnings are not readily understood, seek clarification from qualified personnel before proceeding. Before any service work is done, disconnect all power sources and lock out all controls to prevent an unexpected start-up of the generator set driver. Proper grounding (earthing) of the generator frame and distribution system in compliance with local and national electrical codes and specific site requirements must be provided. These safety precautions are necessary to prevent potential serious personal injury, or even death. The hazards associated with lifting or moving your MagnaPLUS generator are pointed out in the installation and maintenance sections. Incorrect lifting or moving can result in personal injury or damage to the unit. Prior to start-up of the unit ensure that all generator leads are properly connected to the generator link board located inside the connection box. Always assume that there will be voltage present at the generator terminals whenever the generator's shaft is rotating, and proceed accordingly. Residual voltage is present at the generator terminals and at the automatic voltage regulator panel connections even with the regulator fuse removed. Caution must be exercised, or serious injury or death can result. This manual is not intended to be a substitute for properly trained personnel. Installation and repairs should only be attempted by qualified, trained people. The cautions and warnings point out known conditions and situations that are potentially hazardous. Each installation may well create its own set of hazards

UNPACKING AND HANDLING

Carefully read all instruction tags shipped with the unit. When lifting, attach an overhead crane to the lifting lug(s) on the generator frame. Apply lifting forces in a vertical direction. When transporting single bearing generators, the generators rotor must be adequately supported to prevent damage.

WARNING THE LIFTING LUG(S) ON THE GENERATOR ARE DESIGNED TO SUPPORT THE GENERATOR ONLY. DO NOT LIFT A COMPLETE GENERATOR AND DRIVER ASSEMBLY BY MEANS OF LIFTING LUG(S) ON THE GENERATOR. PERSONAL INJURY OR EQUIPMENT DAMAGE MAY RESULT.

STORAGE
In the event that the generator is not immediately installed on its prime mover, it is recommended that the unit be stored indoors in a clean, dry area which is not subject to rapid changes in temperature and humidity. If the generator is stored for a long period of time, the generator should be tested, cleaned and dried as required before being put into service. See the maintenance section of this manual for further information. If the unit has been stored in an area where it has been subject to vibration, it is recommended that the bearing(s) be inspected and replaced as necessary.

PRINCIPLES OF OPERATION
PMG (optional)
PMG Field (rotor) N (+) DC (in) (-) PMG Armature (stator) 3 Phase AC (out) Rotating Rectifier Assembly 3 Phase -- Full Bridge (+) DC (in) (-) 3 Phase AC (out) L2 Exciter Field (stator)

Rotating Assembly
Exciter Armature (rotor) Main Field (rotor) Main Armature (stator) L1

L3

Exciter Field Power (DC out) PMG Input Power (optional) (1 phase, 300/250 hertz) Automatic Voltage Regulator

Input Power -- Single Phase (shunt powered regulator)

Sensing Input -- Single Phase 3 phase (optional)

FIGURE 1 -- MagnaPLUS Circuit Diagram

FIGURE 2 -- Typical MagnaPLUS Layout Diagram

PRINCIPLE OF OPERATION
MagnaPLUS generators are a brushless, self excited, externally voltage regulated, synchronous AC generator. The generator is made up of six major components: main stator (armature), main rotor (field), exciter stator (field), exciter rotor (armature), rectifier assembly, and voltage regulator. In understanding the above terminology, note the following: stators are stationary, rotors rotate, a field is an electrical input, and an armature is an electrical output. These system components are electrically interconnected as shown in figure 1 and physically located as shown in figure 2. The generators exciter consists of a stationary field and a rotating armature. The stationary field (exciter stator) is designed to be the primary source of the generators residual magnetism. This residual magnetism allows the exciter rotor (armature) to produce AC voltage even when the exciter stator (field) is not powered. This AC voltage is rectified to DC by the rotating rectifier assembly and fed directly to the main rotor (field). As the generator shaft continues to rotate, the main rotor (field) induces a voltage into the generator's main stator (armature). At rated speed, the main stators voltage produced by the residual magnetism of the exciter allows the automatic voltage regulator to function. The regulator provides voltage to the exciter resulting in a build-up of generator terminal voltage. This system of using residual magnetism eliminates the need for a special field flashing circuit in the regulator. After the generator has established the initial residual voltage, the regulator provides a controlled DC field voltage to the exciter stator resulting in a controlled generator terminal voltage.

horsepower per generator KW in motor starting capability. For specific data contact Marathon Electric.

PARALLEL OPERATION
All MagnaPlus generators are built with 2/3 pitch main stator windings and full amortisseur (damper) windings. These features make the MagnaPlus generators suitable for parallel operation when equipped with the proper voltage regulators and voltage regulator accessories. Consult with the factory for further information relative to parallel operations.

NONLINEAR LOADING
Solid state electronic control devices (variable frequency drives, precision motor controls, battery chargers, etc.) utilize electronic switching circuits (thyristors, SCRs, Diodes, etc.). These switching circuits introduce high frequency harmonics which distort the normal wave form of the generator. This creates additional heat in the generator windings and may cause the generator to over-heat. Problems which can occur are not limited to the generator. Poor wave shape may adversely effect various loads connected to the generator. Consult Marathon Electric for further information relative to nonlinear loads.

INSTALLATION
PREPARATION FOR USE
Although the generator has been carefully inspected and tested in operation prior to shipment from the factory, it is recommended that the generator be thoroughly inspected. Check all bolts for tightness and examine the insulation on lead wires for chafing prior to proceeding with installation. Remove all shipping tapes, bags, skids and rotor support blocking. For two bearing units, rotate the shaft by hand to ensure that it rotates smoothly without binding.

Voltage Regulation
In the standard configuration (shunt excited), the automatic voltage regulator receives both its input power and voltage sensing from the generator's output terminals (See Figure 1). With the optional PMG configuration, the regulator receives input power from the PMG. The regulator automatically monitors the generator's output voltage against an internal reference set point and provides the necessary DC output voltage to the exciter field required to maintain constant generator terminal voltage. The generator's terminal voltage is changed by adjusting the regulator's reference set point. Consult the regulator manual for specific adjustment and operating instructions.

MOTOR STARTING
When a motor is started, a large surge of current is drawn by the motor. This starting current is equivalent to the motors locked rotor or stall current and is 5 to 10 times normal full load current. When the generator supplies this in-rush of starting current, the generator voltage dips temporarily. If the motor is too large for the generator, the generators voltage dips greater than 30 percent. This may result in the motor starter de-energizing or the motor stalling. MagnaPlus generators generally supply .3 to .4

WARNING DISABLE AND LOCKOUT ANY ENGINE CRANKING DEVICES BEFORE ATTEMPTING TO INSTALL OR SERVICE THE GENERATOR. FOR ELECTRIC START SETS, DISCONNECT THE CRANKING BATTERY. FOR AIR START, DISCONNECT THE AIR SUPPLY. FOR MOTOR GENERATOR SETS, OPEN THE POWER SUPPLY TO THE DRIVE MOTOR. FAILURE TO COMPLY WITH THESE SAFETY PROCEDURES COULD RESULT IN SEVERE PERSONAL INJURY OR EQUIPMENT DAMAGE. NEVER "BAR OVER" THE ENGINE GENERATOR SET USING THE GENERATOR'S FAN. THE FAN IS NOT DESIGNED FOR THIS PURPOSE. BARRING OVER THE SET WITH THE FAN COULD DAMAGE THE FAN AND RESULT IN PERSONAL INJURY OR EQUIPMENT DAMAGE.

driver and the generator's shaft. Aligning the generator and its driver as accurately as possible will reduce vibration, increase bearing life, and ensure minimum coupling wear. It may be necessary to shim the generator feet for proper support and alignment. Secure the feet of the generator with grade 5 or greater bolts through the holes provided in the mounting feet. Consult the coupling manufacturer's instructions for alignment specifications and procedures.

GENERATOR MOUNTING
Two Bearing Units -- Belt Driven Two bearing MagnaPLUS generators can be belt driven provided belts are sized and applied correctly. Please refer to your supplier of belts and sheaves for correct sizing and tensioning specifications. A bearing life calculation should be performed. Marathon Electric recommends a minimum B-10 life of 40,000 hours. If cog type belts are used, a vibration may be introduced which could lead to premature failure of the bearings.

GENERATOR MOUNTING
Single Bearing Units. Single bearing units are provided with an SAE flywheel housing adapter flange and flexible drive discs. Coupling the generator's shaft to the engine flywheel is accomplished with special steel drive discs bolted to the shaft. In addition to the drive discs, there may be a hub spacer, spacer discs, or a combination of hub spacer and spacer discs inserted between the drive discs and the shaft to achieve the proper shaft extension ("G" dimension per SAE J620c). Holes are provided in the periphery of the coupling discs which correspond to tapped holes in the prime mover's flywheel. The outside diameter of the drive discs fit in a rabbet in the flywheel so that concentricity is assured. Grade 8 place bolts and hardened washers are recommended to mount the drive discs to the flywheel. DO NOT USE SPLIT TYPE LOCK WASHERS. Split lock washers when biting into the drive disc cause stress risers which may result in the disc fracturing. The SAE flywheel housing adapter ring and the engine flywheel housing are designed to match each other with no further alignment necessary. Use grade 5 or greater mounting bolts. MagnaPLUS generator frames are constructed with two or three bolt holes per foot. The feet should be shimmed where necessary to obtain solid contact with the sub-base. With the frame securely bolted to the engine flywheel housing, there is no side thrust or pull on the generator frame, thus no real need to secure the feet with more than one bolt per foot.

END PLAY TESTING

Refer to the engine manual for recommended end play specifications and measurement procedures. If end play is not to specification, it is an indication that the generator shaft is not moving freely in the assembly, and normal life of the thrust bearing could be impaired. Probable causes of this problem are: 1. Improper seating of drive discs in the flywheel resulting in misalignment. 2. Improper mating of generator frame to engine flywheel housing resulting in misalignment. 3. Improper "G" dimension per SAE J620c on either the engine or generator.

TORSIONAL VIBRATION
Torsional vibrations are generated in all rotating shaft systems. In some cases, the amplitude of these vibrations at critical speeds may cause damage to either the generator, its driver, or both. It is therefore necessary to examine the torsional vibration effect on the entire rotating system. IT IS THE RESPONSIBILITY OF THE GENERATOR SET ASSEMBLER TO ASSURE THE TORSIONAL COMPATIBILITY OF THE GENERATOR AND ITS DRIVER. Drawings showing pertinent dimensions and weights of the rotating assembly will be supplied by Marathon Electric upon request.

GENERATOR MOUNTING
Two Bearing Generators -- Direct Drive Two bearing generators are provided with a keyed shaft extension. For direct drive generators, the assembler furnishes a flexible coupling which is installed between the

ENVIRONMENTAL CONSIDERATIONS
The MagnaPLUS generator is designed for heavy duty industrial applications; however, dirt, moisture, heat and vibration are enemies of rotating electrical machinery. Excessive exposure to the elements may shorten generator life. The temperature of the cooling air entering the intake openings of the generator should not exceed the ambient temperature shown on the generators nameplate. Generators intended for outdoor application should be protected with housings having adequate ventilation. Although the standard insulation systems are moisture and humidity resistant, space heaters are recommended for extreme conditions. If the generator is to be installed in an area where blowing sand and dust are present, the enclosure should be fitted with filters. Filters reduce erosion on the generator's insulation by blocking high velocity abrasive particles generated by the flow of cooling air through the generator. Consult the factory for appropriate filters and generator deratings required.

interior of the generator from shavings when drilling or sawing. An approved connector must be used in conjunction with the conduit. To minimize the transmission of vibration, it is essential that flexible conduit be used for all electrical entrance to the generator conduit box. All MagnaPLUS generators are equipped with link boards (terminal strips) for both internal and external connections. All connections made to the studs of the link board should be made with high quality ring terminals. Ring terminal sizes are: 6 mm (280 Series Frames) and 10 mm (360 and 430 Series Frames). Torque link board connections to the following specifications: 280 frame -- 5.4 NM (4 Ft Lb); 360 & 430 frame -- 27 NM (20 Ft Lb). Refer to the connection diagram supplied with the generator and / or the proper diagrams shown in this manual. Install all inter-component and external wiring in accordance with national and local electrical codes. The neutral in the following connection diagrams shown below may be either grounded (earthed) or left above ground potential (floating). See national and local codes and / or the system distribution wiring schematic diagram for the proper connection of the neutral. The following connection diagrams are shown for twelve lead generators. Ten lead generators have the same terminal designations except for leads T10, T11, and T12. These three leads are internally connected inside the generator and brought out as a single lead (T0). Ten lead generators can only be connected in a wye configuration

WIRING CONNECTIONS
Wiring of the generator and accessories should be done in accordance with good electrical practices. Follow government, industry and association standards. The generator conduit box construction allows cable entry from multiple sides. A hole saw or other appropriate tool may be used to provide for conduit entrance. Protect the

HIGH (SERIES) WYE CONNECTION

L1 T1 VOLTAGE (HIGH WYE) Hz L-L L-N 60 480 277 460 266 440 254 416 240 380 219 50 416 240 400 231 380 219

T4 T7 T10 T11 T8 T5 T2 L2 L-L

T12 T6 T3 L3 T9

L-N

LOW (PARALLEL) WYE CONNECTION

L1 T7 T1 VOLTAGE (LOW WYE) Hz L-L L-N 60 240 139 230 133 220 127 208 120 190 110 50 208 120 200 115 190 110

T10 T12 T9

T4 T5 T2 T6 T11

L-L

L3

T3

T8 L-N

L2

HIGH (SERIES) DELTA CONNECTION

T12 T9 T6 T3 L3 T11 T8 T5 L-N T2 L1 T1 T4 T7 T10 L2 L-L ` VOLTAGE (HIGH DELTA) Hz L-L L-N 60 277 139 240 120 50 240 120 220 110 200 100

LOW (PARALLEL) DELTA CONNECTION

L1 T12 T6 T7 T9 T3 T11 L3 T5 L-L T10 T8 T2 L2 T4 T1 L-L

VOLTAGE (LOW DELTA) Hz L-L L-N 60 120 NA 110 NA 50 110 NA 100 NA

DOUBLE DELTA -- SINGLE PHASE CONNECTION

T3 T6 L2 T1 L-N L-L T11 T8 T10 L-N
Note: Single phase KW/KVA ratings are approximately equal to 50% of the generators three phase ratings.

T5 T2 T4 T12 T7

T9

L1

VOLTAGE (DOUBLE DELTA) Hz L-L L-N 60 240 120 220 110 50 220 110

LOW ZIG ZAG -- SINGLE PHASE (PARALLEL) CONNECTION

T6 T3 T9 L2 L-N L-L T12 T8 T11 T5 T4 T10 L-N T1 T7 L1
Note: Single phase KW/KVA ratings are approximately equal to 50% of the generators three phase ratings.

T2

VOLTAGE (LOW ZIGZAG) Hz L-L L-N 60 240 120 220 110 50 220 110 200 100

HIGH ZIG ZAG -- SINGLE PHASE (SERIES) CONNECTION

T12 T9 T6 T3 L2 L-N L-L L-N
Note: Single phase KW/KVA ratings are approximately equal to 50% of the generators three phase ratings.

T1 T4 T7 T10 T11 T8 T5 T2 L1

VOLTAGE (HIGH ZIGZAG) Hz L-L L-N 60 480 240 460 220 50 415 208 380 190

DEDICATED SINGLE PHASE CONNECTION HIGH VOLTAGE - SERIES CONNECTED

VOLTAGE (DEDICATED) Hz L-L L-N 60 240 120 220 110 50 220 110 200 100

L1

T1 L-N

T2 L-L

T3 L-N

T4

L2

OPERATION
PRE-START INSPECTION
Before starting the generator for the first time, the following inspection checks are recommended: 1. A visual inspection should be made for any loose parts, bad connections, or foreign materials. Bar the set over by hand for at least 2 revolutions to be sure that there is no interference and that the set turns freely. If the set does not turn freely, check for clearance in the generator and exciter air gap. Check all wiring against the proper connection diagrams, and ensure that all connections and terminations are tight and properly insulated.

8.

