Kolmeks AE-25/4FC, AE-26/2FC, AE-26/4FC, AE-32/4FC, AE-33/2 Operating Instructions Manual

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SARJAT

AE_-, L_-, AL_-, T- and AT-

OPERATING INSTRUCTIONS

CENTRIFUGAL PUMPS WITH INTEGRATED FREQUENCY CONVERTER

FC_ -SERIES

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Content

1. General ............................................................................................ 3

1.1 Symbols ................................................................................................................................................ 3

1.2 Applications ........................................................................................................................................ 3

1.3 Manufacturer ...................................................................................................................................... 3

1.4 Version ................................................................................................................................................. 3

2.1 Handling, transport and storage of the pump .................................................................................. 4

2. Handling, transport and storage of the pump ............................4

3. Design and function ......................................................................4

3.1 Construction ........................................................................................................................................ 4

3.2 Technical data ..................................................................................................................................... 4

3.3 Rating plate ....................................................................................................................................... 5

3.4 Pump identiﬁcation ........................................................................................................................... 5

4. Safety ............................................................................................6

4.1 Safety instructions ............................................................................................................................. 6

4.3 Elements of danger if safety regulations are not obeyed ............................................................... 6

4.4 Safety instructions for inspection and assembly ............................................................................. 6

4.2 Training ............................................................................................................................................... 6

4.5 Operating the pump........................................................................................................................... 6

5. Installation, introduction and start-up ........................................ 6

5.1 General ................................................................................................................................................. 6

5.2 Positions for installation ....................................................................................................................7

5.3 Electrical connections .........................................................................................................................7

5.4 Control methods and connections .................................................................................................... 8

5.4.1 I/O’s of the FC-pump (inputs and outputs) .................................................................................... 8

5.4.2 Factory settings .............................................................................................................................. 8

5.4.3 FCA -pump - speed reference from potentiometer ...................................................................... 9

5.4.4 FCB -pump - constant pressure between the pump ﬂanges ......................................................10

5.4.5 FCC -pump - constant pressure between inlet- and outlet-line ...................................................11

5.4.6 FCCVAK -pump - constant pressure between supply- and return-line with

external controller in use (SETUP 1) ....................................................................................................... 12

5.4.7 FCCVAK -pump - constant pressure between supply- and return-line with

controller of the frequency converter in use (SETUP 2) ........................................................................ 13

5.4.8 FCD -pump - constant pressure in discharge ﬂange ....................................................................14

5.4.9 FCE -pump - sensorless, pre-programmed pump curves ............................................................15

5.4.10 FCF -pump - constant temperature ............................................................................................ 16

5.4.11 FCF -pump - the speed according to temperature ...................................................................... 17

5.4.12 FCG -pump - controlled by external system ................................................................................18

5.4.13 Connections to the alarm receiving station .................................................................................19

5.4.14 Local control panel (optional) ...................................................................................................... 20

6. Service, spare parts and troubleshooting .................................. 22

6.1 Shaft seals......................................................................................................................................... 22

6.2 Other parts ....................................................................................................................................... 22

6.3 Troubleshooting ............................................................................................................................... 23

7. Declaration of Conformity ........................................................... 27

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1. General

1.1 Symbols

Warns that failure to observe the precaution may cause personal injury or damage to property.

Warns that failure to observe the precaution may cause electric shock

Indicates something to be noted by the reader.

1.2 Applications

The most common applications are heating, air condition, cooling systems. Also heat exchangers, pressure boosting systems, district heating systems, ice halls, public baths and industrial processies.

Pump series Applications

AE-, L-, AL-, T-, AT-

L-, ALH-

AEP-, LP-, ALP-

Clean, thin, non-aggressive liquids.

- circulating water in for heating and cooling systems

- water-glycol mixtures. Recommendation: propylene glycol

- nominal pressure 10 bar.

- like in L- and AL -series, but nominal pressure 16 bar.

Clean, thin, slightly aggressive liquids.

- domestic water, oxygen rich waters

- nominal pressure 10 bar.

Agressive, thin, not bigger solid particles containing liquids

LS-, ALS-

All types of

- in addition to above mentioned liquids various acids, salts, oxidizing and chemically active organic ﬂuids

- nominal pressure 16 bar.

Temperature range: -10 ... + 95 °C (continuous + 80°C) Max. temperature of environment +40°C (diurnal average max. +35°C)

FC-pumps

Suitability of materials and seals for pumped liquid shall be always checked between purchaser and supplier.

