Display & Programming. HPL500 Unipower Version 1.0 Technical information English edition Technical Specifications Mechanical spec. Housing Makrolon 8020 (30% GV), UL94V-1 (house). Makrolon 2800, UL94V-2 (connector + front). The HPL500 is programmed by the use of only three keys Mounting located on the front panel, see paragraph about programming Snap-on construction for 35mm DIN-rail on page 2. All directly accessible parameters as well as their adjustable range are listed in the table above. Parameters or wall mounting. are stored in EEProm. If no key is activated for approx. 30 Protection class seconds, the display defaults to kW % . Note that the IP40 (house). function of the keys is repeated if held down continously. IP20 (connector). Access to the parameter list is found under the field Para- Operating Temperature range: meter. The display shows P00, which using the arrow-up key -15 - +50 C surrounding air. must be changed to the desired number (see table to the Weight: Approx. 250g. right). Upon pressing the Mode key the value of the selec- ted parameter is shown. It may now be changed using the Dimensions: D 110 x W 56 x H 75 mm. arrow keys. To store the new value press the Mode key and the unit returns to the parameter list. Pressing the Reset Terminal tight. torque: 7lbs/in, 0.79Nm key instead of the Mode key discards the new value and Use 60/75 copper (CU) wire only keeps the old value and the unit returns to showing kW%. Note: When displaying setpoints a max-limit is displayed Electrical spec. with a red LED and a min-limit with a green LED. This only applies to setpoints and not alarms, which are always displayed Supply / measuring voltage with a flashing red LED. 1x100 - 1x400Vac 10%. Generally 3x100 - 3x575Vac 10% Current range Unipower HPL500 is equipped with a Note: Current must be measured in the L3 phase (Terminal 5). Internal: 0.5, 1, 2.5, 5, 10, 20, 30 & 40A Direction is not important specially developed power supply for use External: With N/5A converter (50-600A) from 100V - 575V - both single phased and Accuracy: Class 2. Consumption: 2 VA three phased. Mains voltages in the whole Frequency range: 45 - 65 Hz world is hereby covered with one unit. Relay spec. HPL500 also measures currents up to 40A 250 VAC/5 Amp. without the use of an external current con- Analogue output verter. 0(4)-20mA, max load 400 As all Unipower HPL-modules the HPL500 galvanically isolated from the measuring naturally integrates the functions necessa- system. ry to establish an efficient and compact su- pervision or control Start timer, reaction CE-mark to: EN61326-1, EN61010-1 timer, setpoints etc. For setup simplicity the HPL500 includes UL certified: peak detectors on the power measure- UL508, File E194022 ment. Additionally also true kW may be displayed Single phase - connect phase to both L2 & L3 as well as the entered kW range. Connection to a single phased load Connection to a three phased load Page 4 Page 1Generally Ts: Start timer Inhibit of alarms (Input S2): Special functions The measurement is based on a fast four quadrant multipli- The programmable start timer (Ts) is used to avoid alarms at Input S2 has two functions: 1. Just as Ts blocks for alarms cation of current and voltage making the HPL500 capable of motor start. When the power consumption exceeds 5%, Ts is during startup, an alarm can be inhibited by connecting S2 to 1. Limit select by input S2 measuring the exact power consumption also on frequency activated. After expiration of Ts limits, hysteresis, Tr etc will Gnd. 2. Limit select - see special functions. In some applications it can be useful to have two selectable inverters. Measurement: P = 3 x U x I x cos. become active. If the power consumption drops below 5%, limits. Examples: Supervising two speed motors used in the supervision is disabled again. Auto Shut Down: cranes, Dalandermotors etc. Programming: If the motor is stopped deliberately a min limit will give an The HPL500 is programmed by the use of only three keys Setpoints: alarm unless Auto Shut Down is activated (P03). Exceeding To change the function of S2 from normal nor (Alarm inhibit) placed on the front panel. The Mode-key is used to select The HPL500 includes two independent limits user selectable the min limit is hereby ignored as long as the measurement to special SPC (Limit select) select (P14) and SPC . This one of the programmable parameters. When a parameter is as max- or min-limits (P01 & P02). drops below Threshold before Tr expires. causes both limits to become max.-limits (Hi) with setpoints selected, the value may be changed using the two arrow keys. Determining the setpoints may be done in two ways: of 80% for limit 1 and 60% for limit 2. Settings may of course To store the new value, press the Mode-key, and the value is 1. Theoretically: Hysteresis: be changed if desired. Now the unit works as follows: stored in EEProm. If the Reset-key is pressed the old value Md = P2 x 60 / 2n, where From the figure to the left it is evident how possible Maximum- is kept and the unit returns to showing kW%. Md: Torque where an alarm is required. and Minimum- hysteresis bands are placed relative to the With S2 open Limit 2 is used and with S2 closed Limit 1 is Please note: The unit is equipped with a key lock which must P2: Corresponding shaft power. limits The hysteresis band always lies above a Min. limit and used. To avoid false