Flowserve KW941 User Manual
USER INSTRUCTIONS
Flowserve KW941
Pump Power Monitor™
Pump Power Monitor for protection against both under load and
over load conditions.
PCN= = 71569285 – 02-12 (E) (incorporates PM-200 & PM-201)
Original instructions.
Installation
Operation
Maintenance
These instructions must be read prior to installing,
operating, using and maintaining this equipment.
KW941 Pump Power Monitor USER INSTRUCTIONS ENGLISH 71569285 02-12
CONTENTS
Page
1 INTRODUCTION AND SAFETY ............................ 3
1.1 General ........................................................... 3
1.2 CE marking and approvals .............................. 3
1.3 Disclaimer ....................................................... 3
1.4 Copyright ......................................................... 3
1.5 Duty conditions ................................................ 3
1.6 Safety .............................................................. 4
1.7 Nameplate and safety labels ........................... 5
1.8 Specific machine performance ........................ 5
2 TRANSPORT AND STORAGE .............................. 5
2.1 Consignment receipt and unpacking............... 5
2.2 Handling .......................................................... 5
2.3 Storage ............................................................ 5
2.4 Recycling and end of product life .................... 5
3 DESCRIPTION ...................................................... 6
3.1 Configurations ................................................. 6
3.2 Nomenclature .................................................. 6
3.3 Design of major parts ...................................... 6
3.4 Performance and operation limits ................... 7
4 INSTALLATION ...................................................... 8
4.1 Location ........................................................... 8
4.2 Electrical connections ..................................... 8
5 SETUP AND OPERATION .................................. 13
5.1 Display Mode – Power Units Selection ......... 13
5.2 Full Scale Adjust ............................................ 13
5.3 Alarms ........................................................... 14
5.4 Demo Mode ................................................... 16
5.5 Current Sensor Field Replacement ............... 16
6 MAINTENANCE ................................................... 17
6.1 Spare parts .................................................... 17
6.2 Tools required ................................................ 17
7 FAULTS: CAUSES AND REMEDIES .................. 17
8 PARTS LIST AND DRAWINGS ........................... 20
9 CERTIFICATION ................................................. 23
10 OTHER RELEVANT DOCUMENTATION AND
MANUALS ........................................................ 23
10.1 Supplementary user instructions .................. 23
10.2 Change Notes .............................................. 23
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KW941 Pump Power Monitor USER INSTRUCTIONS ENGLISH 71569285 02-12
1 INTRODUCTION AND SAFETY
1.1 General
These instructions must always be kept
close to the product's operating location or
directly with the product.
Flowserve products are designed, developed and
manufactured with state-of-the-art technologies in
modern facilities. The unit is produced with great
care and commitment to continuous quality control,
utilizing sophisticated quality techniques and safety
requirements.
Flowserve is committed to continuous quality
improvement and being at service for any further
information about the product in its installation and
operation or about its support products, repair and
diagnostic services.
These instructions are intended to facilitate
familiarization with the product and its permitted use.
Operating the product in compliance with these
instructions is important to help ensure reliability in
service and avoid risks. The instructions may not
take into account local regulations; ensure such
regulations are observed by all, including those
installing the product. Always coordinate repair
activity with operations personnel, and follow all plant
safety requirements and applicable safety and health
laws and regulations.
These instructions must be read prior to
installing, operating, using and maintaining the
equipment in any region worldwide. The
equipment must not be put into service until all
the conditions relating to safety, noted in the
instructions, have been met. Failure to follow and
apply the present user instructions is considered
to be misuse. Personal injury, product damage,
delay or failure caused by misuse are not covered
by the Flowserve warranty.
1.2 CE marking and approvals
It is a legal requirement that machinery and equipment
put into service within certain regions of the world shall
conform with the applicable CE Marking Directives
covering Machinery and, where applicable, Low Voltage
Equipment, Electromagnetic Compatibility (EMC),
Pressure Equipment Directive (PED) and Equipment for
Potentially Explosive Atmospheres (ATEX).
Where applicable, the Directives and any additional
Approvals, cover important safety aspects relating to
machinery and equipment and the satisfactory provision
of technical documents and safety instructions. Where
applicable this document incorporates information
relevant to these Directives and Approvals.
To confirm the Approvals applying and if the product is
CE marked, check the product identification label and
the Certification. (See section 9, Certification.)
1.3 Disclaimer
Information in these User Instructions is believed to
be complete and reliable. However, in spite of all of
the efforts of Flowserve Corporation to provide
comprehensive instructions, good engineering and
safety practice should always be used.
Flowserve manufactures products to exacting
International Quality Management System Standards
as certified and audited by external Quality
Assurance organizations. Genuine parts and
accessories have been designed, tested and
incorporated into the products to help ensure their
continued product quality and performance in use.