The nominal pressure and the max. temperature of pumped liquid are stamped on the pump rating plate. Never use the pump in any other application or conditions without manufacturer’s acceptance. In the case of damage there may be danger to persons by having poisoning, burns, wounds etc. depending on the pumped liquid and it’s temperature and pressure. The pump surface temperature may cause danger depending on the working conditions.

1.3 Manufacturer

This product is manufactured by OY KOLMEKS AB, P.O.BOX 27, FIN-14201 TURENKI, FINLAND.

1.4 Version

Release date of this manual is 04.01.2005. This is version no. 5.

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2. Handling, transport and storage of the pump

2.1 Handling, transport and storage of the pump

Normally the pumps are stable when they are transported and don’t go down even they are bent 10°. Pumps shall be stored in a dry and cool place protected from dust. Temperature of environment must be in -10 °C ... +50°C. It is not allowed to lift the pump from frequency converter. In the case of longer storage time or the pump serves as a stand-by, it is recommended to rotate the pump manually f.ex. from the motor fan at least once a month.

3. Design and function

3.1 Construction

The pump and motor constitute a unit, where the rotating parts of both the pump and the motor are on the same shaft (mono-block design). The motor is of a dry type and the frequency converter is integrated to the electric motor.

Electric motor: Totally enclosed, fan cooled A.C. motor, with frequency converter. Protection form: IP54 Insulating class: F

3.2 Technical data

Pump type Flanges Weight kg

power kW A (400 V) AE_-25/4,-26/4FC_ G 1 15 0,27 0,53 -

AE_-25/2,-26/2FC_ G 1 20 0,85 1,5 AE-32/4, -33/4FC_ G 1 1/4 20 0,5 0,9 AE-32/2, -33/2FC_ G 1 1/4 20 1,5 2,6 L_-32A/4FC_ DN32 19 0,27 0,53 T-32A/4FC_ L_-32A/2FC_ DN32 25 0,85 1,5 T-32A/2FC_ L_-40A/4FC_ DN40 25 0,5 0,9 T-40A/4FC_ L_-40A/2FC_ DN40 29 1,5 2,6 T-40A/2FC_ L_-50A/4FC_ DN50 33 0,7 1,4 T-50A/4FC_ L_-50C/2FC_ DN50 49 2,5 4,5 T-50C/2FC_ L_-65A/4FC_ DN65 47 0,7 1,4 T-65A/4FC_ L_-65A/4FC_ DN65 56 1,6 2,6 T-65A/4FC_ L_-65A/4FC_ DN65 67 2,8 4,7 T-65A/4FC_ L_-65B/2FC_ DN65 69 4,3 6,9 T-65B/2FC_ L_-65B/2FC_ DN65 100 8,0 12,4 T-65B/2FC_ L_-80A/4FC_ DN80 48 0,7 1,4 T-80A/4FC_ L_-80A/4FC_ DN80 62 1,6 2,6 T-80A/4FC_ L_-80A/4FC_ DN80 76 3 4,9 T-80A/4FC_ L_-80A/2FC_ DN80 74 4,3 6,9 T-80A/2FC_ L_-80A/2FC_ DN80 105 8,0 12,4 T-80A/2FC_ AL_-1032/4FC_ DN32 25 0,5 0,9 T-40A/4FC_ (DN40) AL_-1032/2FC_ DN32 29 1,5 2,6 T-40A/2FC_ (DN40) AL_-1066/4FC_ DN65 47 0,7 1,4 T-65A/4FC_ AL_-1066/4FC_ DN65 56 1,6 2,6 T-65A/4FC_ AL_-1066/4FC_ DN65 67 2,8 4,7 T-65A/4FC_ AL_-1065/2FC_ DN65 69 4,3 6,9 T-65B/2FC_ AL_-1065/2FC_ DN65 100 8,0 12,4 T-65B/2FC_ AL_-1081/4FC_ DN80 62 1,6 2,6 T-80A/4FC_ AL_-1081/4FC_ DN80 76 3 4,9 T-80A/4FC_ AL_-1081/2FC_ DN80 74 4,3 6,9 T-80A/2FC_ AL_-1081/2FC_ DN80 105 8,0 12,4 T-80A/2FC_ AL_-1102/4FC_ DN100 70 1,6 2,6 AT-1102/4FC_ AL_-1102/4FC_ DN100 86 3,7 5,8 AT-1102/4FC_ AL_-1106/4FC_ DN100 170 4,4 7,2 AT-1129/4FC_ AL_-1106/4FC_ DN100 200 8,3 13,0 AT-1129/4FC_ AL_-1129/4FC_ DN125 175 4,4 7,2 AT-1129/4FC_

AL_-1129/4FC_ DN125 205 8,3 13,0 AT-1129/4FC_

Max. input Nominal current Twin pump

Noise level of all pump types is under 70 dB (A, 1 m).