alarms a new Ts is activated each time be unlocked before a parameter can be changed. This is done n: Revolutions in rev./min. below a Max. limit. Hysteresis is activated, when an alarm is the S2 input changes state from open to closed or from by selecting Locked and then changing the display value from P1 = P2 + Po (or from the efficiency curve for the motor). generated and hysteresis is enabled in the HPL500 setup closed to open. On to Off with the arrow keys. Setpoint % = 100 x P1/P, where (P04 & P05). P: Measuring range for HPL500. In this mode (Limit select) it is also possible to select sepa- Voltage range: 2. Peak detectors: rate current range for each limit. Both current ranges may be Analogue output The HPL500 is equipped with a newly developed power supply Run the motor at normal load and read the peak values by set independently of the selected limit. The HPL500 features a current output configurable as either unit making the unit applicable for voltages from 100V to 575V activating the arrow keys in the kW % -mode. Place the Max. 0-20mA or 4-20mA (P11). If the output is in a control loop it - single phased as well as three phased. Simply set up the limit suitable above and the Min. limit suitable below. The Peak 2. Shaft power P2: can be inverted (P12). Using the shaft power settings (P06 & connected voltage via the front. detectors may be reset by activating the relevant arrow key HPL500 can compute shaft output power P2 as input power P07), the analogue output may reflect the shaft power P2 and at the same time pressing the Reset key. They are also (P1) minus motor losses (P0) (heat, friction, copper losses, (P08). Measuring range: reset by the power rising through the 5% threshold. Therefore windage etc) The unit contains a current converter up to 40A. Internally the after a power down, or motor resstart Therefore P2 = P1 P0 Zoom: range may be selected from 0.5A to 40A in 8 steps. If a larger The analogue output may be scaled to represent a limited range range is required an external N/5A CT must be used. As for Tr: Reaction timer If you wish to use this feature, during the setup procedure of the power consumption (P09 & P10). This only affects the the voltage - just select the CT via the front and the HPL500 In the figure to the left it is shown, how the reaction timers you have to enter two parameters P06 (max shaft power analogue output - and not the % readout or the setpoints. computes the kw range as P = 3 x U x I. The readout as well (Tr) are activated upon exceeding the setpoints. Tr is used to P2max kW ) and P07 (efficiency at full load % ). as the setup of setpoints are relative to this range. Ex: avoid alarms, unless the setpoint has been exceeded for a Note Please do not confuse efficiency with Cos. In Filter: 1A and 400V gives a range of P = 0,69kW = 100% certain period of time. If Tr is set to 0, the reaction time some motors they may be similar but in others there are big When dealing with fluctuating power signals a built-in dam- equals the time constant in the measuring circuit of approx. differences. ping filter (P13) may be used to advantage. It has a time cons- Functions 40ms. tant of approx. 250ms. The figure below shows a typical consumption curve for an P2max is the kW rating on the motor plate or in the manufac- AC-motor (e.g. pump) immediately after power has been Reset of alarms: turers data, which may also state Motor efficiency . If not Relays: applied to the motor. Below the curve a bar shows the state Alarms may be reset with the Reset key on the front plate then you will have to calculate it. To do this first calculate The unit is equipped with two relays Relay 1 is a change- of the relays. or via the input S1, - see figure 2. It is only possible to reset P1max using the formula over switch which always is related to limit 1. Relay 2 is a an alarm if the alarm condition is no longer present. close / break - switch, which always is related to limit 2. The P1Max = 3 x U x I(max) x cos. polarity of the relays may be inverted independently of each other. Example: 400V Motor rated 3.5kW, 7A full load current, Cos 0.85 Readout: So P1Max = 3 x 400V x 7A x 0.85 = 4122W = 4.122kW The HPL500 displays - like all other HPL units - percentage of the power range. In addition kW may be displayed as well Motor efficiency = P2max/P1max. as the power range. If the shaft power settings are used HPL500 displays computed shaft power percentage of the From the example above we know the motor is rated at 3.5kW rated shaft power. (P2max) and that P1max = 4.122kW. Therefore 3.5 /4.122 = 84.9%, say 85%, and this is parameter P07. Factory settings: The unit may always return to the factory settings (P15), if This is the motor efficiency AT FULL LOAD. However Motor a fresh start parameters set up is desirable. losses decrease as the motor load decreases, therefore changes. To calculate accurate and meaningful Shaft Output Power from Idle to full load power it is necessary to regulate according to the actual motor load in real time. HPL500 does this by using data modelled from typical motors across their entire power range. Your motors data may differ slightly from the model used in HPL500 but the resulting Shaft Out- put Power calculation will still be useful to you. Note If these settings are used all setpoints are related to the shaft power (P2) and not to the input power (P). Figure 2 Page 2 Page 3