Review all prime mover prestart-up instructions, and ensure that all recommended steps and procedures have been followed. Remove any masking materials affixed during painting. Inspect the generator, prime mover, and any accessory equipment to ensure that nameplates, and all safety warning / caution signs and decals provided with the equipment are in place and clearly visible. Note: It is strongly recommended that the authority having jurisdiction over the installation site be consulted to determine if any additional warning or caution notices, or additional safety devices are required by local codes / standards. Any such required notices or devices should be installed prior to initial startup.

9.

2.

3.

START-UP
The following procedure should be followed when starting the generator set for the first time. 1. The generator output must be disconnected from the load. Be sure that the main circuit breaker or fused disconnect is in the open position. Open the input power to the automatic voltage regulator. Remove the fuse or disconnect and insulate one of the regulator input power leads. (See separate regulator manual) Verify that all prime mover start-up procedures have been followed. If the unit is provided with space heaters, ensure that they are de-energized. In some installations, a set of auxiliary contacts on the main circuit breaker or transfer switch will automatically open the space heater circuit when the generator is connected to the load. Start the prime mover, and adjust it for proper speed. See generator nameplate.

WARNING MAGNAPLUS GENERATORS MAY HAVE VOLTAGE PRESENT AT THE LEAD TERMINALS WHEN THE SHAFT IS ROTATING. DO NOT PERMIT OPERATION OF THE GENERATOR UNTIL ALL LEADS HAVE BEEN CONNECTED AND INSULATED. FAILURE TO DO THIS MAY RESULT IN PERSONAL INJURY OR EQUIPMENT DAMAGE

2.

4. 5.

Verify that all equipment is properly grounded (earthed). Clear the surrounding area of any materials that could be drawn into the generator. Check all fasteners for tightness. Check all access plates, covers, screens and guards. If they have been removed for assembly or inspection, reinstall and check for security.

3.

4.

6. 7.

5.

6.

The purpose of this initial test with the regulator out of the circuit is to detect any wiring mistakes without exposing the unit to undue risk. Check all line to line and line to neutral voltages for balanced voltage. If voltages are balanced, shut down the set and reconnect the regulator. If voltages are unbalanced, shut down the equipment and check for improper wiring. If the problem persists, consult the factory. With the regulator de-energized, the residual voltage should be 10 - 25% of rated value. It is recommended that this residual voltage and driver RPM be recorded for use as a future troubleshooting benchmark.

2.

Isolate all conditions that could apply voltage to the generator terminals while the generator is at rest. Failure to comply could result in personnel injury or equipment damage. If the unit is equipped with space heaters, verify that the heater circuit is energized.

3.

MAINTENANCE
The following maintenance procedures should be followed to ensure long equipment life and satisfactory performance. Maintenance intervals will depend upon operating conditions. 1. Routinely check intake and exhaust air screens to ensure that they are clean and free of debris. Clogged intake air screens will reduce cooling air flow and result in higher operating temperatures. This will reduce generator life and may result in generator damage. All MagnaPLUS generators are equipped with double shielded ball bearings lubricated for the life of the bearing. Every 1,000 hours check the bearing(s) for smooth, quiet operation. For continuous duty generators, recommended practice is to replace the bearing during major overhauls of the engine. Periodically inspect the unit for any buildup of contamination (dirt, oil, etc.) on the windings. If the wound components have become coated with heavy concentrations of oil and grime, the unit should be disassembled and thoroughly cleaned. This operation is not one that can be accomplished effectively on site, but rather one that should be conducted by an authorized service center equipped with the appropriate apparatus and solvents necessary to properly clean and dry the generator.

WARNING THE FOLLOWING TEST MUST BE CONDUCTED BY QUALIFIED ELECTRICAL PERSONNEL. LETHAL VOLTAGE MAY BE PRESENT AT BOTH THE GENERATOR AND VOLTAGE REGULATOR TERMINALS DURING THIS PROCEDURE. CAUTION MUST BE EXERCISED NOT TO COME INTO PERSONAL CONTACT WITH LIVE TERMINALS, LINKS, OR STUDS. SERIOUS INJURY OR DEATH COULD RESULT.

2.

7.

Start the set and adjust the terminal voltage to the desired value by means of the regulator voltage adjustment. If the regulator is equipped with a stability adjustment, follow the instructions in the regulator manual to adjust the stability. Again, check all line to line and line to neutral voltages for balance. It is recommended practice to record the no load excitation (DC voltage to the exciter stator), generator terminal voltage, and driver speed as a benchmark for future troubleshooting. Close the main circuit breaker to the load. Monitor the generator output current to verify that it is at or below nameplate value.

3.

8. 9.

WARNING THE FOLLOWING TEST MUST BE CONDUCTED BY QUALIFIED ELECTRICAL PERSONNEL. LETHAL VOLTAGE MAY BE PRESENT AT BOTH THE GENERATOR AND VOLTAGE REGULATOR TERMINALS DURING THIS PROCEDURE. CAUTION MUST BE EXERCISED NOT TO COME INTO PERSONAL CONTACT WITH LIVE TERMINALS, LINKS, OR STUDS. SERIOUS INJURY OR DEATH COULD RESULT.

10. Check generator speed (frequency) under load. Adjust as necessary. (Refer to prime mover or governor manuals)

SHUTDOWN PROCEDURE
There are no specific instructions for shutting down the generator; however, several good practices should be observed to prolong equipment life. 1. It is advisable to disconnect all loads (open main circuit breaker or disconnect) prior to shutdown. This is especially important if loads can be damaged by low voltage or low frequency conditions during generator "coast down". 4.

Every 2,000 operating hours or in conjunction with scheduled engine maintenance, check the DC no load excitation voltage per item #7 in the startup procedure. Compare this voltage with the value recorded during initial startup. If this value of no load excitation voltage is markedly higher than the bench mark reading, it is an indication of problems in either the exciter, main field,

10

or the rotating rectifier assembly. Ensure that RPM is the same as initial test. WARNING 5. Monitor and record insulation resistance with a 500 volt mega-ohm meter. The minimum acceptable reading is 2 mega-ohms. If the reading drops below the minimum, the generator should be cleaned and dried at an authorized service shop. Consult Marathon Electric for more information. THE FOLLOWING TEST MUST BE CONDUCTED BY QUALIFIED ELECTRICAL PERSONNEL. LETHAL VOLTAGE MAY BE PRESENT AT BOTH THE GENERATOR AND VOLTAGE REGULATOR TERMINALS DURING THIS PROCEDURE. CAUTION MUST BE EXERCISED NOT TO COME INTO PERSONAL CONTACT WITH LIVE TERMINALS, LINKS, OR STUDS. SERIOUS INJURY OR DEATH COULD RESULT.

DRYING WINDINGS
Generators in service may inadvertently have their windings exposed to splashing or sprayed water. Units that have been in transit or storage for long periods of time may be subjected to extreme temperature and moisture changes causing excessive condensation. Regardless of the source of moisture, wet windings should be thoroughly dried out before operating the unit. If this precaution is not taken, serious damage to the generator can result. The following procedures may be utilized in drying the generators windings. The method selected will be influenced by winding wetness and situation limitations. Space Heaters An electric heater may have been supplied with the generator. When energized from a power source other than the generator, the heater will gradually dry the generator. This process can be accelerated by enclosing the unit with a covering and inserting additional heating units. A hole should be left at the top of the covering to permit the escape of moisture. Care should be taken not to overheat various accessory equipment mounted with the generator. Forced Air Another method to dry the generator is to run the set with no excitation (see startup procedure item #2). The natural flow of ambient air through the generator will tend to dry the windings. This method can be accelerated by adding a source of heat at the air intake to the generator. Heat at point of entry should not exceed 80 C (180 F).

CONSTANT EXCITATION TEST (12V BATTERY TEST)

The generator no load voltage is dependent on exciter input voltage and generator speed. With the generator operating at rated speed and 12 volts dc applied to the exciter field, the generators terminal voltage will be near rated value. 1. Shutdown the generator set and connect a voltmeter on the generator terminals. Disconnect the regulators F+ (F1) and F- (F2) leads and connect them to a 12V battery. Caution should be taken to ensure that the battery is not exposed to any potential arcing. With no load on the generator (main breaker open) run the generator at rated speed. Measure the generators terminal voltage and compare this value with values recorded during installation.

2.

3.

If voltage readings are normal, the main generator and excitation are operating properly. Troubleshooting should continue with the regulator. If readings are not normal the problem is in the generator. Continue testing diodes, surge suppressor, and windings.

TESTING
Visual Inspection
Remove covers and look for any obvious problems: burnt windings, loose connections, broken wires, frayed insulation, cracked brackets, missing hardware, etc. Check for foreign objects which may have been drawn into the generator. Verify that the generators air gaps (main rotor and exciter) are free from obstructions. If possible, rotate the generator manually to ensure free rotation. Never bar over the engine generator set using the generator fan.

Continuity / Resistance Test

The generator has four components which can be checked using an ohm meter: exciter stator, exciter rotor, main stator and main rotor. Each of these components are comprised of various windings which form a complete electrical path of relatively low resistance. Using an ohm meter measure the loop resistance of each component. Compare these measured values with the values listed in the specification section of this manual. Note that very small resistance values require precision equipment to make accurate measurements; however, a standard ohm meter will provide a good indication of winding continuity.

11

Insulation Test
Insulation resistance is a measure of the integrity of the insulating materials that separate the electrical windings from the generators steel core. This resistance can degrade over time or be degraded by contaminants: dust, dirt, oil, grease, and especially moisture. Most winding failures are due to a breakdown in the insulation system. In many cases, low insulation resistance is caused by moisture collected when the generator is shutdown Insulation resistance is measured with a megger (megaohm meter). A megger measures insulation resistance by placing 500 volts between the winding and the frame of the generator. Caution must be taken to remove all electronic devices (regulators, diodes, surge protectors, capacitors, protective relays, etc.) from the winding circuit before checking the insulation. Winding insulation can be checked on the main stator, main rotor, exciter stator, and exciter rotor. Minimum resistance is 2 mega-ohms. If the winding resistance is low it must be dried (see maintenance section) or repaired.

When the positive test probe is connected to the diode's anode and the negative test probe is connected to the diode's cathode (forward biased), the diode will switch on and conduct electricity (figure 3). This is observed by a low resistance reading when using an ohm meter or the lighting of the bulb when using a battery light continuity tester. Reversing the test leads (reverse biased) will result in the diode switching off and no electricity will be conducted. The results of these tests should indicate one of three conditions: 1. Good diode: Will have a much greater resistance in one direction than the other. Typical reverse biased resistance will be 30,000 ohms or greater, while forward biased resistance will be less than 10 ohms. The battery-light tester will have the light "on" in one direction and "off" in the other. Shorted condition: Ohmmeter reading will be zero, or very low in both directions. The continuity tester will have the light "on" in both directions. Open condition: Ohmmeter will have a maximum (infinity) reading in both directions. Continuity tester light will be off in both directions.

2.

3.

DIODE TESTING
If the generator is close coupled to an engine, it may be necessary to "bar over" the engine in order to gain access to a given area of the rectifier assembly. NEVER use the generator's fan as a fulcrum to accomplish this. Use the engine manufacturer's recommended practice to manually turn over the engine. To prevent possible injury to personnel, and damage to the equipment, ensure that the engine cannot start during this procedure. Remove the two main rotor leads and the three exciter rotor leads from the rectifier assembly (figure 4). The rectifier assembly is now electrically isolated from the generator. The diodes remain mounted and the diode leads remain connected to the terminal posts. Using an ohmmeter or a battery light continuity tester, place one test probe on the diode lead terminal post. In succession, touch the other test probe to the lead screw hole in each heat sink. Reverse the probes and repeat the procedure. You have now tested the three diodes connected to this terminal post in both the forward and reverse direction. Repeat the procedure using the other diode terminal post.

Diode failure after a 25 hour "run-in" period is generally traceable to external causes such as a lightning strike, reverse current, line voltage spikes, etc. All 6 diodes are essentially in the same circuit. When a diode is stressed to failure, there is no easy method to determine remaining life in the other diodes. To avoid possible continued failures, it is recommended that the entire rectifier assembly be replaced rather than replacing individual diodes.

SERVICE
GENERAL
The service procedures given in this section are those which can reasonably be conducted on-site with a minimum number of special tools and equipment. All service procedures should be conducted by qualified maintenance personnel. Replacement parts may be ordered through an authorized service center or directly from the factory.

Forward

Terminal End Anode Cathode (+) (-) Stud End Cathode Anode (-) (+)

Reverse

FIELD FLASHING
Restoring Residual Magnetism (not applicable on PMG equipped generators) To restore residual magnetism to the generator, connect a 12 volt battery to the exciter field while the generator using the following procedure: 1. Shutdown the generator set. Remove the exciter field leads F+ and F- from the regulator.

FIGURE 3: DIODE POLARITY

12

CAUTION: Failure to remove the exciter field leads from the automatic voltage regulator during flashing procedures may destroy the regulator. 2. Connect the F+ and F- leads to the batterys corresponding positive and negative terminals. This should be done using an appropriate length of lead wire to separate the battery from the point of connection (batteries may explode when exposed to an electric arc). After 3 to 5 seconds, remove the F- lead. An inductive arc should result. If no arc is drawn, repeat the procedure. 3. Reconnect the F+ and F- leads to the regulator. Restart the generator and verify that terminal voltage is developed. If terminal voltage does not develop, repeat the field flashing procedure and / or consult the trouble shooting section.

clear the locating register on the frame. Lower the shaft extension until the rotor is resting on the main stator core. Continue to pull the bracket free from the bearing. Visually inspect the bearing bore for damage or wear. If worn or damaged, sleeve or replace prior to reassembly. Reassembly note: Before the bearing bracket is seated against the frame, a threaded rod may be used to help align the inner bearing cap with the bearing bracket.

BEARING REPLACEMENT
Using a bearing puller, remove the existing bearing. It is strongly recommended that the bearing be replaced any time the it is removed from the shaft. ALWAYS install the same type and size bearing that was supplied as original equipment. Order by part number from the parts list, and include the unit serial number and part number when ordering. Heat the bearing to a maximum of 100oC (212oF) in an oven. Apply a thin coat of clean lubricating oil to the press-fit area of the rotor shaft. Using suitable heat resistant gloves, install the bearing over the end of the shaft until it seats against the shaft shoulder. The bearing should slide on the shaft and be seated without excessive force. Should the bearing bind on the shaft prior to being seated against the shoulder, a piece of tubing slightly larger than the press fit area can be used to drive the bearing to its final position. Using light taps with a soft mallet, apply pressure to the inner race only.

BEARING REMOVAL
Prior to performing this operation, it is suggested that the alternator's shaft be rotated until two of the main rotor poles are in a vertical position. Once the bearing bracket is backed out, the rotor will drop on the main stator core. Having the rotor in this position will limit the amount of rotor drop to that of the air gap. Visually inspect the bearing bore for damage or wear. If worn or damaged, replace prior to reassemble. Opposite Drive End Bearing Bracket Removal. Prior to proceeding with bracket removal, disconnect exciter field leads F+ and F- from the automatic voltage regulator and ensure that they are free to move when the bearing bracket is removed. Remove the bearing bracket retaining bolts. Using a pair of screw drivers, wedge the bracket off the frame. After approximately 1/8 inch, the bracket will clear the locating register on the frame and will drop until the rotor is resting on the main stator core. Continue to pull the bracket free from the bearing. Visually inspect the bearing bore and o-ring (if equipped) for damage or wear. If worn or damaged, repair or replace prior to reassembly. Drive End Bearing Bracket Removal, Two Bearing Units. Remove any drive arrangement from the generator shaft extension. Remove the bearing lock ring retaining screws. There is no o-ring in the drive end bearing bracket. The shaft extension must be supported before proceeding further. A hoist and sling, jack, or some other means of support with a capacity of 2 tons should be used. Remove the bearing bracket retaining cap screws. Using a flat bladed screw driver or chisel, pry the bracket back from the frame. After approximately 1/8 inch, the bracket will

RECTIFIER ASSEMBLY REMOVAL

The rectifier assembly cannot be removed until the opposite drive end bearing bracket and bearing have been removed (see bearing removal procedure). Remove the three exciter rotor leads from the heat sinks and the two main rotor leads from the main rotor posts (see Figures 4). Remove the screws securing the rectifier assembly and pull the assembly free from the shaft.

DIODE REPLACEMENT
Prior to installing a replacement diode on the heat sink, apply a thin film of conductive heat sink compound around the base of the diode (do not coat the threads). When installing a diode on the heat sink, care should be taken not to over torque the retaining nut which could cause damage to the device. Torque to 28 pound-inches. If not damaged, the existing diode lead wire may be unsoldered from the failed diode, and resoldered on the replacement.