Single pump weight (AL). The weight of the twin pump (T/AT) is depending on the size of the motor and equipment

each unit. The weight of the twin pump is about two times the single pump weight.

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3.3 Rating plate

Shows the information about the electric motor and also design data of the pump.

LP-50A/4FCC1045 S6 K2 V1-C320001

123456/04

OKFC-100 B2 F15

400

5 - 30

1,4

135

0,45

0,70

3.4 Pump identiﬁcation

Pump series:

L_= single in-line pump, with ﬂanges AL_= single in-line pump, with ﬂanges AT,T = twin in-line pump, with ﬂanges AE = single in-line pump, with pipe connection

Material of pump housing, sealing ﬂange and impeller / nominal pressure of the pump:

no letter = grey cast iron EN-GJL-200 / 10 bar H = nodular cast iron EN-GJS-400 / 16 bar P = bronze CuPb5Sn5Zn5 / 10 bar S = stainless steel AISI 316 / 16 bar

Flange sizes:

AE_: 25/26 = G 1 32 = G1 1/4

AL_/AT: x03 = DN 32 x05 = DN 50 x06 = DN 65 x08 = DN 80 x10 = DN 100 x12 = DN 125

L_/T: 40 = DN 40 50 = DN 50 65 = DN 65 80 = DN 80 100 = DN 100 125 = DN 125

L P - 50 A / 4 FC C 10 45

Version number (AL/AT) or letter (L_ /T)

Poles of the electric motor:

2 = rotation speed 50 r/s (50 Hz) 4 = rotation speed 25 r/s (50 Hz) rotation speed 30 r/s (60 Hz)

FC = the frequency converter is integrated to the motor

Control method:

A, B, C, D, E, F, G (please check 5.4 Control methods and connections)

The range of the pressure (dierence) transmitter:

Examble: 10 = 0 - 1 bar 60 = 0 - 6 bar

Control range (depending on pump type): Examble:

45 = 0,5 - 4,5 m 80 = 0,5 - 8 m 20 = 2 - 20 m 60 = 1 - 6 bar

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4. Safety

This manual includes important information concerning installation and operating the pump. Persons who are involved in installation or/and operation of the pump, should read and understand these instruction before installation or starting the pump.

There are live parts inside the frequency converter, when the supply voltage is connected. Incorrect installation may cause damage to the pump or bodily injuries, even death. Touching the live parts may be mortal even the supply voltage is disconnected. Wait at least 4 minutes! Obey instructions of this manual and national and local requirements and standards.

- installation must be protected by fuses and insulated correctly.

- covers and cable inlet must be installed.

Attention: It is user’s or certﬁed electrician’s responsibility to ensure the correct earthing and protection in accordance with applicable national and local requirements and standards.

4.1 Safety instructions

1. FC-pump must be disconnected from the mains if repair work is to be carried out. Check that the mains supply has been disconnected and necessary time has passed (at least 4 minutes).

2. The device must be connected correctly to the earth. User must be protected from supply voltage and the pump must be protected from short circuit according to the national and local requirements and standards. The overload protection is included in FC -pump.

3. Earth leakage is more than 3,5 mA. It means, that installation of supply cable must be ﬁxed.

4.2 Training

The persons who have responsibility for installing or/and operating the pump, should be trained.

4.3 Elements of danger if safety regulations are not obeyed

If the safety regulations are not obeyed, personal injuries or damage to the pump or related devices may occur. Validity safety instructions must be obeyed.

4.4 Safety instructions for inspection and assembly

it is user’s responsibility to ensure that persons who carry out inpections and installations are qualiﬁed experts and familiarized themselves with these instructions carefully.

4.5 Operating the pump

Working safety of the delivered pump and related devices can be ensured only if these devices are operated according to the section 1.2 Applications of this manual.