As Flowserve cannot test parts and accessories
sourced from other vendors the incorrect
incorporation of such parts and accessories may
adversely affect the performance and safety features
of the products. The failure to properly select, install
or use authorized Flowserve parts and accessories is
considered to be misuse. Damage or failure caused
by misuse is not covered by the Flowserve warranty.
In addition, any modification of Flowserve products or
removal of original components may impair the safety
of these products in their use.
1.4 Copyright
All rights reserved. No part of these instructions may
be reproduced, stored in a retrieval system or
transmitted in any form or by any means without prior
permission of Flowserve.
1.5 Duty conditions
This product has been selected to meet the
specifications of your purchase order. The
acknowledgement of these conditions has been sent
separately to the Purchaser. A copy should be kept
with these instructions.
The product must not be operated beyond
the parameters specified for the application.
If there is any doubt as to the suitability of the
product for the application intended, contact
Flowserve for advice, quoting the part number.
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KW941 Pump Power Monitor USER INSTRUCTIONS ENGLISH 71569285 02-12
If the conditions of service on your purchase order are
going to be changed (for example supply voltage or
frequency) it is requested that the user seeks the
written agreement of Flowserve before start up.
1.6 Safety
1.6.1 Summary of safety markings
These User Instructions contain specific safety
markings where non-observance of an instruction would
cause hazards. The specific safety markings are:
This symbol indicates electrical safety
instructions where non-compliance will involve a high
risk to personal safety or the loss of life.
This symbol indicates safety instructions where
non-compliance would affect personal safety and could
result in loss of life.
This symbol indicates “hazardous and toxic
substances” safety instructions where non-compliance
would affect personal safety and could result in loss of
life.
This symbol indicates safety instructions
where non-compliance will involve some risk to safe
operation and personal safety and would damage the
equipment or property.
This symbol indicates explosive atmosphere zone
marking according to ATEX. It is used in safety
instructions where non-compliance in the hazardous
area would cause the risk of an explosion.
This symbol is used in safety instructions to
remind not to rub non-metallic surfaces with a dry
cloth; ensure the cloth is damp. It is used in safety
instructions where non-compliance in the hazardous
area would cause the risk of an explosion.
Always coordinate repair activity with operations and
health and safety personnel, and follow all plant
safety requirements and applicable safety and health
laws and regulations.
1.6.3 Safety action
This is a summary of conditions and actions to help
prevent injury to personnel and damage to the
environment and to equipment.
NEVER DO MAINTENANCE WORK
WHEN THE UNIT IS CONNECTED TO POWER.
LOCK OUT THE POWER SUPPLY.
Dangerous voltages are present in
motor control panels and circuits. INSTALLATION
MUST BE PERFORMED BY QUALIFIED
PERSONNEL!
Improper installation or operation can
cause damage to the unit and can result in an
unprotected pump or nuisance tripping of the pump.
The current transformer/toroid
secondary leads must always be shorted together or
connected to an appropriate measuring device to
provide a suitable burden whenever the primary
circuit is energized. Operation of a current
transformer/toroid with an open secondary will result
in hazardous voltages and destruction of the device!
This sign is not a safety symbol but indicates
an important instruction in the assembly process.
1.6.2 Personnel qualification and training
All personnel involved in the operation, installation,
inspection and maintenance of the unit must be
qualified to carry out the work involved. If the personnel
in question do not already possess the necessary
knowledge and skill, appropriate training and instruction
must be provided. If required the operator may contact
the manufacturer/supplier to provide applicable
training/technical support.
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KW941 Pump Power Monitor USER INSTRUCTIONS ENGLISH 71569285 02-12
1.7 Nameplate and safety labels
1.7.1 Safety labels
2 TRANSPORT AND STORAGE
2.1 Consignment receipt and unpacking
Immediately after receipt of the equipment it must be
checked against the delivery/shipping documents for
its completeness and that there has been no damage
in transportation. Any shortage and/or damage must
be reported immediately to Flowserve Pump Division
and must be received in writing within ten days of
receipt of the equipment. Later claims cannot be
accepted.
Check all crates, boxes or wrappings for any
accessories or spare parts that may be packed
separately from the equipment or attached to side
walls of the box or equipment.
The current senor (toroid) is shipped inside
the KW941 underneath the wiring compartment
cover.
2.2 Handling
The KW941 Power Monitor is small and light so
handling and mounting are easy. The unit weighs
approximately 2.3 kg (5 lbs).
2.3 Storage
1.8 Specific machine performance
For performance parameters see section 1.5, Duty
conditions. Where performance data has been supplied
separately to the purchaser these should be obtained
and retained with these User Instructions.
Store the pump in a clean, dry location
away from vibration. If kept in its original packaging
and protected from excessive environmental effects
like continuous high humidity or corrosive gases the
shelf life would be decades.