13

430 FRAME

280 / 360 FRAME

A - Exciter Rotor Lead, B - Main Rotor Lead, C - Red (+) Suppressor Lead, D - Black (-) Suppressor Lead

FIGURE 4: ROTATING RECTIFIER ASSEMBLY RETURNED GOODS

Contact Marathon Electric Manufacturing Corporation for authorization before returning any product. We can not be responsible for any items returned without authorization. CAUTION Single bearing generators must have their rotor assembly properly secured to prevent damage during transit to the factory, or to an authorized service center.

The first step of troubleshooting is to gather as much information as is possible from operating personnel and individuals present during the failure. Typical information includes: how long the unit had been operating; what loads were on line; weather conditions; protective equipment that did or did not function. In addition, information as to the operating condition of the generator's prime mover is vital. Has the prime mover been maintaining constant speed? If not, have there been extended periods of under speed operation? Has the prime mover experienced an over-speed condition? If yes, what was the maximum speed, and how long did the unit operate at that elevated speed? The generator speed should be maintained at rated nameplate value during all operating tests. The frequency of the generator depends upon rotational speed. Most regulators used with MagnaPLUS generators have built in under frequency protection such that if the speed is reduced more than 5%, the voltage will drop off rather rapidly with further reductions in speed.

TROUBLESHOOTING
This section is intended to suggest a systematic approach to locating and correcting generator malfunctions. The section is arranged according to the symptoms of the problem. The steps have been arranged in an attempt to do the easy checks first and prevent further damage when troubleshooting a disabled machine.

14

WARNING HIGH VOLTAGES MAY BE PRESENT AT THE GENERATORS TERMINALS WHEN THE UNIT IS RUNNING. SOME ACCESSORY EQUIPMENT SUCH AS SPACE HEATERS MAY BE ENERGIZED FROM AN OUTSIDE POWER SOURCE WHEN THE UNIT IS AT REST. TOOLS, EQUIPMENT, CLOTHING AND YOUR BODY MUST BE KEPT CLEAR OF ROTATING PARTS AND ELECTRICAL CONNECTIONS. SPECIAL PRECAUTIONS MUST BE TAKEN DURING TROUBLESHOOTING SINCE PROTECTIVE COVERS AND SAFETY DEVICES MAY BE REMOVED OR DISABLED TO GAIN ACCESS AND PERFORM TESTS. BE CAREFUL. SERIOUS PERSONAL INJURY OR DEATH CAN RESULT FROM THESE HAZARDS. CONSULT QUALIFIED PERSONNEL WITH ANY QUESTIONS.

GENERATOR PRODUCES NO VOLTAGE

CAUSE Voltmeter off or defective Incorrect or defective connections CHECK AND REMEDY Check voltage with a separate meter at the generator terminals. Verify generator connections. See drawings supplied with the generator or lead connection diagrams in this manual. Inspect all wiring for loose connections, open circuits, grounds, and short circuits. Flash the field. Refer to field flashing in the service section. If the generator is equipped with a PMG, field flashing is not necessary -- check regulator fuse and input power from the PMG. Test the generator using the 12 volt battery test as specified in the testing section. If the results indicate generator problems, perform insulation, continuity, and diode tests as specified in the testing section. Adjust regulator. Consult regulator manual. Adjust or replace regulator. Consult regulator manual.

Loss of residual

Defective diodes, suppressor, or windings

Regulator protection operating Regulator inoperative

GENERATOR PRODUCES LOW VOLTAGE, NO LOAD

CAUSE Underspeed operation Voltmeter off or defective Incorrect or defective connections CHECK AND REMEDY Check speed using a tachometer or frequency meter. Check voltage with a separate meter at the generator terminals. Verify generator connections. See drawings supplied with the generator or lead connection diagrams in this manual. Inspect all wiring for grounds, open circuits and short circuits. Check regulator fuse and input power. Input power is produced by the generators residual voltage or from an optional PMG. Adjust regulator settings. Consult regulator manual. Review the generator connection diagram or reference the regulator manual. Test the generator using the 12 volt battery test as specified in the testing section. If the results indicate generator problems, perform insulation, continuity, and diode tests as specified in the testing section. Adjust or replace regulator. Consult regulator manual.

Loss of regulator power

Regulator adjustment Regulator incorrectly connected Defective diodes, suppressor, or windings

Regulator inoperative

15

GENERATOR PRODUCES LOW VOLTAGE WHEN LOAD APPLIED

CAUSE Excessive load CHECK AND REMEDY Reduce load. The load on each leg should be evenly balanced, and rated current should not be exceeded on any leg. Motor starting currents are too large for the generator. When starting multiple motors, sequence the motors and start the largest motors first. Reduce lagging power factor load. Check driver. If belt driven, check belt tension. Check under frequency setting on regulator. Under frequency voltage roll-off may be activated. If the generator is equipped for parallel operation, some droop is normal as reactive load increases. When operating as a single unit, the parallel CT can be shorted to eliminate this effect. Refer to Regulator manual. If voltage is proper at generator terminals but low at load terminals, increase external wire size. Test the generator using the 12 volt battery test as specified in the testing section. If the results indicate generator problems, perform insulation, continuity, and diode tests as specified in the testing section.

Large motor starting or low load power factor Driver speed droop or belt slip

Reactive droop

Line drop

Defective diodes, suppressor, or windings

GENERATOR PRODUCES FLUCTUATING VOLTAGE

CAUSE Fluctuating engine speed Regulator stability Regulator external rheostat Defective rectifier assembly Loose terminal or load connections Defective regulator CHECK AND REMEDY Check engine and governor systems for malfunctions. Check load for fluctuation. Adjust Regulator stability. Refer to Regulator manual. Replace defective or worn rheostat. Use shielded cable to minimize electrical noise. Check assembly for loose connections. Test the diodes as specified in the test section. Improve connections both mechanically and electrically. Replace regulator.

GENERATOR PRODUCES HIGH VOLTAGE

CAUSE Faulty metering Incorrect connections CHECK AND REMEDY Check voltage with separate meter at generator terminals. Verify generator connections. Refer to drawings supplied with the generator or connection diagrams in this manual. Adjust regulator. Consult regulator manual. Check the power factor of the load. If power factor is leading, change load configuration. Excessive leading power factor (capacitors) can cause voltage to climb out of control. Verify regulator voltage sensing is connected correctly. Consult regulator manual. Replace regulator.

Regulator adjustments Leading power factor

Incorrect regulator connection Defective regulator

16

GENERATOR BUILDS VOLTAGE FROM STARTUP, THEN GOES TO LOW (RESIDUAL) VOLTAGE
CAUSE Regulator protective circuit operating CHECK AND REMEDY Check indicators on regulator. Correct problems and adjust regulator as is required. Refer to regulator manual.

GENERATOR IS OVERHEATING
CAUSE Generator is overloaded Clogged ventilating screens High room temperature or altitude Insufficient circulation of cooling air CHECK AND REMEDY Reduce load. Check with ammeter and compare with nameplate rating. Clean air passages. Improve ventilation or reduce load. Generator location and enclosure design must provide adequate air flow and minimize recirculation of hot air. The load on each leg should be as evenly balanced as possible and should not exceed rated current on any one leg.

Unbalanced load

GENERATOR PRODUCES MECHANICAL NOISE

CAUSE Defective bearing Loose or misaligned coupling Belt slap or loose guards CHECK AND REMEDY Replace bearing. Tighten, realign, or replace coupling. Check belt tensioning. Check belt guard fasteners.

EQUIPMENT RUNS NORMALLY ON UTILITY POWER, BUT WILL NOT RUN ON GENERATOR SET
CAUSE Distorted voltage waveform CHECK AND REMEDY Analyze load. Excessive SCR (thyristor) loading will cause distortion. Some equipment may be sensitive to distorted waveforms. Refer to Marathon Electric.. Check name plates of devices comprising the load. Compare required voltage and frequency with that of the generator. Adjust driver speed and/or generator voltage as necessary to match generator output to load requirements.

Improper generator voltage or frequency

CAUTION: Compare required voltage, frequency, and KVA with generator nameplate to ensure adequate generator capacity. If in doubt, consult Marathon Electric for information regarding generator capacity.

17

SPECIFICATIONS
MODEL / FRAME SIZE 281, 282, 283, 284 361, 362, 363 -- three phase 361, 362, 363 -- dedicated single phase 431, 432, 433 -- three phase 431, 432 -- dedicated single phase EXCITER RESISTANCE STATOR ROTOR 23.0 .120 23.5 .120 23.0 .135 20.33 .076 18.0 .105 NO LOAD TERMINAL VOLTAGE WITH 12 VDC FIXED EXCITATION HIGH WYE / 60 HZ HIGH WYE / 50 HZ 485 400 490 404 528 435 500 415 490 400 515 415 495 400 480 390 480 375 485 400 475 385 460 370 480 380 500 405 475 380 440 360 455 385 455 370 475 390 440 360 445 385 425 345 430 350

EXCITER FIELD GENERATOR RESISTANCE NO LOAD VOLTS STATOR* ROTOR 480 V / 60 HZ 281PSL1500 4.20 .400 11.0 281PSL1501 4.15 .400 11.0 281PSL1502 3.20 .439 9.0 282PSL1503 2.00 .470 10.4 282PSL1504 1.51 .512 11.3 282PSL1505 1.00 .575 10.1 283PSL1506 .681 .654 11.0 283PSL1507 .480 .758 12.0 284PSL1508 .346 .875 12.0 361PSL1600 .381 .750 11.8 361PSL1601 .264 .810 12.5 361PSL1602 .181 .990 14.1 362PSL1604 .138 1.05 12.2 362PSL1606 .0980 1.20 10.8 363PSL1607 .0692 1.37 12.2 431PSL6202 .0214 .8114 15.1 431PSL6204 .0477 .6373 13.6 431PSL6206 .0371 .6793 13.82 431PSL6208 .0133 .715 12.20 432PSL6210 .0214 .8114 15.1 432PSL6212 .0226 .8656 14.1 433PSL6216 .01215 1.0672 16.2 433PSL6220 .01214 .9743 15.6 * Stator resistance measured line to line in a high wye connection. MODEL DEDICATED SINGLE PHASE 281PSL1511 281PSL1512 281PSL1513 282PSL1514 282PSL1515 283PSL1516 284PSL1517 284PSL1518 361PSL1611 361PSL1612 361PSL1613 362PSL1615 363PSL1617 431PSL1811 431PSL1813 432PSL1814 432PSL1815 GENERATOR RESISTANCE STATOR ROTOR 1.420 .381 1.106 .395 .632 .430 .436 .450 .240 .520 .160 .620 .0918 .760 .0610 .857 .0695 .750 .0434 .857 .0369 .926 .0191 1.20 .0119 1.35 .0248 .516 .0129 .615 .00931 .643 .00723 .852

EXCITER FIELD NO LOAD VOLTS / 60 HZ 8.3 8.1 8.7 9.2 9.7 13.3 12.2 16.6 17.5 16.1 13.6 17.0 23.0 9.9 13.8 15.1 11.2

18

PARTS LIST SINGLE BEARING Typical Generator Cross Section

Reference Number 1 2 3 4 5 6 7 8 9 10 Note:

Part Name End Bracket (under end cover 360 & 430 frames) Bearing O-ring (280 frame only) Rectifier Assembly Air Intake Screen (280 frame only) Exciter Rotor Exciter Stator Link Board (terminal block) Conduit Box Generator Frame

Reference Number 11 12 13 14 15 16 17 18 19 20

Part Name Main Stator Main Rotor Rotor Integral Keyway Fan Mounting Adapter (SAE) Shaft Drive Hub Drive Disk (SAE) Exhaust Screen (drip cover not shown) Mounting Base

Illustration above is a 280 frame MagnaPlus. Other Frame sizes are typical. Optional PMG not shown. The generator model and serial numbers are required when ordering parts.

19

PARTS LIST DUAL BEARING Typical Generator Cross Section

Reference Number 1 2 3 4 5 6 7 8 9 10 Note:

Part Name End Bracket (under end cover 360 & 430 frames) Bearing (nondrive end) O-ring (280 frame only) Rectifier Assembly Air Intake Screen (280 frame only) Exciter Rotor Exciter Stator Link Board (terminal block) Conduit Box Generator Frame

Reference Number 11 12 13 14 15 16 17 18 19 20

Part Name Main Stator Main Rotor Rotor Integral Keyway Fan End Bracket (drive end) Bearing (drive end) Shaft Key Exhaust Screen (drip cover not shown) Mounting Base

Illustration above is a 280 frame MagnaPlus. Other Frame sizes are typical. Optional PMG not shown. The generator model and serial numbers are required when ordering parts.

20

SB 504 9/03

SE350 VOLTAGE REGULATOR INSTRUCTION MANUAL

INTRODUCTION
The SE350 voltage regulator is an encapsulated electronic voltage regulator that controls the output of a brushless AC generator by regulating the current into the exciter field. SPECIFICATION Sensing & Power Input Burden Output Power- Continuous Output Power - Forcing(240 Vac Input Power) Regulation Remote Voltage Adjustment Range Frequency Compensation Roll off frequency Operation Operating Temperature Storage Temperature Power Dissipation Size Voltage Buildup SE350 REGULATOR 190-240 Vac 500 VA 73 Vdc at 3.5 Adc (255w) 105 Vdc at 5 Adc (525w) 1 .0% 10% with 2000 ohm rheostat 5% with l000 ohm rheostat Adjustable 54-61 Hz for 60 Hz 45-51 Hz for 50 Hz Weight6.5 oz. - 40C to + 60C - 65C to + 85C 8 watts maximum 3.94" L X 2.66 W X 2.20: H Internal provisions forautomatic voltage build up from generator residual voltage as low as 10 Vac. Internal Electromagnetic Interference Filter (EMI Filter )

EMI Suppression

WARNING TO PREVENT PERSONAL INJURY OR EQUIPMENTDAMAGE ONLY QUALIFIED PERSONNEL SHOULD INSTALL, OPERATE, OR SERVICE THIS DEVICE.

CAUTION: DO NOT megger or high-pot the generator with the regulator connected. DO NOT high-pot the regulator.

The SE350 voltage regulator can be mounted in any plane, following are mounting dimensions.

FIGURE 1

FUSE
A 4 Amp, 250 V, 5 X 20 mm fuse is supplied with the regulator (Part A-527066). It can be located on the rear face of the voltage regulator.

EXCITER POWER CIRCUIT

Connect the regulator wire F+ to the generator F+ or Fl field terminal. Connect the regulator wire F- to the generator F- or F2 field terminal. See Figure 2 for typical connection diagram

SENSING/POWER INPUT CIRCUIT

Input power and sensing is achieved through terminals 3 and 4. The voltage input requirement of the SE350 is 190 to 240 Vac. See Figure 2

FIGURE 2

VOLTAGE ADJUST
The screwdriver adjustable potentiometer adjusts the generator output voltage. Adjustment clockwise increases the generator output voltage. When using a remote voltage adjust rheostat, remove the jumper wire across terminals 6 and 7 and install a 2000 ohm 1/2 watt (minimum) rheostat. This will give 10% voltage variation from the nominal. (For 5% voltage variation use a 1000 ohm 1/2 watt rheostat). See Figure 2.

STABILITY ADJUST
System stability is the ability of the generator to respond to load transients. Decreasing the stability makes the generator less sluggish and faster to respond to toad transients. If the stability of the regulator is decreased too much, the generator will tend to hunt under steady state conditions. The screwdriver adjustable potentiometer adjusts the system stability. Adjustment clockwise increases the stability. Increasing the stability increases the response time of the generator. Conversely, decreasing the stability decreases the response time of the generator.

V/HZ ROLL-OFF FREQUENCY SELECTION

The roll off point is the frequency where the generator voltage starts to decrease. This reduces the Kilowatt load to the engine, which allows the engine to recover in speed under any load transient condition. Use jumper to select 50 HZ or 60 Hz. The screwdriver adjustable potentiometer sets the roll-off frequency from 54-61 Hz in the 60 Hz setting or from 45-51 Hz in the 50 Hz setting. The SE350 has the roll-off point preset to 58 Hz in the 60 Hz mode and 48 Hz in the 50 Hz mode. To change the roll-off point, adjust engine speed to the desired rated speed. (50 or 60 Hz). Set the voltage to the desired setting at rated speed. Adjust engine speed to the desired roll-off point. Turn the potentiometer counterclockwise until the voltage starts to drop off. Then adjust the potentiometer clockwise until the voltage returns to rated voltage. Re-adjust engine speed to rated speed.