5. Installation, introduction and start-up

5.1 General

The position of the motor unit with the frequency converter can be changed by removing the motor unit from the pump housing and setting it to the desired position (not in LH- and ALH-serie and in FCB, FCC ja -FCD-types with certain limitations).

When installating the pump pay attention to the following:

- space enough for service and inspection of the pump

- free visibility to the scale of the potentiometer and curve plate of the pump.

- possibility to use lifting mechanism if needed

- shut-o valves on the both sides of the pump

- the frequency converter is not too close hot pipes.

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5.2 Positions for installation

Allowed positions

Allowed positions, if the pipes of the pressure dierence transmitter are not installed to the ﬂanges of the

pump

Not allowed positions

5.3 Electrical connections

All electrical work shall be carried out by qualiﬁed electrician approved by the local authorities. Supply voltage may be connected with standard cable, screened cable is not required. Ensure, that the nominal voltage of the electric motor corresponds the local supply voltage.

Use always screened control cables.

ATTN

Before starting the pump ﬁll and vent the system. Make sure that the pump rotates freely by rotating it manually f.ex. from the motor fan. Never start or let the pump run dry.

Before starting the pump ﬁll and vent the system. After starting make sure that there is no extra noise coming from the pump and that no leakages appear.

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5.4 Control methods and connections

5.4.1 I/O’s of the FC-pump (inputs and outputs)

Terminal 1 / X101 analog input 0-20 or 4-20 mA (dierent possible functions)

Terminal 2 / X101 analog input 0-10V or digital input (dierent possible functions)

Terminals 3, 4 and 5 / X101 digital input (dierent possible functions)

Terminal 6 / X101 24 V DC supply for digital inputs and feedback (max. 150 mA )

Terminal 7 / X101 10 V DC supply for potentiometer (max. 15 mA )

Terminal 8 / X101 0 V for terminals 1-7 ja 9

Terminal 9 / X101 analog or digital input (dierent possible functions,

Relay output: Terminals 1, 2 and 3 / X102 relay output (dierent possible functions), potential free change-over

contacts, max. 250 V / 5 A

5.4.2 Factory settings

Terminal 1 / X101. No operation (setup1) or Feedback 4-20 mA (setup2) depending on selected control method.

Terminal 2 / X101. Speed reference 0-10V (setup1) or Reference of controller 0-10V (setup2) depending on selected

control method.

Terminal 3 / X101. Setup selection. Terminals 6-3 open/closed means setup1/setup2 selected. If setup1 is selected, speed reference 0-10V is connected to the terminals 2-8 with potentiometer or external signal. The speed of the pump is controlled according to the voltage signal. If the voltage is selected with potentiometer, the speed is constant. When Setup2 is selected the controller of frequency converter is in use. The reference of controller 0-10V is connected to the terminals 2-8 with potentiometer or external signal. Feedback signal 4-20 mA is connected to the terminal 1. The speed of the pump changes according to the need of regulation.

Terminal 4 / X101. Stop / Start. Terminals 6-4 open means pump is not running, closed means pump is running.

Terminal 5 / X101. Reference freeze (both setup’s). When terminals 5 and 6 are connected, the speed reference (se-

tup 1) or the reference of the controller (setup 2) is freezed (not possible to change with potentiometer). By disconnecting the wire between terminals 5 and 6, reference (0-10V) to the terminal 2 / X101 is in use.

Terminal 9 - (8) / X101. Digital output signal (24VDC, max. 25 mA) - fault. The voltage in termina indicast the fault in the pump / inverter. Voltage is zero, if the supply voltage is not connected or there is no fault. If the potential free contact is needed, the separate relay (24 VDC, < 25 mA) is needed. Please check the wiring diagram in section 5.4. This terminal is possible to program with separate local control panel (not included is standard delivery) to an other digital or analog output. E.g. 0 (4) - 20 mA analog output for frequency, reference, feedback, etc.

Relay output: Terminals 1, 2 and 3 / X102. Terminals 1 and 2 are connected when motor is running. Terminals 1 and 3 are connected when motor is not running (or the supply voltage is not connected).

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5.4.3 FCA -pump - speed reference from potentiometer

Applications

Systems, where the duty point remains constant and where is no need for continuous automated regulation.

Accessories

Pump, frequency converter and potentiometer.