2.4 Recycling and end of product life
At the end of the service life of the product or its
parts, the relevant materials and parts should be
recycled or disposed of using an environmentally
acceptable method and in accordance with local
regulations. If the product contains substances that
are harmful to the environment, these should be
removed and disposed of in accordance with current
local regulations. This also includes the liquids
and/or gases that may be used in the "seal system"
or other utilities.
Make sure that hazardous substances are
disposed of safely and that the correct personal
protective equipment is used. The safety
specifications must be in accordance with the current
local regulations at all times.
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KW941 Pump Power Monitor USER INSTRUCTIONS ENGLISH 71569285 02-12
3 DESCRIPTION
3.1 Configurations
The KW941 Pump Power Monitor provides a power
measurement, display and trip-point system to detect
and protect against both UNDERLOAD and
OVERLOAD conditions. The KW941 monitors
MOTOR POWER by sensing both VOLTAGE and
CURRENT. By factoring in motor efficiency, the
KW941 can be scaled to display PUMP POWER. The
adjustable trip-points can be set using power
information provided by the Flowserve Pros+
software for Flowserve pumps.
The KW941 consists of a current sensor and a
Display/Control module. The sensor, through which
one motor power lead passes, normally is located
inside the motor starter panel and provides a sample
of motor current to the Display/Control module. A
voltage sample is provided by a control voltage
transformer (not supplied) located between two of the
three motor power phases. The Display/ Control
module (located outside the starter panel) processes
the current and voltage sample information, contains
the LED display, alarm relays, and provides operator
interface.
Three models of the KW941 Power Monitor are
available based upon the supply voltage at the
customer’s site. The part numbers are listed below:
AY56930B = 110-120v, 60Hz
AY56930C = 220-240v, 50Hz
AY56930D = 220-240v, 60Hz
3.2 Nomenclature
3.2.1 Product Identification Label
3.2.2 Abbreviations
TS = terminal strip
TS1 = terminal strip screw position #1
Jp = jumper
NO = normally open
NC = normally closed
FS = full scale (power)
CR = control relay
MOL = motor overload
3.3 Design of major parts
3.3.1 Enclosure
• Material: polycarbonate, with see-through cover.
• Protection rating: NEMA 4X / IP66. Use only
certified liquid-tight access hole fittings/conduit
hubs to maintain enclosure protection rating.
• Overall dimensions: 182 mm W x 180 mm L x 90
mm H (7.17"W x 7.09"L x 3.54"H).
• Mounting hole spacing: 167 mm W x 173 mm H
(6.57"W x 6.81"H).
• Mounting screws: 4 mm (#8), quantity of four.
• Enclosure can be drilled, sawed or punched for
wiring access holes.
Do not damage the internal
components of the KW941 unit while making access
holes.
3.3.2 Power Requirements
• 110 Vac Model (110/115/120 nominal Vac),
60 HZ @ 0.100 amps
• 220 Vac Models (220/230/240 nominal Vac),
50/60 HZ @ 0.05 amps
• Fuse: (Internal to TS1 #2 VAC connection, not
user accessible.)
• For 110 Vac Models: 200 mA, 125 Vac, Slo
Blo, 5 x 20 mm
• For 220 Vac Models: 100 mA, 250 Vac, Slo
Blo, 5 x 20 mm
Power to the KW941 is supplied by a
(customer-supplied) control voltage transformer
connected between two of the three motor power
supply phases. Power may be supplied by an
existing appropriately connected transformer with
adequate capacity. Consult area codes/regulations
for transformer fusing and grounding requirements.
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KW941 Pump Power Monitor USER INSTRUCTIONS ENGLISH 71569285 02-12
Fusing of the control voltage transformer primary
and/or secondary circuit supplying power to the
KW941 may be required. Please consult local area
electrical codes/regulations.
• Control Voltage Transformer: (Not Supplied)
Rating: 15 VA (Volt Amps) or greater.
• Power On/Off Switch: (Not Supplied)
No On/Off switch is provided with the
KW941. It is intended to be On (operational)
whenever power is supplied to the motor starter
control circuits, whether or not the motor is running,
so that it can be set up prior to starting the equipment
and provide protection on startup. The transformer
supplying power to the KW941 is normally installed
ahead of the motor starter contactor but after the
starter power disconnect switch, so that power can be
turned off with the disconnect switch. If required, the
control transformer circuit supplying power to the
KW941 can be switched.
3.3.3 Wiring and Grounding
• Maximum TS1 connection wire size: #14 AWG.
• Use wire with adequate insulation and current
carrying capability for the application.
• Terminal TS1 #1 is internally connected to the
KW941's metal chassis. Connect this point to
earth ground.
• Use of metallic conduits will require bonding
between the conduits.