PRELIMINARY SET-UP
Ensure the voltage regulator is correctly connected to the generator. Refer to the specific connection diagram supplied with the generator. Set the regulator voltage adjust to full counter-clockwise (minimum voltage level). Set the remote voltage adjust (if used) to the center position. Set the stability control full clockwise (maximum stability level). Connect the positive lead of a 100 V D.C. voltmeter to Fl and the negative lead of the voltmeter to F2 or use an appropriate AC voltmeter on the generator output leads.

SYSTEM START-UP
Start and run the generator at no load and rated speed. The generator voltage should build up to a minimum level. (Actual level is dependent upon connection). If it does not build up, refer to field flashing section in generator manual. Slowly adjust the voltage control until the generator voltage reaches the nominal value. If used, adjust the remote voltage rheostat to set the generator voltage to the exact value desired. Turn the stability adjust counter-clockwise until instability is shown on either of the voltmeters mentioned in the PRELIMINARY SET-UP section. With the system operating in an unstable condition, slowly adjust the stability control clockwise until generator stability is reached. Interrupt regulator power for a short time (approximately 1-2 seconds). If the generator remains stable, no further adjustment is necessary. If the generator does not remain stable, increase the stability slightly and interrupt regulator power again. This procedure should be repeated until system stability is reached and maintained.

TROUBLESHOOTING
Symptom Residual Voltage -No Output Cause Residual voltage at regulator power input wires 3 & 4 below 10 V ac. Action Check wiring diagram for proper connections. Flash generator field. Refer to field flashing section in generator manual. Reduce acceleration time. Interrupt power input to regulator after achieving rated speed. Connect field leads Fl, F2. Connect power-input leads 3,4. Replace fuse. Replace regulator. Consult generator manual. Check wiring diagram for proper connections. Rotate voltages adjust CW until desired voltage is reached. Rotate remote voltages adjust CW until desired voltage is reached. Replace regulator. Rotate voltages adjust CCW until desired voltage is reached. Rotate remote voltages adjust CCW until desired voltage is reached. Replace regulator. Reverse the wiring of the remote voltage adjust. Rotate the stability adjusts in a CW direction until hunting stops. Replace regulator.

Acceleration time to rated speed too long.

Field leads Fl, F2 not connected. Power input leads not connected. Blown or missing fuse. Defective regulator. Defective generator. Incorrect connections.

Output Voltage Low

Voltages adjust turned down.

Remote voltage adjust is turned down.

Output Voltage High

Defective regulator. Voltages adjust turned too high.

Remote voltage adjust is turned too high. Output Voltage High - Defective regulator. No Adjustment Remote Voltage Adjust Voltages adjust wire backwards. Operates Backwards Generator Output Voltage Hunting Poor Regulation Stability adjusts not set properly.

Defective regulator.

Siemens Energy & Automation, Inc. Power Distribution & Controls Division 3333 Old Milton Parkway Alpharetta, GA 30005

For Nearest Sales Office

1-800-964-4114 or 800-241-4453 www.sea.siemens.com/ For Product Information sales/salesoffices.html www.sea.siemens.com/power/

Energy Division
http://energy.tycoelectronics.com

Installation and Operating Manual Switchboard Integra 1540, 1000, 0640, 0440 0340 & 0240 Digital Metering Systems

Tyco Electronics UK Limited Crompton Instruments Freebournes Road, Witham, Essex, CM8 3AH, UK Tel: +44 1376 509 509 Fax: +44 1376 509 511

Crompton Switchboard Integra

Multifunctional metering for Three-phase Electrical Systems Models 1540, 1000, 0640, 0440, 0340, 0240

Operating Instructions

Important safety information is contained in the seperate installation leaflet. Installers must familarise themselves with this information before installation

Crompton Instruments Freebournes Road Witham Essex CM8 3AH England Tel: +44 (0) 1376 509 509 Fax: +44 (0) 1376 509 511 E-Mail: crompton.info@tycoelectronics.com

Integra 1540, 1000, 0640, 0440, 0340, 0240 Issue 1 04/03

Contents
1 Introduction
1.1 1.1.1 1.1.2 1.1.3 1.1.4 1.1.5 1.2 1.3 1.4 1.5 1.6 1.7 Unit Characteristics 0240 0340 0440 and 0640 1000 1540 Maximum Power Secondary Voltage Demand Calculation RS485 Serial Option Pulse Output Option Analogue Output Option

Page
5 6 6 6 6 7 8 9 9 9 10 10 10

2 Display Screens
2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 Layout Start Up Screens System Screen System %THD Screen Line to Neutral Voltages Line to Neutral Voltage %THD Line to Line Voltages Line to Line Voltages %THD Line Currents Line Currents %THD Neutral Current, Frequency and Power Factor Power Active Energy (kWh) Reactive Energy (kVArh)

11 11 11 12 13 13 13 14 14 14 15 15 15 16 16

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Contents
2.15 2.16 2.17 2.18 2.19 Demand Maximum Demand Over Range kWh and kVArh Display Range Error Messages

Page
17 17 17 18 18

3 Setting up
3.1 3.2 3.3 3.3.1 3.3.2 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 Introduction Number Entry Procedure Access Access with No Password Protection Access with Password Protection Changing the Password Full Scale Current Potential Transformer Primary Voltage Potential Transformer Secondary Value Demand Integration Time Resets Pulsed Output, Pulse Duration Pulse Rate RS485 Baud Rate RS485 Parity Selection RS485 Modbus Address Analogue Output Set Up

18 18 19 21 21 21 23 24 24 26 27 28 29 30 31 32 33 34 34 35 36 39 40 41 42

3.15.1 Introduction 3.15.2 Analogue Output Scaling Example 3.15.3 Power Factor 3.15.4 Phase Angle 3.15.5 Parameters available for analogue outputs 3.15.6 Reading (Parameter Selection) - A1r or A2r 3.15.7 Reading Top A1rt or A2rt

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Contents
3.15.8 Reading Bottom - A1rb or A2rb 3.15.9 Output Top A1ot or A2ot 3.15.10 Output Bottom A1ob or A2ob

Page
43 43 43

4 Specification
4.1 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.1.6 4.1.7 4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.2.7 4.2.8 4.2.9 Display Only Versions Input Auxiliary Power Supply EMC Standards Safety Insulation Environmental Enclosure Display/Transducer Combined Versions Inputs Auxiliary Power Supply Measuring Ranges Accuracy Reference conditions of influence quantities EMC Standards Safety Insulation Environmental

44 44 44 44 44 45 45 45 45 45 45 46 47 47 47 47 48 48 48 48 48 48 49 49 50 50

4.2.10 Enclosure 4.3 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 Display/Tranducer Combined 1000 and 1540 Inputs Auxiliary Power Supply Accuracy Reference conditions Reference conditions of influence quantities

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Contents
4.3.6 4.3.7 4.3.8 4.3.9 Nominal range of use of influence quantities for measurands Functional ranges Screen Standards

Page
51 51 51 51 52 52 52 52 52 53 53

4.3.10 Safety 4.3.11 Insulation 4.3.12 Environmental 4.3.13 Enclosure 4.3.14 Serial Communications Option 4.3.15 Active Energy Pulsed Output Option 4.3.16 Integra 1540 Only

5 Basis of measurement and calculations

54

6 Serial Communications
6.1 6.2 6.3 RS485 Port - Modbus or JC N2 Modbus Implementation RS485 Implementation of Johnson Controls Metasys

56 56 56 60

7. Maintenance

63

8 Appendix A CE Declaration of Conformity

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Integra 1540, 1000, 0640, 0440, 0340, 0240 Issue 1 04/03

1 Introduction
This manual provides operating instructions for the Crompton Switchboard Integra series of Digital Metering Systems. Some versions of the Integra incorporate the metering transducer that provides the interface for the measurement of power supply parameters such as voltage, current, power, frequency etc. In other versions, the display and transducer are separate, interconnected units. The display allows the user to set up metering transducer parameters and to monitor the measurements. Some Integra models can be supplied as either an integral or display-only version, while others are only available in one format. This manual provides user instructions. A separate leaflet provides installation instructions. Table1 lists the various models of Integra and shows their distinctive characteristics. Table 1 Summary of Integra models Model 0240 0340 0440 0640 1000 1540 V V V V V V V A A A A A A F F F F F F PF kW kWh THD Analogue Serial Pulse Freq 45-65 Hz 45-65 Hz 360-400 Hz 45-65 Hz 45-65 Hz

PF PF

kW kWh kW kWh THD Analogue option*

RS485 option RS485 option

Pulse option Pulse option

45-65 Hz

* When used with an 1560/80 transducer that includes analogue options. Voltage and current readings are true RMS, up to the 15th harmonic (31st for 1560/80 transducer). The unit can be powered from an auxiliary a.c. or d.c. supply that is separate from the metered supply. Versions of each model are available to suit 100-250V 45-65 Hz a.c./d.c. and 12-48V d.c nominal supplies. In this manual, the graphic 0240 0340 0440 0640 1000 1540

is used to show the models to which a screen applies. Boxes are greyed out to show models that do not have that type of screen. 0240 0340 0440 0640 1000 1540

This example indicates that the screen only applies to Models 1000 and 1540. 0240 0340 0440 0640 1000 1540 Option

This indicates that the screen is an option on models 1000 and 1540. Important safety information is contained in the accompanying installation instructions. Installers must familarise themselves with this information before installation.

Integra 1540, 1000, 0640, 0440, 0340, 0240 Issue 1 04/03

1.1 Unit Characteristics

1.1.1 0240
The 0240 will display the following parameters: System voltage (average of all phases) System frequency (Hz) Voltage line to neutral for each phase (4-wire systems only) Voltage line to line for each phase (calculated in 4-wire) The 0240 has Set-up screens for potential transformer primary and secondary voltages. Default display

1.1.2 0340
The 0340 will display the following parameters: System voltage (average of all phases) System current (average of all phases) Voltage line to neutral for each phase (4-wire systems only) Voltage line to line for each phase (calculated in 4-wire) Current in each line. The 0340 has Set-up screens for: Default display Full-scale current value Potential transformer primary and secondary voltages.

1.1.3 0440 and 0640

The 0440 operates on a mains frequency of 400 Hz nominal and the 0640 at 45-65 Hz. The units can measure and display the following parameters: System voltage (average of all phases) System current (average of all phases) System frequency (Hz) Voltage line to neutral for each phase (4-wire systems only) Voltage line to line for each phase (calculated in 4-wire) Default display Current in each line The 0440 and 0640 have Set-up screens for: Full-scale current value Potential transformer primary and secondary voltages.

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1.1.4 1000
The 1000 will display the following parameters: Default display System voltage (average of all phases) System current (average of all phases) System frequency (Hz) Voltage line to neutral for each phase (4-wire systems only) Voltage line to line for each phase (calculated in 4-wire) Current in each line Neutral current1 Power Factor Active Power (kW) Reactive Power (kVAr) Apparent Power (kVA) Active Energy (kWh)2 Reactive Energy (kVArh)2 Total System Current Demand (AD)2 Total System Active Power Demand (kWD)2 Maximum Total System Current Demand (AD)2 Maximum Total System Active Power Demand (kWD)2

The 1000 has Set-up screens for: Full-scale current value Potential transformer - primary voltages. Demand integration time and energy/demand resets Pulse output duration and rate divisor (option) RS485 serial Modbus parameters (option)

A pulsed relay output, indicating kWh, and an RS485 ModbusTM output are available as optional extras. The Modbus output option allows remote monitoring from a Modbus master.

Neutral referenced parameters are only available when used with 4-wire and single phase configured transducers. All energy and demand measurements are importing only unless connected as exporting unit.

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1.1.5 1540
The1540 is available either as a display unit operating in conjunction with a 15xx measurement transducer or as a self-contained unit incorporating a transducer. The unit can measure and display the following: Default display System voltage (average of all phases) System current (average of all phases) System frequency (Hz) Voltage line to neutral for each phase (4-wire systems only) Voltage line to line for each phase (calculated in 4-wire) Current in each line. Neutral current1 Power Factor Active Power (kW)2 Reactive Power (kVAr)2 Apparent Power (kVA) Active Energy (kWh)2 Reactive Energy (kVArh)2 Total System Current Demand (Admd)2 Total System Active Power Demand (kWD)2 Maximum Total System Current Demand (AD)2 Maximum Total System Active Power Demand (kWD)2

The 1540 has Set-up screens for:

1

Full-scale current value Potential transformer - primary and secondary voltages (Dis 1540 and Integra 15xx) Potential transformer - primary voltages (self contained) Demand integration time and energy/demand resets Pulse output duration and rate divisor (option) RS485 serial Modbus parameters (option) Analogue current output (option, with separate transducer only)

Neutral referenced parameters are only available when used with 4-wire and single phase configured transducers.

All energy and demand measurements are importing only unless connected as exporting unit.

A pulsed relay output, indicating kWhr (and Kvarh on the two part Dis 1540 and Integra 15xx combination), and an RS485 ModbusTM output are available as optional extras. The Modbus output option allows remote monitoring from another display (not self contained) or a Modbus master. The Analogue current output option provides a current output that indicates the value of a chosen parameter.

Integra 1540, 1000, 0640, 0440, 0340, 0240 Issue 1 04/03

1.2 Maximum Power

Products covered in this manual are limited to a maximum power of 360 MW. During set-up, primary voltage and current setting are checked and the unit will not accept entries that breach the 360 MW limit. This is covered in more detail in the sections that show primary voltage and current set-up. The Maximum Power restriction of 360 MW refer to 120% of nominal current and 120% of nominal voltage, i.e. 250 MW nominal system power.

1.3 Secondary Voltage

0240 0340 0440 0640 1000 1540

Most of the products described in this manual allow the user to specify, within a range, the secondary voltage of the potential transformer (PT) with which it is to be used. The exception is the Integra 1000 and self contained Integra 1540, which has the PT secondary factory set. On the Integra 1000/1540, the user cannot change this value.

1.4 Demand Calculation

0240 0340 0440 0640 1000 1540

The maximum power consumption of an installation is an important measurement, as most power utilities base their charges on it. Many utilities use a thermal maximum demand indicator (MDI) to measure this peak power consumption. An MDI averages the power consumed over a number of minutes, reflecting the thermal load that the demand places on the supply system. The Integra uses a sliding window algorithm to simulate the characteristics of a thermal MDI instrument, with the demand being calculated once per minute. The demand period can be reset, which allows synchronisation to other equipment. When it is reset, the values in the Demand and Maximum Demand registers are set to zero. Demand Integration Times can be set to 8, 15, 20 or 30 minutes. The number of sub-intervals, i.e. the demand time in minutes, can be altered either by using the Demand Integration Time set-up screen (see Section 3.8) or via the RS485 port, where available, using the ModbusTM protocol. During the initial period, when the elapsed time since the demands were last reset or since the Integra was switched on is less than one minute, the maximum demands (current MaxAD and power MaxkWD) will remain at zero and not follow the instantaneous demands. Maximum Demand is the maximum power or current demand that has occurred since the unit was last reset as detailed in Section 3.9 Resets.

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1.5 RS485 Serial Option

0240 0340 0440 0640 1000 1540 Option

This option is available on two-part (separate transducer and display) units and on 1000 and self-contained 1540 units. This option uses an RS485 serial port with Modbus or JC NII protocol to provide a means of remotely monitoring and controlling the Integra unit. Both protocols are supplied in the same unit. Communications automatically configure according to the protocol that is recognized when the master sends a message. Where the installation comprises separate display and transducer units, the display communicates with the transducer using a modified Modbus protocol via the RS485 port. Such a transducer may have two such ports, either or both of which can be used for connection to a display. Where a port is available, it can be connected to a PC for control and monitoring purposes. Set-up screens are provided for setting up the Modbus port. See Sections 3.12 to 3.14. These screens are not applicable for setting up a port connected to a display unit, as the characteristics of such a port are preset. On a two-port unit, communications settings made from an Integra display affect the other communications port, unless the second port is also connected to a display, in which case the changes have no effect.