Operation principle

The speed of electric motor can be adjusted manually at the site. Useful feature for commissioning of the pump. The pump will run with constant speed. The reference can be freezed by connecting wire between terminals 5 and 6.

ATTN

Mark the position of the potentiometer to the sticker in cover of the frequency converter.

Pump curve

QH-curve of the pump is equal with that of single speed pump.

Standard control connections

FACTORY DEFAULT: SETUP 1 SETUP 1 = speed reference (FCA) SETUP 2 = controller of the frequency converter in use, e.g. FCB, FCC

l/s

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min.

An example of curve plate of FCA -pump.

The control range is shown in curve plate which is located in cover of the frequency converter.

Subject to change without prior notice

max.

5.4.4 FCB -pump - constant pressure between the pump ﬂanges

Applications

Systems, where are variations in the ﬂow and where pressure losses are generated mainly on the consumption equipment. Heating circulation, where the pressure loss on the heat exchanger is small.

Accessories

Pump, frequency converter, potentiometer and dierential pressure transducer with pipes to the pump ﬂange.

Operation principle and ﬂow adjustment

The level of the constant pressure dierence between the pump ﬂanges can be adjusted by potentiometer. The set value for the pressure dierence can be found from the curve plate of the pump. The pump will run with variable speed. When adjusting the ﬂow of the system, the main control valve must be opened as open as possible and then the ﬂow is adjusted by potentiometer. The reference can be freezed by connecting wire between terminals 5 and 6.

ATTN

Mark the position of the potentiometer to the sticker in cover of the frequency converter.

Pump curve

QH-curve of the pump is controlled to a horizontal line.

Standard control connections

FACTORY DEFAULT: SETUP 2 SETUP 2 = constant pressure dierence (FCB, controller of the frequency converter in use) SETUP 1 = speed reference (FCA)

l/s

By disconnecting the wire from potentiometer to the terminal 2 and connecting the external 0-10V signal to the terminals 2-8, the reference for pressure dierence is given externally. Please check section 5.4.7.

dierential pressure transducer

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min.

An example of curve plate of FCB -pump.

The control range is shown in curve plate which is located in cover of the frequency converter.

Subject to change without prior notice

max.

5.4.5 FCC -pump - constant pressure between inlet- and outlet-line

Applications

Systems, where are variations in the ﬂow and where pressure losses are generated mainly on the source of heat equipment. Heating and cooling circulations and the pressure boosting of parellel circulations.

Accessories

Pump, frequency converter, potentiometer and dierential pressure transducer with pipes. One pipe to be installed to the suction or pressure ﬂange of the pump and the another one on to the system, inlet or outlet pipe.

Operation principle and ﬂow adjustment

The level of the constant pressure dierence between the inlet- and outlet-line of the system can be adjusted by potentiometer. The set value for the pressure dierence can be found from the curve plate of the pump. The pump will run with variable speed. When adjusting the ﬂow of the system, the main control valve must be opened as open as possible and then the ﬂow is adjusted by potentiometer. The reference can be freezed by connecting wire between terminals 5 and 6.

ATTN

Pump curve

QH-curve of the pump is controlled to a quadratic. The relation of pressure loss in the source of heat (cold) to the loss in the system deﬁnes the shape of the curve.When the losses in the heat exchanger are large part of the whole losses in the system the curve is more steep.

Mark the position of the potentiometer to the sticker in cover of the frequency converter.

Standard control connections

FACTORY DEFAULT: SETUP 2 SETUP 2 = constant pressure dierence (FCC, controller of the frequency converter in use) SETUP 1 = speed reference (FCA)

l/s

By disconnecting the wire from potentiometer to the terminal 2 and connecting the external 0-10V signal to the terminals 2-8, the reference for dierential pressure is given externally. Please check section 5.4.7.

min.

max.

An example of curve plate of FCC -pump.

dierential pressure transducer

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The control range is shown in curve plate which is located in cover of the frequency converter.

Subject to change without prior notice

5.4.6 FCCVAK -pump - constant pressure between supply- and return-line with external controller in use (SETUP 1)

Operation principle (speed reference 0-10 V for pump)

The level of the constant pressure dierence between the inlet- and outlet-line of the system can be adjusted by external control system (speed reference 0-10 V to the terminal 2).