PLEASE FOLLOW ALL AREA
ELECTRICAL CODES/REGULATIONS!
3.3.4 Full Scale Range
• 0.7 to 112 KW (1 to 150 HP) @ 460 Vac, 50/60
Hz three phase power with the supplied current
sensor (toroid).
• Contact Flowserve Engineering for higher power
capabilities (to 999 hp with auxiliary current
sensor) and for special applications.
3.3.5 Current Sensor (also known as a toroid or
current transformer)
• 200 amp (primary), current sensing toroid
• 12" #24 AWG leads
• Max lead extension length = 30.5 m (100 feet).
• O.D: 51 mm (2.0 in.)
• I.D.: 18 mm (0.7in.) – this limits the maximum
wire size that can go through current sensor.
• Ht.: 20 mm (0.8 in.)
3.3.6 Alarm Output Relay Contacts
5 amps @ 125 VAC
3 amps @ 277 VAC
5 amps @ 30 VDC
3.3.7 Analog Output
• 4 to 20 milliamp source, proportional to full
scale.
• Maximum loop load resistance = 600 Ohms.
3.3.8 Digital Display
• 3 digit, 0.6" high, seven segment, red LED.
• Displays 0.0 to 999
3.3.9 Timers
• Start-Up Delay Timer: Adjustable 0 to 999
seconds.
• Trip Delay Timers: Adjustable 0 to 999 seconds.
3.3.10 Remote Reset
• Momentary external mechanical or solid state
switch to conduct < 200 microamps DC between
"RESET +" and "RESET -" terminals.
• Reset input specifications (for use with solid
state logic switch resets)
• For NORMAL operation: +2 to +5 VDC
between reset terminals
• For RESET: -0.3 to +0.8 VDC between reset
terminals (minimum pulse width 20
milliseconds).
3.4 Performance and operation limits
Operating Temperature: -40 to 70 °C (-40 to 158 °F) .
Effective toroid power limit = 112 KW (150 HP)
Power monitoring using only the supplied
current sensor is limited by its 200 amp current limit
and the size of the motor lead that can fit through the
toroid’s internal diameter (18 mm (0.7 in.)).
Use of a second current transformer in series with the
supplied toroid can allow the KW941 to monitor
power levels up to 745 KW (999 HP).
Supply voltage should not exceed 230 Vac at 50 Hz
or the internal fuse may blow.
Unbalanced power line/load conditions will affect
power readings.
The motor efficiency value used during initial setup
(Section 4 Installation) affects the KW941 power
reading displayed.
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KW941 Pump Power Monitor USER INSTRUCTIONS ENGLISH 71569285 02-12
4 INSTALLATION
Dangerous voltages are present in
motor control panels/circuits. Make sure power is off
and locked out during installation.
INSTALLATION MUST BE PERFORMED BY
QUALIFIED PERSONNEL!
The KW941 Pump Power Monitor and its
current sensing toroid must not be installed in a
potentially explosive atmosphere.
It is important to be aware of the EUROPEAN
DIRECTIVE on electromagnetic compatibility when
wiring up and installing equipment on site. Attention
must be paid to ensure that the techniques used
during wiring/installation do not increase
electromagnetic emissions or decrease the
electromagnetic immunity of the equipment, wiring or
any connected devices. If in any doubt, contact
Flowserve for advice.
The Flowserve KW941 Pump Power
Monitor has a CE Mark approval for EMC and Low
Voltage Directive Compliance.
4.1 Location
The KW941 Display/Control module can be mounted
on the outside of the motor starter panel or a nearby
wall or structure. Use the four corner mounting screw
holes located below the see - through front cover
screws. Refer to Figure 4.1 for mounting dimensions.
The KW941 Display/Control module can be located
up to 30.5 m (100 ft.) from the motor lead that must
run through the current sensor (toroid). This is the
length limit for extending the toroid leads.
Figure 4.1
4.2 Electrical connections
Connections are made in the wiring compartment,
accessible by removing the separate cover plate on
the lower portion of the KW941. Loosen the two
thumbscrews to remove the cover plate (see Figure
4.2).
Figure 4.2
Entry for wiring/conduit is made by drilling, sawing or
punching the required hole(s) into the wiring
compartment area. Use caution when making access
holes to prevent damage to the internal components.
The following information is required for installation:
1) Motor Nameplate Full Load Power
2) Motor Nameplate Voltage and Hertz (Hz)
3) Control Volts (110 or 220/240 VAC) from
transformer between motor power phases.
4) Motor efficiency.
Record this information on the worksheet provided in
Section 8 of this manual.
4.2.1 Control Voltage
Refer to the product identification label on the outside
of the KW941 enclosure for the selected factory
preset VAC and HZ options (110/120 or 220/240
VAC, 50 or 60 HZ).
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