1.6 Pulse Output Option

0240 0340 0440 0640 1000 1540 Option

This option provides a relay pulse output indication of measured active energy (kWh). The unit can produce one pulse for every 1, 10 or 100kW of energy consumed. Two-part 1540 display units operating with 1560 or 1580 transducers can also produce a pulse for every 1000 kW of energy consumed. The pulse divisor can be set from the Set-up screen as detailed in Section 3.11 Pulse Rate. The pulse width (duration) can be set as detailed in Section 3.10 Pulsed Output, Pulse Duration. On two part units, two pulsed outputs are available with common pulse rate divisions and pulse widths.

1.7 Analogue Output Option

0240 0340 0440 0640 1000 1540 Option

This option is available on two-part (separate transducer and display) units and provides an analogue current output that indicates the value of a chosen parameter. The parameter can be chosen and set up via the set-up screen as described in Section 3.15 Analogue Output Set Up.

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2 Display Screens
2.1 Layout
The screen is used in two main modes: display of measured values and parameter setup. In display mode, three measured values can be shown, one on each row. For each row, the LED indicators show the parameter being measured and the units. The >> button moves between display screens.

Voltage display In Set up mode, the top row shows an abbreviation of the parameter name, the middle row shows the parameter value being set and the bottom row is used for confirmation of the entered value. In general, the key changes a parameter value and the >> key confirms a value and moves on to the next screen. This example is the potential transformer primary voltage confirmation screen.

Setup confirmation screen

The example screens shown in this manual are those relating to the 1540 models the most complex. The screens for simpler models are similar except that some of the parameters and values are omitted. Section 1.1 shows the default display screens for the various models.

2.2 Start Up Screens

Initially, when power is applied to the Integra Display, two screens will appear. The first screen lights the LEDs and can be used as a display LED check.

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11

The second screen indicates the firmware installed in the display unit. This example states that the version is 0.008. The version on a particular unit will differ in line with ongoing development and improvements. After a short delay, the default Display screen will appear.

Use the >> (Next) key to move from one screen to the next in the sequence. The sequence depends on the supply configuration (single phase 2 or 3 wire, 3 phase 3 or 4 wire).

2.3 System Screen

0240 0340 0440 0640 1000 1540

The following sections show 3 and 4 wire systems. Single phase 2 and 3 wire systems have similar display screens. The system screen is the default display. It appears when the unit is energised after the start up screens. Section 1.1 shows the default system screens for the various models.

System Average Voltage (Volts)* System Average Line Current (Amps). System Total Active Power (kW). Pressing key >> moves to the next screen * Line to Line for 3 wire systems, Line to Neutral for 4 wire and single phase 3 wire systems.

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2.4 System %THD Screen

0240 0340 0440 0640 1000 1540

Average % Total Harmonic Distortion for System Voltages. Average % Total Harmonic Distortion for System Currents.

Key >> moves to next screen.

2.5 Line to Neutral Voltages

0240 0340 0440 0640 1000 1540

Three phase, four wire systems only.

Voltage Line 1 to Neutral (Volts). Voltage Line 2 to Neutral (Volts). Voltage Line 3 to Neutral (Volts). Key >> moves to next screen.

2.6 Line to Neutral Voltage %THD

0240 0340 0440 0640 1000 1540

Three-phase, four wire systems only.

%THD of Line 1 Voltage to Neutral. %THD of Line 2 Voltage to Neutral. %THD of Line 3 Voltage to Neutral. Key >> moves to next screen.

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2.7 Line to Line Voltages

0240 0340 0440 0640 1000 1540

Voltage Line 1 to Line 2 (Volts). Voltage Line 2 to Line 3 (Volts). Voltage Line 3 to Line 1 (Volts). Key >> moves to next screen.

2.8 Line to Line Voltages %THD

0240 0340 0440 0640 1000 1540

Three-phase, three wire systems only.

Line 1 to Line 2 Voltage %THD. Line 2 to Line 3 Voltage %THD. Line 3 to Line 1 Voltage %THD. Key >> moves to next screen.

2.9 Line Currents

0240 0340 0440 0640 1000 1540

Line 1 Current (Amps). Line 2 Current (Amps). Line 3 Current (Amps). Key >> moves to next screen.

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2.10 Line Currents %THD

0240 0340 0440 0640 1000 1540

Line 1 Current %THD. Line 2 Current %THD. Line 3 Current %THD. Key >> moves to next screen.

2.11 Neutral Current, Frequency and Power Factor

0240 0340 0440 0640 1000 1540

Neutral Current (Amps). (4-wire and single phase 3 wire system only). Frequency (Hz). Power Factor (0 to 1, on 1000 and combined 1540; sign (-) prefix, on 1540 two part: prefix C indicates Capacitive load and L = Inductive). Key >> moves to next screen.

2.12 Power
0240 0340 0440 0640 1000 1540

Reactive Power (kVAr). Apparent Power (kVA). Active Power (kW). Key >> moves to next screen.

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2.13 Active Energy (kWh)

0240 0340 0440 0640 1000 1540

This is the energy that has been consumed since the unit was last reset (see Section 3.9 Resets).

Active Energy (kWh) 7 digit reading i.e. 0001243.

Key >> moves to next screen.

2.14 Reactive Energy (kVArh)

0240 0340 0440 0640 1000 1540

This is the reactive energy that has been consumed since the unit was last reset (see Section 3.9 Resets). The reading shows the energy (kVArh) in the reactive component of the supply.

Reactive Energy (kVArh) 7 digit reading i.e. 0000102

Key >> moves to next screen.

16

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2.15 Demand
0240 0340 0440 0640 1000 1540

This screen displays the present demand, i.e. the maximum power and the maximum current demanded during the defined integration window period. See Section 3.8 Demand Integration Time.

System Total Active Power Demand (kWD) System Total Current Demand (AD) Key >> moves to the next screen.

2.16 Maximum Demand

0240 0340 0440 0640 1000 1540

This screen displays the maximum power and the maximum current that has been demanded since the unit was last reset (see Section 3.9 Resets).

Maximum System Total Active Power Demand (kWD) Maximum System Total current Demand (AD) Key >> returns to the start of the sequence with the System Screen

2.17 Over Range

The displayed values must be in the range 999 x 1000 to 9999 x 1000. Any parameter value outside this range will cause the display to show overrange. This situation will be indicated by displaying four bars in the appropriate line:

The value on the middle line is over range.

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2.18 kWh and kVArh Display Range

0240 0340 0440 0640 1000 1540

The kWh and kVArh display range is limited to 9999999. If the unit is allowed to increment beyond this value the count will either wrap back to zero (if the 1560/1580 transducer is set to 7 digit mode) or continue to be updated in the 1560/1580 transducer but the display will change to seven bars. The value will continue to be available via the Modbus output.

2.19 Error Messages

The display repeatedly requests new values from the measurement processor. If there is a problem obtaining these values, the display will continue to retry but will alert the user by displaying the message Err1. This message may be seen briefly during conditions of extreme electromagnetic interference with the normal display returning once the interference has ceased. If the Err1 message persists, try interrupting, for ten seconds, the auxiliary supply (or supplies) to the Integra (display and transducer). This may restore normal operation. Also check that auxiliary power is reaching the transducer and is within specification. Check that there are no problems with the communications cable between the display and transducer, where applicable.

3 Setting up
3.1 Introduction
The following sections give step by step procedures for configuring the Integra transducer for a particular installation using an attached display. To access the Set-up screens, press and hold the (Adjust) key and the >> (Next) keys simultaneously for five seconds. This brings up the password entry stage. (See Section 3.3 Access). On completion of the last Set-up screen, the program exits Set-up mode and returns to the last selected Display screen. To return to the Display screens at any time during the set up procedures, press the and the >> keys simultaneously for five seconds.

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3.2 Number Entry Procedure

When setting up the unit, many screens require the setting up of a number, usually on the middle row of digits. In particular, on entry to the setting up section, a password must be entered. The procedure is as follows: In general, press the (adjust) key to change something on the current screen. Pressing the >> (next) key normally leaves the current screen unchanged and brings up the next screen. The example below shows how the number 0000 can be changed to 1234. The digits are set one at a time, from left to right. The decimal point to the right of the digit (* in the picture) flashes to indicate which digit can currently be changed. It thus acts as a cursor. Where the cursor coincides with a genuine decimal point on the display, the decimal point will flash. Press the key to scroll the value of the first digit from 0 through to 9, the value will wrap from 9 round to 0. For this example, set it to 1. Press the >> key to confirm your setting and advance to the next digit.

First digit

Use the

key to set the second digit to the required value.

Press the >> key to confirm your selection and advance to the next digit.

Second digit

Use the

key to set the third digit to the required value.

Press the >> key to confirm your selection and advance to the next digit.

Third digit

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Use the

key to set the fourth digit to the required value.

Press the >> key to confirm your selection. If the unit accepts your entry, the Confirmation screen will appear. If the unit does not accept your entry, e.g. an incorrect password, a rejection screen will appear, with dashes on the bottom line.

Fourth digit

The Confirmation screen shows the entered number on the bottom row with all decimal points showing. If the displayed number is correct, press the >> key to move to the next Set-up screen. If not, press the key to return to restart the number entry. The first digit entry screen will appear.

Confirmation

If a rejection screen appears, press the entry procedure.

key to restart the

Rejection

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3.3 Access
To access the Set-up screens, press the Password Introduction screen appears. and >> keys simultaneously for five seconds, until the

Password protection can be enabled to prevent unauthorised access to Set-up screens. Password protection is not normally enabled when a product is shipped. The unit is protected if the password is set to any four digit number other than 0000. Setting a password of 0000 disables the password protection.

3.3.1 Access with No Password Protection

Press >> from the Password Introduction screen. The 0000 password confirmation screen will appear. Password introduction

Press >> again to proceed to the first Set-up screen. 0000 Password confirmation

3.3.2 Access with Password Protection

If the unit is protected by a password, proceed as follows:

Password introduction

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Enter the four-digit password using the method described in Section 3.2 Number Entry Procedure.

First digit On pressing >> to confirm the last digit, the Confirmation screen will appear, provided the password is correct. From the Password Confirmation screen, there is the option of changing the password, as described in Section 3.4 Changing the Password. To proceed to the first Set-up screen, press >>.

Password Confirmation

If the password is incorrect, the Password Request screen will reappear to permit a retry. Press to start a retry or >> to exit to the Display screens.

Password Incorrect

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3.4 Changing the Password

The option to change the password is only available from the Password Confirmation screen immediately after the user has entered the existing password, if applicable. Press to start changing the password.

The password screen for the first digit will appear, with the old password on the bottom line.

Password Confirmation

Set up the new password on the bottom line, as described in Section 3.2 Number Entry Procedure. On pressing >> to confirm the last digit, the Password Confirmation screen will appear.

First new password digit

Press >> to confirm the new password. The first Set-up screen will appear. Press to try again. The first digit screen will appear again.

New password confirmation

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3.5 Full Scale Current

0240 0340 0440 0640 1000 1540

This parameter is the value of nominal Full Scale Currents that will be displayed as the Line Currents. This screen enables the user to display the Line Currents inclusive of any transformer ratios. The values displayed represent the current in amps. For example setting 800 on this screen will cause the display to indicate 800 amps when the nominal maximum (typically 5A or factory build option of 1A) current flows through the transducer current inputs.The maximum value is as specification. Press >> to accept the present value and move on to the next Set-up screen (Section 3.6 Potential Transformer Primary Voltage). To change the Full Scale Current, press and change the current value as detailed in Section 3.2 Number Entry Procedure. If the presently displayed current, together with the full scale voltage value, results in an absolute maximum power (120% of nominal current and voltage) of greater than 360 Megawatts, the range of the most significant digit will be restricted. Edit The Maximum Power restriction of 360 Megawatts refers to 120% of nominal current and 120% of nominal voltage, i.e. 250 Megawatts nominal system power.

When the least significant digit has been set, pressing the >> key will advance to the Full Scale Current Confirmation stage. The minimum value allowed is 1. The value will be forced to 1 if the display contains zero when the >> key is pressed.

3.6 Potential Transformer Primary Voltage

0240 0340 0440 0640 1000 1540

This value is the nominal full scale voltage which will be displayed as L1-N, L2-N and L3-N for a four wire system, L1-2, L2-3 and L3-1 in a three wire system or system volts for single phase. This screen enables the user to display the line to neutral and line to line voltages inclusive of any transformer ratios. The values displayed represent the voltage in kilovolts (note the x1000 indicator). For example, on a 2.2kV system with 110V potential transformer secondary, set 2.200 at this screen. If there is no potential transformer (PT) in the system, i.e. the voltage terminals are connected directly to the metered voltage, leave this value unchanged and skip this set up step. If the PT primary and secondary values are changed and it is desired to revert to a set-up with no PT, then set both PT primary and secondary values to the nominal maximum voltage for the Integra transducer.

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To set up the PT primary, proceed as follows: To accept the currently displayed value, press >>. The screen will move on to the next Set-up screen (Section 3.7 Potential Transformer Secondary Value). Press to change the PT Primary voltage.

Initially all the digits of the present value will be flashing and the decimal point position will be illuminated. This is to indicate that initially the multiplier must be selected. Press to set the decimal point position. Note that the x1000 indicator is on. Decimal Point Press >> to accept the displayed (decimal point position). The digits stop flashing and the PT Primary Value screen appears Set the display to read the value of the PT Primary voltage, using the method described in Section 3.2 Number Entry Procedure. The primary voltage that can be set will be restricted to a value such that, together with the full scale current value (previously set), the absolute maximum power (120% of nominal current and voltage) cannot exceed 360 Megawatts. After the last digit has been accepted, the Confirmation screen will appear. Digit Edit This example confirmation screen shows a primary voltage setting of 2.2 kV. Press >> to accept the displayed PT Primary Voltage. The next Set-up screen will appear (Section 3.7 Potential Transformer Secondary Value). To change the displayed value, press screen will reappear. . The Decimal Point

Confirmation

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3.7 Potential Transformer Secondary Value

0240 0340 0440 0640 1000 1540

In Model 1000 and 1540 combined, the PT Secondary Value is factory set, as marked on the barrel. The PT Secondary Value is user programmable on the 1540 and Integra 1560 two part. This value must be set to the nominal full scale secondary voltage which will be obtained from the transformer when the potential transformer (PT) primary is supplied with the voltage defined in Section 3.6 Potential Transformer Primary Voltage. This defines the actual full scale voltage that will be obtained from the PT secondary and measured by the unit. The ratio of the full scale primary to full scale secondary voltage is the transformer ratio. Given full scale primary and secondary voltages, the unit knows what primary voltage to display for any given measured secondary voltage. The secondary voltage displayed is in volts. Following the previous example, on a 2.2 kV system with 110V PT secondary, set this screen to 110.0. If there is no PT associated with this unit, leave this value unchanged and skip this step. To accept the displayed PT Secondary Voltage, press >>. The next Set-up screen will appear (Section 3.8 Demand Integration Time). To change the PT Secondary Voltage display, press .

Note that the decimal point edit screen will only appear when the display unit is connected to a transducer designed for connection to voltages in the range 57.7 to 139V. Initially all the digits of the present value will be flashing and the decimal point position will be illuminated. This is to indicate that initially the multiplier must be selected. Press to change the decimal point position.

Decimal Point

Press >> to accept the decimal point position. The Digit Edit screen appears. Set the display to read the value of the PT Secondary voltage, as described in Section 3.2 Number Entry Procedure. After the last digit has been set and accepted, the Confirmation screen will appear.

Digit Edit

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Press >> to accept the displayed value. Depending on the model, this may take you out of the Set-up screens and back to the last selected Display screen. Press to return to the Decimal Point screen.

The secondary value may only be set to values within the range defined by the factory voltage build option. These nominal rms input voltages are as shown in the relevant measurement transducer specification (see separate document for two-part products or Section 4.2.1 Inputs for combined products). Confirmation

3.8 Demand Integration Time

0240 0340 0440 0640 1000 1540

This screen is used to set the period over which current and power readings are integrated (see Section 1.4 Demand). The value displayed represents time in minutes. To accept the displayed Demand Integration Time, press >>. The next Set-up screen will appear (Section 3.9 Resets) To change the Demand Integration Time, press key to scroll through the available values. and use this

Select the required value and press >> to accept it. The Confirmation screen will appear.

Value Press >> to accept the displayed value . The next Set-up screen will appear (Section 3.9 Resets). Press to return to the Value screen and change the value.