Flow adjustment and balansing the system

Before adjusting and balancing the system the dierential pressure transducer is connected to the external control system. The main control valve must be opened as open as possible and then the ﬂow is adjusted by potentiometer, which is connected to the terminal 2 (constant speed) to replace external speed reference while adjusting and balancing the system. When the system has adjusted and balanced, the value of the pressure dierence is read and saved to the control system as a reference value.

Alternatively the correct pressure dierence value can be adjusted with potentiometer when the pump is connected as a standard FCC -pump (check the previous page). When the system has adjusted and balanced, the reference of the pressure dierence (m) can be read from the scale of the potentiometer (e.g. 20 % = 1.7 m), which is then saved as a reference value to the external control system.

Check and update the connections!

Standard control connections

FACTORY DEFAULT: SETUP 1 SETUP 1 = speed reference from external controller (FCCVAK1) SETUP 2 = reference for dierential pressure from external control system (controller of the frequency converter is in use, FCCVAK2)

In the cover of the frequency converter is curve plate, where the set value for the pressure dierence can be found in ratio (%) to the range of the reference of the pressure dierence and to the position of the potentiometer. Curve plate is valid, when setup2 is selected, terminal 6-3 is closed. According to the factory default, the setup1 is selected, speed reference 0 V corresponds the minimum speed and 10 V corresponds maximum speed. The rotation speed unit is r/s, which is marked in the rating plate. The corresponding frequencies are minimum 10 Hz and maximum 50 or 60 Hz. The datasheet, where the pump curves can be read with dierent frqeuncies, is also delivered with this version.

The switch in external control system between terminals 4-6 väliin (e.g. automatic summer stoppage).

*) When pump is delivered from the factory, the wire of the potentiometer is connected to the terminal 2 then the pump can be operated as FCA -pump. By disconnecting the wire and connecting the external voltage signal to the terminal 2, the pump is controlled externally.

dierential pressure transducer

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An example of curve plate of FCCVAK -pump.

The control range is shown in curve plate which is located in cover of the frequency converter.

Subject to change without prior notice

5.4.7 FCCVAK -pump - constant pressure between supply- and return-line with controller of the frequency converter in use (SETUP 2)

Operation principle (reference for pressure dierence 0-10 V for pump)

The level of the constant pressure dierence between the inlet- and outlet-line of the system can be adjusted by external control system (reference for dierential pressure 0-10 V to the terminal 2). The operation and connections are the same like in FCC -pump (section 5.4.5), except the reference for pressure dierence in given from the external control system.

Standard control connections

FACTORY DEFAULT: SETUP 2 SETUP 2 = reference for dierential pressure from external control system (controller of the frequency converter is in use, FCCVAK2) SETUP 1 = speed reference from external controller (FCCVAK1)

The switch in external control system between terminals 4-6 (e.g. automatic summer stoppage).

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5.4.8 FCD -pump - constant pressure in discharge ﬂange

Applications

Pressure boosting or other open systems, where constant pressure is required.

Accessories

Pump, frequency converter, potentiometer and pressure transmitter with pipes. The pressure transmitter is installed to the pressure ﬂange of the pump or near to the consumtion in the pipe line.

Operation principle

The level of the constant pressure on the pressure ﬂange of the pump or on the outlet-line of the system can be adjusted by potentiometer. The set value for the pressure dierence can be found from the curve plate of the pump. The pump will run with variable speed. The reference can be freezed by connecting wire between terminals 5 and 6.

ATTN

Mark the position of the potentiometer to the sticker in cover of the frequency converter.

Standard control connections

FACTORY DEFAULT: SETUP 2 SETUP 2 = constant outlet pressure (controller of the frequency converter is in use, FCD) SETUP 1 = speed reference from potentiometer (FCA)

min.

max.

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An example of curve plate of FCD

-pump.

The control range is shown in curve plate which is located in cover of the frequency converter.

*) Pressure switch for dry run protection can be connected between terminals 6-4. Pressure switch is not included in standard delivery.

Subject to change without prior notice

5.4.9 FCE -pump - sensorless, pre-programmed pump curves

Applications

Systems, where are variations in the ﬂow. Heating and cooling circulations and the pressure boosting of parellel circulations.

Accessories

Pump, frequency converter and potentiometer.

Operation principle, pump curve and adjusting the ﬂow

The pump curve is selected with potentiometer from the curve plate. The selection is stepless. When adjusting the ﬂow of the system, the main control valve must be opened as open as possible and then the ﬂow is adjusted by potentiometer.

ATTN

Mark the position of the potentiometer to the sticker in cover of the frequency converter.