Confirmation

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3.9 Resets
0240 0340 0440 0640 1000 1540

The following screens allow resetting of the Energy and Demand readings individually or altogether. Resetting the cumulative Energy (h) resets both Active and Reactive Energy. Resetting Demand (d) resets: Active Power Demand Current Demand Maximum Active Power Demand Maximum Current Demand Press >> to move on to the next Set-up screen without resetting any readings. To reset one or more readings press (All) will appear. . The first reset screen

Reset (None) Use to scroll through the parameters that can be reset:

h Active and reactive energy d Demands and maximum demands None no reset All h and d combined. Select the option required and press >> to confirm your selection. The appropriate confirmation screen will appear. (The confirmation screen will not appear if None has been selected.)

Reset All

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Press

to return to the Reset screen.

Press >> to reset the selected reading(s). The next screen will appear.

Confirmation

3.10 Pulsed Output, Pulse Duration

0240 0340 0440 0640 1000 1540 Option

This applies to the Relay Pulsed Output option only. Units with this option provide pulses to indicate power consumption (kWh). See Section 1.6 pulse output option. This screen allows the user to set the duration of the relay output pulse. The value displayed represents the pulse duration in milliseconds (ms). On a two part DIS 1540/Integra 1560, this screen will set the pulse duration for the Kvarh pulse relay (where fitted) also. To retain the current setting, press >>. The next Set-up screen will appear. To change the pulse duration, press Use the and 200. .

key to scroll through the available values of 60, 100

Select the value required and press >> to confirm your selection. The confirmation screen will appear.

Edit To change the value again, press reappear. . The Edit screen will

To accept the displayed pulse duration, press >>. The next screen will appear. Depending on the model, this may take you out of the Set-up screens and back to the last selected Display screen.

Confirmation

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3.11 Pulse Rate

0240 0340 0440 0640 1000 1540 Option

This applies to the Relay Pulsed Output option only. Units with this option provide pulses to indicate power consumption (kWh). This screen allows setting of the kWh pulse rate divisor. On a two part DIS 1540/Integra 1560, this screen will set the pulse rate for the kvarh pulse relay (where fitted) also. By default, the unit produces one pulse per kWh. Changing this divisor changes the output pulse rate, as follows: Divisor 1 10 100 1000 One pulse per: 1 kWh 10 kWh 100 kWh 1000 kWh (DIS1540 with 1560/1580 only)

Press >> to accept the currently displayed value. The next Set-up screen will then appear. To change the pulse rate divisor, press .

Use the key to scroll the value through the available values 1, 10, 100, 1,000. If the maximum power is greater than 3.6 megawatts, the range of divisors will be restricted to force an upper limit to the number of pulses/hour of 3600. Select the required divisor and press >> to confirm your selection. The Confirmation screen will appear. Edit To change the value again, press reappear. . The Edit screen will

To accept the displayed value, press >>. The next Set-up screen will appear.

Confirmation

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3.12 RS485 Baud Rate

0240 0340 0440 0640 1000 1540 Option

Use this screen to set the Baud Rate of the RS485 Modbus/JC NII port. The values displayed are in kbaud. Where the transducer unit may be separate from the display unit, the transducer has two Modbus ports, at least one of which may be used for communicating with a display. The RS485 Baud Rate option only sets the Baud Rate for a port that is not communicating with a display unit. The port characteristics for communication with a display are preset. If the JC NII protocol is to be used, the baud rate must be set to 9.6. If a display is detected on an RS485 port at start-up, any user settings for that port will be ignored. Press >> to accept the currently displayed value. The next Set-up screen will then appear. To change the baud rate, press .

Use the key to scroll through the available values 2.4, 4.8, 9.6 and 19.2. Select the required baud rate and press >> to confirm your selection. The Confirmation screen will appear.

Edit Press >> to accept the new setting. The next Set-up screen will appear. To change the value again, press reappear. . The Edit screen will

Confirmation

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3.13 RS485 Parity Selection

0240 0340 0440 0640 1000 1540 Option

This screen allows setting of the parity and number of stop bits of the RS485 Modbus/JC II port. Where the transducer unit is separate from the display unit, the transducer has two Modbus ports, one of which may be used for communicating with a display. The RS485 Parity Selection option only sets the parity for a port that is not communicating with a display unit. The port characteristics for communication with a display are preset. If the JC NII protocol is to be used, this parameter must be set to No parity and One stop bit. Press >> to accept the currently displayed value. The next Setup screen will then appear. To change the parity press Use the .

key to scroll through the available values:

odd odd parity with one stop bit E even parity with one stop bit no 1 no parity one stop bit, no 2 no parity two stop bits. Edit Select the required setting and press >> to confirm your selection. The Confirmation screen will appear. Press >> to accept the new setting. The next Set-up screen will appear. Press to return to the Edit screen.

Confirmation

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3.14 RS485 Modbus Address

0240 0340 0440 0640 1000 1540 Option

This screen allows setting of the Modbus/JC NII device address for the instrument. Where the transducer unit is separate from the display unit, the transducer has two RS485 ports, one of which may be used for communicating with a display. The Address option only sets the address for a port that is not communicating with a display unit. The port characteristics for communication with a display are preset. Press >> to accept the currently displayed value. The next Set-up screen will then appear. To change the address, press .

Set the three-digit address using the method described in Section 3.2 Number Entry Procedure. The range of the allowable addresses is 1 to 247. The range of selectable digits is restricted so that no higher number can be set. Press >> to confirm your selection. The Confirmation screen will appear. Edit If the new address is correct, press >>. Depending on the model, this may take you out of the Set-up screens and back to the last selected Display screen. If the new address is not correct, press screen. to return to the Edit

Confirmation

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3.15 Analogue Output Set Up

0240 0340 0440 0640 1000 1540 Option This is an option on Models 1540 that have separate (1560 or 1580) transducers.

3.15.1 Introduction
This applies to the analogue output option only, allowing the parameter to be selected, and the upper and lower limits adjusted, for either one or two channels. For each analogue output fitted, provision is made for five values to be user selected. These are: A1r Parameter, from Table 2. This is the measured input that is to be represented by the analogue output, for example, Watts or Frequency. A1rt Reading Top. This is the value of the electrical parameter that will cause the analogue output to produce Output Top. A1rb Reading Bottom. This is the value of the electrical parameter that will cause the analogue output to produce Output Bottom. A1ot Output Top. This is the value of output that will be reached when the measured electrical parameter is at the reading top value. A1ob Output Bottom. This is the value of output that will be reached when the measured electrical parameter is at the reading bottom value. To aid understanding, a simple example is shown in Section 3.15.2.

3.15.1.1 Second Channel

The screens following show the set-up for the first analogue channel. Set-up of the second analogue output is identical except that screens show A2 instead of A1, i.e. A2r, A2rt, A2rb, A2ot, A2ob. At the end of the set up for the second analogue output pressing >> will exit the set up system and enter the display mode.

3.15.1.2 Reverse Operation

It is possible to set reading top below reading bottom. In the example of Section 3.15.2, setting reading top to 95 volts and reading bottom to 135 volts would cause the output current to decrease from 20mA to 4mA as the measured voltage increased from 95 to 135 volts.

3.15.1.3 Reduced output range

Note that if the output values are adjusted to reduce output range, accuracy may be degraded. For example, if a 0-20mA capable output is set to operate over 0-1mA, then the specified accuracy will be degraded by a factor of 20.

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3.15.2 Analogue Output Scaling Example

In this example, the Integra has an output current range of 0 to 10mA and it is required that this output range represents a reading range of 95 to 135V.
Example Output top 10mA 135V Reading top

Analogue Output current from unit

Reading Value represented by Output

Output bottom 0mA

95V Reading bottom

3.15.2.1 Reading (A1r or A2r)

The measured electrical parameter that the analogue output will represent. Example: Volts Ave (Average Voltage) As shown in Table 2, any continuously variable parameter (volts, amps, watts etc) can be selected for output as an analogue value. The table also shows those values that may be signed (where the value may go negative).

3.15.2.2 Reading Top (A1rt or A2rt)

This is the value of the electrical parameter that will cause the analogue output to produce Output Top. Example: 135 volts.

3.15.2.3 Reading Bottom (A1rb or A2rb)

This is the value of the electrical parameter that will cause the analogue output to produce Output Bottom. Example: 95 volts. This value may be set to any value between zero and 120% of nominal. (Or between 120% and +120% of values that may be signed for example VAr)

3.15.2.4 Output
The two Output values specify the analogue current outputs that will represent the top and bottom Reading values. They are included to allow additional versatility where particular requirements prevail or to convert a 0-20mA output to 4-20mA. However it is suggested that, in most other cases, these values should be set to the limits that the hardware can cover. The range of the analogue output(s) for the unit is marked on the product label.

3.15.2.5 Output Top (A1ot or A2ot)

This is the value of output that will be reached when the measured electrical parameter is at the reading top value. Example: 10mA.

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3.15.2.6 Output Bottom (A1ob or A2ob)

This is the value of output that will be reached when the measured electrical parameter is at the reading bottom value. Example: 0mA

3.15.2.7 Summary
In the above example, the analogue output will be 0 mA when the average voltage is 95 volts, 5 mA at 115 volts and 10 mA at 135 volts.

3.15.3 Power Factor

When analogue output current is used to represent power factor, it can indicate the power factor for an inductive or capacitive load on imported or exported power. This can be shown in two dimensions as follows:

The polarity of the power factor reading indicates the direction of power flow: Positive Negative PF relates to imported power PF relates exported power.

This assumes that the unit is connected for a predominantly import application. See Installation sheet for further details.

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When setting up the analogue output for a power factor reading, the Reading Top value must be in one of the left-hand quadrants and the Reading Bottom value must be in one of the righthand quadrants.

Hence, if the Reading Top value is set to 0.5, this will be a power factor of 0.5 for power exported to an inductive load (bottom left-hand quadrant). Conversely, the Reading Bottom value must be in one of the two right-hand quadrants. If the Reading Bottom value is set to 0.5, this will be a power factor of 0.5 for power exported to a capacitive load (bottom right-hand quadrant). Thus a power factor of +1 (for true power imported to a resistive load) is always included in the analogue output range. In specifying the Output Top and Output Bottom values, there are two conventions one for European areas of influence and one for North American areas. The two conventions are: Europe USA Output Top greater or more positive than Output Bottom. Output Top less or more negative than Output Bottom.

The examples below show cases where power is only imported and the load may be either capacitive or inductive. The Reading Top and Reading Bottom values of zero ensure that the whole range of possible (import) power factor readings is covered. The unit in the left-hand example has an analogue output range of +1 to 1 mA and, since the Output Top value (+1 mA) is more positive than the Output Bottom value (-1 mA), this arrangement complies with the European convention. The right-hand example shows the North American convention.

In the above symmetrical arrangement, 0 mA corresponds to unity power factor. This is not the case with the following asymmetrical arrangement.

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In the example above, the unit has an analogue output range of 0 to 1 mA, all power is imported and the load is inductive. The 1 mA Output range covers a reading power factor range of 0.6, from 0.9 capacitive to 0.5 inductive. The capacitive overlap is provided in case of overcompensation of power factor. The Output to Reading correlation is as follows: Reading 0.9 PF cap. 1 PF 0.9 PF ind. 0.8 PF ind. 0.7 PF ind. 0.6 PF ind. 0.5 PF ind. European Convention Output 0 mA 0.167 mA 0.333 mA 0.500 mA 0.667 mA 0.833 mA 1 mA North American Convention Output 1 mA 0.833 mA 0.667 mA 0.500 mA 0.333 mA 0.167 mA 0 mA

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In this example, the unit is set to represent the full range of inductive and capacitive loads on imported and exported power. The unit has an analogue output range of 1 to +1 mA. Both Reading Top and Reading Bottom are set to 1 power factor.

3.15.4 Phase Angle

The Phase Angle analogue outputs are treated in a similar manner to Power Factor, with values specified in degrees. The following figure shows the relationship between phase angle in degrees and power factor.

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3.15.5 Parameters available for analogue outputs

Table 2 Analogue output parameter selection Parameter Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 24 25 27 29 31 32 34 36 43 44 53 54 101 102 Parameter Volts 1 (L1 N 4W or L1 L2 3W) Volts 2 (L2 N 4W or L2 L3 3W) Volts 3 (L3 N 4W or L3 L1 3W) Current 1 Current 2 Current 3 Watts Phase 1 Watts Phase 2 Watts Phase 3 VA Phase 1 VA Phase 2 VA Phase 3 VAr Phase 1 VAr Phase 2 VAr Phase 3 Power Factor Phase 1 Power Factor Phase 2 Power Factor Phase 3 Phase Angle Phase 1 Phase Angle Phase 2 Phase Angle Phase 3 Volts Ave Current Ave Current Sum Watts Sum VA Sum VAr Sum Power Factor Ave Average Phase Angle Frequency W Demand Import W Max. Demand Import A Demand A Max. Demand V L1-L2 (calculated) V L2-L3 (calculated) 3 4 wire
                                                                                                    

3 1 1 3 wire 3 wire 2 wire

              

+/-

  

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Parameter Number 103 104 113 118 119 120 121 122 123 125 126

Parameter V L3-L1 (calculated) Average Line to Line Volts Neutral Current THD Volts 1 THD Volts 2 THD Volts 3 THD Current 1 THD Current 2 THD Current 3 THD Voltage Mean THD Current Mean

3 4 wire
          

3 1 1 3 wire 3 wire 2 wire

                    

+/-

3.15.6 Reading (Parameter Selection) - A1r or A2r

Use this screen to choose the parameter that the analogue Output current will represent. The number displayed on the screen is the Parameter Number shown in Table 2. If the displayed Parameter Number is already correct, press >> to move on to the next Set-up screen. To change the Parameter Number, press and set the threedigit number using the method described in Section 3.2 Number Entry Procedure. Parameter Selection Press >> to confirm your selection. The Confirmation screen will appear. If the new Parameter Number is correct, press >>. The next Set-up screen will appear. If not, press screen. . You will be returned to the Parameter Selection

Confirmation

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3.15.7 Reading Top A1rt or A2rt

The top reading is limited to 120% of the nominal maximum value of the parameter. For example, a 230V nominal can be adjusted from 0 to 276V. The minimum is zero or 120% if the parameter is signed. This screen allows a negative value to be specified as the top reading. It will only be available if the parameter selected on the previous screen can be negative. For these parameters, the +/- column of Table 2 has a tick (). To accept the current value (- for negative, no symbol for positive), press >> to advance to the Alrb screen. Use to select the - sign for a negative Reading or no symbol for a positive Reading. Press >> to accept the current sign and advance to the next screen.

Sign edit

Use this screen to set the position of the decimal point. This screen will not appear when the selected parameter is frequency, as there is no choice of decimal point position. Pressing the key will advance the decimal point position to the right, illuminating the x1000 indicator as necessary and wrapping the decimal point position when the highest available position for the currently selected reading has been exceeded. (Maximum resolution is 3 digits of the metered value.) Select the required decimal point position and press >> to confirm your selection. The next screen will appear.

Decimal Point Position

Use this screen to set the value of the Reading Top Set the three-digit Reading Top value using the method described in Section 3.2 Number Entry Procedure. Press >> to confirm your selection. The Confirmation screen will appear.

Value Entry

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Press >> to accept the displayed Reading Top value, The next Set-up screen will appear. Press to return to the Edit screen.

Confirmation

3.15.8 Reading Bottom - A1rb or A2rb

Use these screens to specify the minimum or most negative value for the Reading Bottom value. The method of setting the Reading Bottom screens is the same as for setting the Reading Top screens, as described in Section 3.15.7. The Reading Bottom screens show A1rb (or A2rb for the Analogue output 2) on the top line.

3.15.9 Output Top A1ot or A2ot

Use these screens to set the maximum analogue output current (in mA). This current will represent the highest reading value. You cannot specify a greater current than the actual value that the unit can supply, e.g. 1 mA. The method of setting the Output Top screens is the same as for setting the Reading Top screens, as described in Section 3.15.7. The Output Top screens show A1ot (or A2ot for the Analogue output 2) on the top line.

3.15.10 Output Bottom A1ob or A2ob

Use these screens to set the minimum or most negative analogue output current (in mA). This current will represent the lowest or most negative reading value. The current cannot be set to a value that exceeds the actual capability of the unit, e.g. it cannot be set it to 10 mA if the unit can only handle 1 mA. The method of setting the Output Bottom screens is the same as for setting the Reading Top screens, as described in Section 3.15.7. These screens show A1ob (or A2ob for Analogue output 2) on the top line.

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4 Specification
The parameters listed in this section apply only to those models that can measure those parameters.

4.1 Display Only Versions

4.1.1 Input
RS485 Dedicated to Crompton Integra transducers

4.1.2 Auxiliary Power Supply

The unit can be powered from an auxiliary a.c. or d.c. supply that is separate from the metered supply. Versions of the unit are available to suit 100-250V 45-65 Hz a.c./d.c. and 12-48V d.c supplies.

4.1.2.1 High Voltage version

Standard nominal supply voltages 100 - 250V a.c. nominal 15% (85V a.c. absolute minimum to 287V a.c. absolute maximum) or 100 - 250V d.c. nominal -15%, +25% (85V d.c. absolute minimum to 312V d.c. absolute maximum) 45 to 66 Hz or 360 to 440 Hz (Model 0440) 4VA approx.

A.C. supply frequency range A.C. supply burden

4.1.2.2 Low Voltage version

D.C.supply D.C. supply burden 12 - 48V d.c. -15% + 25% (10.2V d.c. absolute minimum to 60V d.c. absolute maximum) 4VA approx.

4.1.3 EMC Standards

EMC Immunity EMC Emissions EN61326 for Industrial Locations to performance criterion A EN61326 to Class A - Industrial

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4.1.4 Safety
IEC1010-1 (BSEN 61010-1) Permanently connected use, Normal Condition Installation category III, pollution degree 2, Basic Insulation 300V RMS maximum. Auxilary circuits (12-48V auxiliary, communications, relay and analogue outputs, where applicable) are separated from metering inputs and 100-250V auxiliary circuits by at least basic insulation. Such auxiliary circuit terminals are only suitable for connection to equipment which has no user accessible live parts. The insulation for such auxiliary circuits must be rated for the highest voltage connected to the instrument and suitable for single fault condition. The connection at the remote end of such auxiliary circuits should not be accessible in normal use. Depending on application, equipment connected to auxiliary circuits may vary widely. The choice of connected equipment or combination of equipment should not diminish the level of user protection specified.

4.1.5 Insulation
Dielectric voltage withstand test 3.25kV RMS 50 Hz for 1 minute between all electrical circuits

4.1.6 Environmental
Operating temperature Storage temperature Relative humidity Shock Vibration Enclosure integrity (front face only) -10 to +60C -20 to +85C 0 .. 95% non condensing 30g in 3 planes 10 to 15 Hz @ 1.5 mm peak-peak 15 to 150 Hz @ 1.0g IP54

4.1.7 Enclosure
Style Material Terminals ANSI C39.1 Polycarbonate front and base, steel case Screw clamp style

4.2 Display/Transducer Combined 0240, 0340, 0440, 0640

For Model 1000 and 1540 specification, refer to Section 4.3.

4.2.1 Inputs
Three phase three wire voltage range: ELV LOV MIV HIV Three phase four wire voltage range: ELV 100 - 120V L-L 121 - 240V L-L 241 - 480V L-L 481 - 600V L-L 100 - 120V L-L (57.7 - 70V L-N)

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LOV MIV HIV

121 - 240V L-L (70.1 - 139V L-N) 241 - 480V L-L (140 - 277V L-N) 481 - 600V L-L (277 - 346V L-N)

(Voltage range is defined by factory build option.) Nominal input voltage (a.c. rms) System PT/VT primary values Max continuous input voltage Max short duration input voltage Nominal input voltage burden Nominal input current System CT primary values 57.7 to 346V L-N 100 to 600V L-L 1V to 400 kV 120% of nominal (up to 720 V max.) Twice nominal (1s application repeated 10 times at 10s intervals) 0.2 VA approx. per phase 1 or 5 A a.c. rms Standard values up to 9999 Amps (5 A secondaries) (1 A on application) 120% of nominal 20 times nominal (1s application repeated 5 times at 5 min intervals) 0.6 VA approx. per phase

Max continuous input current Max short duration current input Nominal input current burden

4.2.2 Auxiliary Power Supply

The unit can be powered from an auxiliary a.c. or d.c. supply that is separate from the metered supply. Versions of the unit are available to suit 100-200V 45-65 Hz a.c./d.c. and 12-48V d.c supplies.

4.2.2.1 High Voltage version

Standard supply voltage 100 to 250V a.c. nominal 15% (85V a.c. absolute minimum to 287V a.c. absolute maximum) or 100V to 250V d.c. nominal +25%, -15% (85V d.c. absolute minimum to 312V d.c. absolute maximum) 45 to 66 Hz or 360 to 440 Hz (Model 0440) 3W

a.c. supply frequency range a.c. supply burden

4.2.2.2 Low Voltage version

d.c.supply d.c. supply burden 12 to 48V d.c.. nominal +25%, -15% (10.2V d.c. absolute minimum to 60V d.c. absolute maximum) 3W

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4.2.3 Measuring Ranges

Values of measured quantities for which errors are defined. Voltage Current Frequency 70 .. 120% of nominal 5 .. 120% of nominal 45 .. 66 Hz, 360 .. 440 Hz (Model 0440) Crest values of voltage and current must remain within 168% of nominal maximum rms values

4.2.4 Accuracy
Voltage Current Frequency (not 0340) Temperature coefficient Response time to step input Screen update time 0.4% of reading 0.1% of range 1% of range maximum for Model 0440 0.4% of reading 0.1% of range 1% of range maximum for Model 0440 0.15% of mid frequency 1% of mid frequency for Model 0440 0.013%/C typical 1.5 seconds approx. 0.5 second approx.

4.2.5 Reference conditions of influence quantities

Values that quantities which affect measurement errors to a minor degree have to be for the intrinsic (headline) errors for measured quantities to apply. Ambient temperature Input frequency Input waveform Sinusoidal Auxiliary supply voltage Nominal Auxiliary supply frequency Nominal Auxiliary supply distortion factor Magnetic field of external origin 23C 50 or 60 Hz 2% (distortion factor 0.005) 1% 1% 0.05 Terrestrial flux

4.2.6 EMC Standards

EMC Immunity EN61326 for Industrial Locations to performance criterion A EMC Emissions EN61326 to Class B - Domestic

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4.2.7 Safety
IEC1010-1 (BSEN 61010-1) Permanently connected use, Normal Condition Installation category III, pollution degree 2, Basic Insulation 720V RMS maximum. Auxiliary circuits (12-48V auxuliary, communications, relay and analogue outputs, where applicable) are separated from metering inputs and 100-250V auxiliary circuits by at least basic insulation. Such auxiliary circuit terminals are only suitable for connection to equipment which has no user accessible live parts. The insulation for such auxiliary circuits must be rated for the highest voltage connected to the instrument and suitable for single fault condition. The connection at the remote end of such auxiliary circuits should not be accessible in normal use. Depending on application, equipment connected to auxiliary circuits may vary widely. The choice of connected equipment or combination of equipment should not diminish the level of user protection specified.

4.2.8 Insulation
Dielectric voltage withstand test 3.25kV RMS 50Hz for 1 minute between all isolated electrical circuits

4.2.9 Environmental
Operating temperature Storage temperature Relative humidity Shock Vibration Enclosure integrity (front face only) Harmonic distortion -20 to +70C -20 to +80C 0 .. 95% non condensing 30g in 3 planes 10 to 15 Hz @ 1.5 mm peak-peak 15 to 150 Hz @ 1.0g IP54 max 50% THD up to 15th harmonic

4.2.10 Enclosure
Style Material Terminals Weight ANSI C39.1 Polycarbonate front and base, steel case 6-32 UNC slotted barrier type 1.3kg

4.3 Display/Tranducer Combined 1000 and 1540

See section 4.3.16 for specifications particular to the 1540

4.3.1 Inputs
Nominal input voltage (a.c. rms) 57.7 to 600V L-N (single phase) 100 to 600V L-L (3 wire) 57.7 to 346V L-N (4 wire) 1V to 400KV

System PT/VT primary values

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Max continuous input voltage Max short duration input voltage Nominal input voltage burden Nominal input current System CT primary values Max continuous input current Max short duration current input Nominal input current burden

120% of nominal (up to 720V max.) 2*nominal (1s application repeated 10 times at 10s intervals) 0.2VA approx. per phase 1 or 5A a.c. rms Std. values up to 4kA (1 or 5 Amp secondaries) 120% of nominal 20*nominal (1s application repeated 5 times at 5 min intervals) 0.6VA approx. per phase

4.3.2 Auxiliary Power Supply

The unit can be powered from an auxiliary a.c. or d.c. supply that is separate from the metered supply. Versions of the unit are available to suit 100-200V 45-65 Hz a.c./d.c. and 12-48V d.c supplies. Standard supply voltage 100 to 250V a.c. nominal 15% (85V a.c. absolute minimum to 287V a.c. absolute maximum) or 100V to 250V d.c. nominal +25%, -15% (85V d.c. absolute minimum to 312V d.c. absolute maximum) 45 to 66 Hz or 360 to 440 Hz (Model 0440) 3W 12 to 48V d.c.. nominal +25%, -15% (10.2V d.c. absolute minimum to 60V d.c. absolute maximum) 3W

a.c. supply frequency range a.c. supply burden d.c.supply d.c. supply burden

4.3.3 Accuracy
Voltage Current Neutral current Frequency Power factor Active power (W) Reactive power (VAr) Apparent power (VA) Active energy (W.h) Reactive energy (VAr.h) Temperature coefficient Response time to step input Error change due to variation of an influence quantity in the manner described in section 6 0.4% of reading 0.1% of range 0.4% of reading 0.1% of range 4% of range 0.15% of mid frequency 1% of Unity 0.9% of reading 0.1% of range 1.9% of reading 0.1% of range 0.9% of reading 0.1% of range 1 Class (IEC 1036, Active PF 0.8-1-0.8 importing) 2%, Reactive PF 0.8-1-0.8 importing) 0.013%/C typical 1.5 seconds approx. Twice the error allowed for the reference condition applied in the test.

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of IEC688:1992 Error in measurement when a measurand is within its measuring range, but outside its reference range. Twice the error allowed at the end of the reference range adjacent to the section of the measuring range where the measurand is currently operating or being tested.

4.3.4 Reference conditions

Reference conditions of measurands and, where applicable, components of the measurand Values of measured quantities, and of components of measured quantities, where the intrinsic (headline) errors for the measured quantities apply. Voltage Current Frequency Active power (Watt) Voltage Current Active power factor Reactive power (VAr) Voltage Current Reactive power factor Apparent Power (VA) Voltage Current Power factor Voltage Current 50 .. 100% of nominal 10 .. 100% of nominal Nominal 10% 10 .. 100% of nominal Nominal 2% 10 .. 100% of nominal 1 .. 0.8 leading or lagging 10 .. 100% of nominal Nominal 2% 10 .. 100% of nominal 1 .. 0.8 leading or lagging 10 .. 100% of nominal Nominal 2% 10 .. 100% of nominal 1 .. 0.8 leading or lagging Nominal 2% 40 .. 100% of nominal

4.3.5 Reference conditions of influence quantities

Values that quantities which affect measurement errors to a minor degree have to be for the intrinsic (headline) errors for measured quantities to apply. Ambient temperature Input frequency Input waveform Auxiliary supply voltage Auxiliary supply frequency Auxiliary supply distortion factor Magnetic field of external origin 23C 50 or 60 Hz 2% Sinusoidal (distortion factor 0.005) Nominal 1% Nominal 1% 0.05 Terrestrial flux

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4.3.6 Nominal range of use of influence quantities for measurands

Values of quantities which affect measurement errors to a minor degree for which the magnitude of the measurement error is defined in this specification. Voltage Current Frequency Power factor (active/reactive as appropriate) Temperature Input waveform distortion Auxiliary supply voltage Auxiliary supply frequency Magnetic field of external origin 50 .. 120% of nominal 5 .. 120% of nominal Nominal 10% 0.5 lagging .. 1 .. 0.8 leading ,importing -20C to +70C 20% 3rd Harmonic distortion Nominal 10% Nominal 10% 400A/m Crest values of voltage and current must remain within 168% of nominal maximum rms values

4.3.7 Functional ranges

The functional ranges of measurands and of influence quantities for measurands Values of measured quantities, components of measured quantities, and quantities which affect measurement errors to a minor degree, for which the product gives meaningful readings. Voltage Current Frequency Power Factor Temperature Active power (Watt) Reactive power (VAr) Apparent power (VA) 5 .. 120% of nominal (below 5% of nominal voltage, current indication is only approximate) 0 .. 120% of nominal (2 .. 120% of nominal for Power Factor) 45 .. 66 Hz 1 .. 0 leading or lagging, importing (active/reactive as appropriate) -20C to +70C 0 .. 120% of nominal, 360 MW Max. 0 .. 120% of nominal, 360 MVAr Max. 0 .. 120% of nominal, 360 MVA Max.

4.3.8 Screen
Update 0.5 second approx.

4.3.9 Standards
Terms, Definitions and Test Methods EMC IEC688 (BSEN 60688) IEC1036 (BSEN 61036) IEC 61326

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4.3.10 Safety
IEC1010-1 (BSEN 61010-1) Permanently connected use, Normal Condition Installation category III, pollution degree 2, Basic Insulation 720V RMS maximum. Auxiliary circuits (12-48V auxuliary, communications, relay and analogue outputs, where applicable) are separated from metering inputs and 100-250V auxiliary circuits by at least basic insulation. Such auxiliary circuit terminals are only suitable for connection to equipment which has no user accessible live parts. The insulation for such auxiliary circuits must be rated for the highest voltage connected to the instrument and suitable for single fault condition. The connection at the remote end of such auxiliary circuits should not be accessible in normal use. Depending on application, equipment connected to auxiliary circuits may vary widely. The choice of connected equipment or combination of equipment should not diminish the level of user protection specified.

4.3.11 Insulation
Dielectric voltage withstand test 3.25kV RMS 50Hz for 1 minute between all isolated electrical circuits

4.3.12 Environmental
Operating temperature Storage temperature Relative humidity Warm up time Shock Vibration Enclosure code (front) Harmonic distortion -20C to +70C -20C to +80C 0 .. 95% non condensing 1 minute 30g in 3 planes 10 to 15 Hz @ 1.5 mm peak-peak 15 to 150 Hz @ 1.0g IP54 max 50% THD up to 15th harmonic

4.3.13 Enclosure
Style Material Terminals Weight ANSI C39.1 or JIS C-1102 Polycarbonate Front, Steel case 6-32 UNC slotted barrier style. 1.3kg

4.3.14 Serial Communications Option

Protocol Baud rate Parity MODBUS (RS485) 19200, 9600, 4800 or 2400 (programmable) Odd or Even, with 1 stop bit, or None with 1 or 2 stop bits.

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4.3.15 Active Energy Pulsed Output Option

Rated Default pulse rate Pulse rate divisors SPNO, 100V dc, 0.5A Max. 1 per kWhr 1 10 (yielding 1 pulse per 10 kWhr) 100 (yielding 1 pulse per 100 kWhr) 60ms, 100ms or 200ms, 3600 Pulses per hour max

Pulse duration

4.3.16 Integra 1540 Only

Measuring Range: Total Harmonic Distortion: Accuracy: Reference conditions of measurands: Reference conditions of measurands: Reference conditions of measurands: Up to 15th Harmonic 0%-50% Total Harmonic Distortion 1% Voltage: 60% to 100% of nominal for THD Total Harmonic Distortion: 20% to 100% of nominal for THD Total Harmonic Distortion: 0-30%

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5 Basis of measurement and calculations

Reactive and Apparent Power
Active powers are calculated directly by multiplication of voltage and current. Reactive powers are calculated using frequency corrected quarter phase time delay method. Apparent power is calculated as the square root of sum of squares of active and reactive powers. For 4 wire products, overall powers are the sum of the per phase powers. For 3 phase 3 wire products, the "two wattmeter" method is used for overall powers.

Energy resolution
Cumulative energy counts are reported using the standard IEEE floating point format. Reported energy values in excess of 16MWh may show a small non cumulative error due to the limitations of the number format. Internally the count is maintained with greater precision. The reporting error is less than 1 part per million and will be automatically corrected when the count increases.