Standard control connections

FACTORY DEFAULT: SETUP 2 SETUP 2 = variable pressure (FCE) SETUP 1 = speed reference from potentiometer (FCA)

l/s

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min.

max.

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5.4.10 FCF -pump - constant temperature

Applications

Heating and cooling systems, where the constant temperature is required.

Accesories

Pump, frequency converter, potentiometer, temperature transmitter (and sensor).

Operation principle

The constant temperature, which is adjusted by potentiometer, is kept up by regulating the ﬂow. The reference can be freezed by connecting wire between terminals 5 and 6.

ATTN

When ordering the pump, the response of the control must be informed. In the heating system the response is normal, in the cooling system inverse.

Mark the position of the potentiometer to the sticker in cover of the frequency converter.

Standard control connections

FACTORY DEFAULT: SETUP 2 SETUP 2 = constant temperature (FCF1, controller of the frequency converter in use) SETUP 1 = speed reference (FCA).

By disconnecting the jumper between terminals 3-6 (setup1), the pump is running at constant speed (FCA -pump).

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min.

max.

An example of curve plate of FCF

-pump.

The control range is shown in curve plate which is located in cover of the frequency converter.

Subject to change without prior notice

5.4.11 FCF -pump - the speed according to temperature

Applications

Heating and cooling systems, where the ﬂow is controlled by temperature.

Accesories

Pump, frequency converter, potentiometer, temperature transmitter (and sensor).

Operation principle

The speed reference is given by temperature transmitter.

ATTN

When ordering the pump, the response of the control must be informed. In the heating system the response is normal, in the cooling system inverse.

Mark the position of the potentiometer to the sticker in cover of the frequency converter.

Standard control connections

FACTORY DEFAULT: SETUP 2 SETUP 1 = speed reference (FCA) constant temperature (FCF, controller of the frequency converter in use) SETUP 2 = speed referense according to the temperature (FCF2)

By disconnecting the jumper between terminals 3-6 (setup1), the pump is running at constant speed (FCA -pump).

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5.4.12 FCG -pump - controlled by external system

Applications

Systems, where are variations in the ﬂow and/or where the ﬂow is controlled mainly with the pump. The pump is controlled by external system or controller.

Accessories

Pump, frequency converter, potentiometer (for FCA -connections).

Operation principle

The speed reference for pumps is given from external control system, external controller, process control, etc.

Standard control connections

FACTORY DEFAULT: SETUP 1 SETUP 1 = speed reference 0-10 V (FCA, from potentiometer or FCG from external controller) SETUP 2 = controller of the frequency converter in use (e.g. FCB, FCC)

The switch in external control system between terminals 4-6 väliin (e.g. automatic summer stoppage). When pump is delivered from the factory, the wire of the potentiometer is connected to the terminal 2 then the pump can be operated as FCA -pump

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5.4.13 Connections to the alarm receiving station

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5.4.14 Local control panel (optional)

The FC_ -pump optionally features a Local Control Panel - LCP, which makes up the complete interface for operation and monitoring of the FC_ -pump.

LCP installation

LCP is connected to the terminal X100, 1-4

LCP functions

The functions of the control panel can be divided into three groups:

- display

- keys for changing program parameters

- keys for local operation

All data are indicated by means of 4-line alpha-numeric display, which in normal operation is able to show 4 measurements and 3 operation conditions continuously. During programming, all the information required for quick, eective parameter setup of the FC_ -pump will be displayed. As a supplement to the display, there are three LEDs for voltage, warning and alarm. All programming parameters of the FC_ -pump can be changed immediately from the control panel, unless this function has been blocked vial parameter 018.

Control panel is connected to these terminals

Reference, value of potentiometer (or other value which is deﬁned in

parameter 010))

Motor current or other value which is deﬁned in parameter 011

Feedback value or other value which is deﬁned in parameter 012

Frequency or other value which is deﬁned in parameter 009. Active warnings and alarms.

Mode. Normal: REM RUN OK

DISPLAY STATUS - changes the ﬁrst line from headline to analog values. If button is hold, the titles of the analog values are shown: REF. , CURR. , FEEDB. eferense, motor current and feedback)

By pushing CHAN- GE DATA button the submenu of paramater setup is selected.

Active setup. Setup1 speed reference (A- or G-version ), Setup2 Reference control ( B,C,D)

With MENU button the parameter mode is selected.