Power Factor
The magnitude of Per Phase Power Factor is derived from the per phase active power and per phase apparent power. The power factor value sign is set to negative for an inductive load and positive for a capacitive load. The magnitude of the System Power Factor is derived from the sum of the per phase active power and per phase apparent power. The system power factor value sign is set to negative for an inductive load and positive for a capacitive load. The load type, capacitive or inductive, is determined from the signs of the sums of the relevant active powers and reactive powers. If both signs are the same, then the load is inductive, if the signs are different then the load is capacitive. The magnitude of the phase angle is the ArcCos of the power factor. It's sign is taken as the opposite of the var's sign.

Maximum Demand
The maximum power consumption of an installation is an important measurement as power utilities often levy related charges. Many utilities use a thermal maximum demand indicator (MDI) to measure this peak power consumption. An MDI averages the power consumed over a number of minutes, such that short surges do not give an artificially high reading. Integra uses a sliding window algorithm to simulate the characteristics of a thermal MDI instrument, with the demand period being updated every minute. The demand period can be reset, which allows synchronisation to other equipment. When it is reset, the values in the Demand and Maximum Demand registers are set to zero.

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Time Integration Periods can be set to 8, 15, 20 or 30 minutes. Note: During the initial period when the "sliding window" does not yet contain a full set of readings (i.e. the elapsed time since the demands were last reset or the elapsed time since Integra was switched on is less than the selected demand period) then maximum demands may not be true due to the absence of immediate historical data. The Time Integration Period can be user set either from the Integra 1540 Display or by using the communications option.

Total Harmonic Distortion (1540 only)

The calculation used for the Total Harmonic Distortion is: THD = ((RMS of total waveform - RMS of fundamental) / RMS of total waveform) x 100 This is often referred to as THD - R The figure is limited to the range 0 to 100% and is subject to the 'range of use' limits. The instrument may give erratic or incorrect readings where the THD is very high and the fundamental is essentially suppressed. For low signal levels the noise contributions from the signal may represent a significant portion of the "RMS of total waveform" and may thus generate unexpectedly high values of THD. To avoid indicating large figures of THD for low signal levels the product will produce a display of 0 (zero). Typically, display of THD will only produce the 0 (zero) value when the THD calculation has been suppressed due to a low signal level being detected. It should also be noted that spurious signals (for example, switching spikes) if coincident with the waveform sampling period will be included in the "RMS of the total waveform" and will be used in the calculation of THD. The display of THD may be seen to fluctuate under these conditions.

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6 Serial Communications
6.1. RS485 Port Modbus or JC N2
0240 0340 0440 0640 1000 1540 Option

INTEGRA 1000 and 1540 offer the option of an RS485 communication port for direct connection to SCADA systems. This port can be used for either an RS485 Modbus RTU slave, or as a Johnson Controls N2 protocol slave. Choice of reply protocol is made by the Integra on the basis of the format of request, so that a Modbus request receives a Modbus reply, and an N2 protocol request receives an N2 protocol reply.

6.2 Modbus Implementation

This section provides basic information for the integration of the product to a Modbus network. If background information or more details of the Integra implementation is required please refer to our Guide to RS485 Communications and the Modbus Protocol, available on our CD catalogue or from any recognised supplier. The Modbus protocol establishes the format for the master's query by placing into it the device address, a function code defining the requested action, any data to be sent, and an error checking field. The slave's response message is also constructed using Modbus protocol. It contains fields confirming the action taken, any data to be returned, and an error-checking field. If an error occurs in receipt of the message, or if the slave is unable to perform the requested action, the slave will construct an error message and send it as its response. Framing errors receive no response from the Integra. The electrical interface is 2-wire RS485, via 3 screw terminals. Connection should be made using twisted pair screened cable (Typically 22 gauge Belden 8761 or equivalent). All "A" and "B" connections are daisy chained together. The screens should also be connected to the Gnd terminal. To avoid the possibility of loop currents, an Earth connection should be made at only one point on the network. Line topology may or may not require terminating loads depending on the type and length of cable used. Loop (ring) topology does not require any termination load. The impedance of the termination load should match the impedance of the cable and be at both ends of the line. The cable should be terminated at each end with a 120 ohm (0.25 Watt min.) resistor. A total maximum length of 3900 feet (1200 metres) is allowed for the RS485 network. A maximum of 32 electrical nodes can be connected, including the controller. The address of each Integra 1000/1540 can be set to any value between 1 and 247. Broadcast mode (address 0) is not supported. The maximum latency time of an Integra 1000/1540 is 150ms i.e. this is the amount of time that can pass before the first response character is output. The supervisory programme must allow this period of time to elapse before assuming that the Integra is not going to respond.

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The data format in RTU mode is: Coding System: Data Format: 8-bit per byte 4 bytes (2 registers) per parameter. Floating point format ( to IEEE 754) Most significant register first (Default). The default may be changed if required - See Holding Register "Register Order" parameter. 2 byte Cyclical Redundancy Check (CRC) 1 8 1 1 start bit data bits, least significant bit sent first bit for even/odd parity or no parity stop bit if parity is used; 1 or 2 bits if no parity

Error Check Field: Framing:

Data Transmission speed is selectable between 2400, 4800, 9600 and 19200 baud.

Input Registers
Input registers are used to indicate the present values of the measured and calculated electrical quantities. Each parameter is held in two consecutive 16 bit registers. The following table details the 3X register address, and the values of the address bytes within the message. A tick () in the column indicates that the parameter is valid for the particular wiring system. Any parameter with a cross (X) will return the value Zero (0000h). Some parameters are only available on the Integra 1540, as shown in the table below.. Each parameter is held in the 3X registers. Modbus Function Code 04 is used to access all parameters. e.g. to request Volts 1 Start address No of registers Volts 2 Start address No of registers = = = = 00 02 02 02

Each request for data must be restricted to 40 parameters or less. Exceeding the 40 parameter limit will cause a Modbus exception code to be returned.

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Register

Parameter Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 24 25 27 29 31 32 34 36 37 39 43 44 53 54 101 102 103 104 113 118 119 120 121 122 123 125 126 128

Parameter

30001 30003 30005 30007 30009 30011 30013 30015 30017 30019 30021 30023 30025 30027 30029 30031 30033 30035 30037 30039 30041 30043 30047 30049 30053 30057 30061 30063 30067 30071 30073 30077 30085 30087 30105 30107 30201 30203 30205 30207 30225 30235 30237 30239 30241 30243 30245 30249 30251 30255

Volts 1 (L1 N 4W or L1 L2 3W) Volts 2 (L2 N 4W or L2 L3 3W) Volts 3 (L3 N 4W or L3 L1 3W) Current 1 Current 2 Current 3 Watts Phase 1 - Integra 1540 only Watts Phase 2 - Integra 1540 only Watts Phase 3 - Integra 1540 only VA Phase 1 - Integra 1540 only VA Phase 2 - Integra 1540 only VA Phase 3 - Integra 1540 only var Phase 1 - Integra 1540 only var Phase 2 - Integra 1540 only var Phase 3 - Integra 1540 only Power Factor Phase 1 - Integra 1540 only Power Factor Phase 2 - Integra 1540 only Power Factor Phase 3 - Integra 1540 only Phase Angle Phase 1 - Integra 1540 only Phase Angle Phase 2 - Integra 1540 only Phase Angle Phase 3 - Integra 1540 only Volts Ave Current Ave Current Sum - Integra 1540 only Watts Sum VA Sum var Sum Power Factor Ave Average Phase Angle - Integra 1540 only Frequency Wh Import varh Import W Demand Import W Max. Demand Import A Demand A Max. Demand V L1-L2 (calculated) V L2-L3 (calculated) V L3-L1 (calculated) Average Line to Line Volts Neutral Current THD Volts 1 - Integra 1540 only THD Volts 2 - Integra 1540 only THD Volts 3 - Integra 1540 only THD Current 1 - Integra 1540 only THD Current 2 - Integra 1540 only THD Current 3 - Integra 1540 only THD Voltage Mean - Integra 1540 only THD Current Mean - Integra 1540 only Power Factor (+Ind/-Cap)

Modbus Start 3 3 1 1 Address Hex 4 wire 3 wire 3 wire 2 wire High Byte Low Byte 00 00     00 02    X 00 04   X X 00 06     00 08    X 00 0A   X X 00 0C  X   00 0E  X  X 00 10  X X X 00 12  X   00 14  X  X 00 16  X X X 00 18  X   00 1A  X  X 00 1C  X X X 00 1E  X   00 20  X  X 00 22  X X X 00 24  X   00 26  X  X 00 28  X X X 00 2A     00 2E     00 30     00 34     00 38     00 3C     00 3E     00 42     00 46     00 48     00 4C     00 54     00 56     00 68     00 6A     00 C8  X  X 00 CA  X X X 00 CC  X X X 00 CE  X  X 00 E0  X   00 EA     00 EC    X 00 EE   X X 00 F0     00 F2    X 00 F4   X X 00 F8     00 FA     00 FE    

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Modbus Holding Registers and Integra set up

Holding registers are used to store and display instrument configuration settings. All holding registers not listed in the table below should be considered as reserved for manufacturer use and no attempt should be made to modify their values. The demand parameters may be viewed or changed using the Modbus protocol. Each parameter is held in the 4X registers. Modbus Function Code 03 is used to read the parameter and Function Code 16 is used to write. Register Parameter Parameter Number Modbus Start Address Hex High Low Byte Byte 00 00 00 02 00 06 00 08 00 0A 00 0C 00 0E 00 16 00 18 00 24 00 28 01 2A Valid range Mode

40001 40003 40007 40009 40011 40013 40015 40023 40025 40037 40041 40299

1 2 4 5 6 7 8 12 13 19 21 150

Demand Time Demand Period System Voltage System Current System Type Relay Pulse Width Energy Reset Pulse Divisor Password System Power Register Order Secondary Volts

0 only 8,15,20,30 minutes. 1V - 400kV 1-9999 A 3,5,10 (x20mS) 0 only 1,10,100,1000 0000-9999 2141.0 only Min Vin-Max Vin

r/w r/w r/wp r/wp ro r/w wo r/w r/w r/o wo r/wp

r/w = read/write r/wp = read and write with password clearance ro = read only wo = write only Password Settings marked r/wp require the instrument password to have been entered into the Password register before changes will be accepted. Once the instrument configuration has been modified, the password should be written to the password register again to protect the configuration from unauthorised or accidental change. Power cycling also restores protection. Reading the Password register returns 1 if the instrument is unprotected and 0 if it is protected from changes. Demand Time is used to reset the demand period. A value of zero must be written to this register to accomplish this. Writing any other value will cause an error to be returned. Reading this register after instrument restart or resetting demand period gives the number of minutes of demand data up to a maximum of the demand period setting. For example, with 15 minute demand period, from reset the value will increment from zero every minute until it reaches 15. It will remain at this value until a subsequent reset occurs. Demand Period The value written must be one of the following 8,15, 20 or 30 (minutes), otherwise an error will be returned. System Type The System type address will display '1' for single phase 2 wire, '2' for 3 Phase 3 Wire, '3' for 3 Phase 4 Wire or 4 for single phase 3 wire.

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Relay Pulse Width is the width of the relay pulse in multiples of 20 ms. However, only values of 3 (60 ms), 5 (100 ms) or 10 (200 ms) are supported. Writing any other value will cause an error to be returned. Reset Energy is used to reset the Energy readings. A value of zero must be written to this register to accomplish this. Writing any other value will cause an error to be returned. Pulse Rate Divisor, supports only values of 1,10,100 or 1000. Writing any other value will cause an error to be returned. System Power, is the maximum system power based on the values of system type, system volts and system current. Register Order, the instrument can receive or send floating-point numbers in normal or reversed register order. In normal mode, the two registers that make up a floating point number are sent most significant bytes first. In reversed register mode, the two registers that make up a floating point number are sent least significant bytes first. To set the mode, write the value '2141.0' into this register - the instrument will detect the order used to send this value and set that order for all Modbus transactions involving floating point numbers. Secondary Volts indicates the voltage on the VT secondary when the voltage on the Primary is equal to the value of System Volts . The value of this register can be set to between the minimum and maximum instrument input voltage.

6.3 RS485 Implementation of Johnson Controls Metasys

These notes explain Metasys and Crompton Instruments Integra 1000/1540 integration. Use these notes with the Metasys Technical Manual, which provides information on installing and commissioning Metasys N2 Vendor devices.

Application details
The Integra 1000/1540 is a N2 Vendor device that connects directly with the Metasys N2 Bus. This implementation assigns 33 key electrical parameters to ADF points, each with override capability. Components requirements Integra 1000/1540 with RS485 option. N2 Bus cable.

Metasys release requirements

Metasys OWS software release 7.0 or higher. Metasys NCM311. NCM360.

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Support for Metasys Integration

Johnson Control Systems System House, Randalls Research Park, Randalls Way, Leatherhead, Surrey, KT22 7TS England

Support for Crompton Integra operation

This is available via local sales and service centre.

Design considerations
When integrating the Crompton equipment into a Metasys Network, keep the following considerations in mind. Make sure all Crompton equipment is set up, started and running properly before attempting to integrate with the Metasys Network. A maximum of 32 devices can be connected to any one NCM N2 Bus. Vendor Address Port Set-up Baud Rate Duplex Word Length Stop Bits Parity Interface 1-247 (Limited by co-resident Modbus protocol) 9600 Full 8 1 None RS485

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METASYS N2 application
Integra 1560/1580 Point Mapping table
Address 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Parameter Description Voltage 1 Voltage 2 Voltage 3 Current 1 Current 2 Current 3 Voltage average Current average Power (Watts) Sum VA Sum var Sum Power Factor average Frequency Active Energy (Import) Reactive Energy (Import) Watts Demand (Import) Maximum Watts Demand (Import) Amps Demand Maximum Amps Demand Voltage L1-L2 (calculated) Voltage L2-L3 (calculated) Voltage L3-L1 (calculated) Neutral Current Active Energy (Import) Reactive Energy (Import) Units Volts Volts Volts Amps Amps Amps Volts Amps kW kVA kvar Hz kWh kvarh kW kW Amps Amps Volts Volts Volts Amps GWh Gvarh

The following parameters are available only on the Integra 1540 26 27 28 29 30 31 32 33 THD THD THD THD THD THD THD THD V1 V2 V3 I1 I2 I3 Vmean Imean % % % % % % % %

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7 Maintenance
Warning
During normal operation, voltages hazardous to life may be present at some of the terminals of this unit. Installation and servicing should be performed only by qualified, properly trained personnel' abiding by local regulations. Ensure all supplies are de-energised before attempting connection or other procedures. It is recommended adjustments be made with the supplies de-energised, but if this is not possible, then extreme caution should be exercised. Terminals should not be user accessible after installation and external installation provisions must be sufficient to prevent hazards under fault conditions. This unit is not intended to function as part of a system providing the sole means of fault protection - good engineering practice dictates that any critical function be protected by at least two independent and diverse means. In normal use, little maintenance is needed. As appropriate for service conditions, isolate electrical power, inspect the unit and remove any dust or other foreign material present. Periodically check all connections for freedom from corrosion and screw tightness, particularly if vibration is present. The front of the case should be wiped with a dry cloth only. Use minimal pressure, especially over the viewing window area. If necessary wipe the rear case with a dry cloth. If a cleaning agent is necessary, isopropyl alcohol is the only recommended agent and should be used sparingly. Water should not be used. If the rear case exterior or terminals should accidentally be contaminated with water, the unit must be thoroughly dried before further service. Should it be suspected that water might have entered the unit, factory inspection and refurbishment is recommended. In the unlikely event of a repair being necessary, it is recommended that the unit be returned to the factory or nearest Crompton service centre.

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Integra 1540, 1000, 0640, 0440, 0340, 0240 Issue 1 04/03

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Notes

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The Information contained in these installation instructions is for use only by installers trained to make electrical power installations and is intended to describe the correct method of installation for this product. However, Tyco Electronics has no control over the field conditions which influence product installation. It is the user's responsibility to determine the suitability of the installation method in the user's field conditions. Tyco Electronics' only obligations are those in Tyco Electronics' standard Conditions of Sale for this product and in no case will Tyco Electronics be liable for any other incidental, indirect or consequential damages arising from the use or misuse of the products. Crompton is a trade mark.

Tyco Electronics UK Limited Crompton Instruments Freebournes Road, Witham, Essex, CM8 3AH, UK Tel: +44 1376 509 509 Fax: +44 1376 509 511

http://energy.tycoelectronics.com