With OK button the changes are conﬁrmed. Sometimes the change is conﬁrmed without pushing OK.

With CANCEL button you'll get back without conﬁrming the changes, if OK is not pushed.

START button. FC-pump must be left to RUNNING MODE before disconnection of control panel!!

After pushing MENU button, parameter group 0 … 9 are selected with these narrow buttons or after pushing CHANCE DATA but- ton the required decimal is selected with these narrow buttons.

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With +/- buttons the large reading can be selected. 23 dierent option eg. the feedback mA or reference V also motor power, current, temperatures etc. Parameters are selected with +/- button after pushing MENU button and selection parameter group with narrow buttons. After pushing CHANCE DATA button with +/- buttons is the new value of the parameter selected

Subject to change without prior notice

Exambles

Checking of the duty poin of the pump:

Push DISPLAY STATUS button once and read the values of ﬁrst line. Normally the ﬁrst value is reference, the second is motor current and the third is feedback (if the setup 1 is selected the third value is power). If DISPLAY STATUS is hold, the titles of the analog values are shown. ( REF. (reference), CURR. (motor current) and FEEDB. (feedback)

Checking and changing of the numerical parameter: e.g. swithing frequency from 8000 Hz to 7000 Hz ( parameter No 411 ). Push MENU button once, then the number of the parameter group is on the bottom line. If necessary push narrow buttons until required group (4..) is selected. Push + or - buttons until parameter 411 is on the bottom line. Also the present value is shown. Push CHANCE DATA button to select the parameter changing mode. Move the ﬂashing cursor with narrow buttons to the digit which is to be changed. Change the digit with + or - buttons. The new value becomes eective immediately, but the selection must be conﬁrmed with OK button. Push DISPLAY

STATUS button to return to the ﬁrst display.

Checking and changing of the text parameter:

e.g. parameter 437 changing from NORMAL to INVERSE (application: temp. control in coolling system). Push MENU button once, then the number of the parameter group is on the bottom line. If necessary push narrow buttons until required group (4..) is selected. Push + or - buttons until parameter 437 is on the bottom line. Also the present value is shown. Push CHANCE DATA button to select the parameter changing mode. Change the value with + or - buttons. Conﬁrm the selection with OK button. ATTENTION! All parameters are not allowed to change without stoppage of the pump with STOP RESET button. After changing parameters start the frequency converter always with START button.

Checking of the analog mA -value of the feedback transmitter (terminal N:o 1):

In ﬁrst display (if necessary push ﬁrst DISPLAY STATUS) push + or - buttons until to the ﬁrst line comes the text ANALOG INPUT 1. The large value in display is the mA -value of the feedback transmitter. The value must be over 4 mA lower than 20 mA in the normal situation. In the same way is checked the reference V -value ANALOG INPUT 2. The value must be over 0 V but lower than 10 V in the normal situation.

Checking of fault log (parameter 615):

Push MENU button once, then the number of the parameter group is on the bottom line. If necessary push narrow buttons until required group (6..) is selected. Push + or - buttons until parameter 615 is on the bottom line. Push CHANCE DATA button to select the parameter reading mode.

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6. Service, spare parts and troubleshooting

The pump doesn’t need any regular servicing. As a shaft seal is used an adjustment free mechanical seal. It is a wearing part which has to be replaced if it starts to leak. Note that few drops leakage per hour can be quite normal especially when coolants (f.ex. glycol) are pumped.

6.1 Shaft seals

Pump type Shaft O-ring mm / gasket mm AE_-25/-26 FC_ 12 123x2,5 L-32A FC_ 12 100x2,5 L_-40A, AL_-1032, AE_-32/-33 FC_ 12 145x2,5 L_-50A, AL_-1054 FC_ 12 150x3 L_-50C, AL_-1055 FC_ 18 150x3 L_-65A, L_-65B, AL_-1065, -1066, L_-80A, AL-1081, -1102 FC_ 18 179,3x5,7 AL_-1106, -1129 FC_ 32 309/295x1

The motor is equipped with ball bearings which are lubricated for life and therefore do not need any service. In the case of any motor malfunction it is recommended to replace the whole motor unit.

1 Rotating ring 2 Stationary ring 3 Body / bellows 4 Spring 5 O-ring

6.2 Other parts

1 Electric motor 2 Pump housing 3 Impeller 5 Sealing ﬂange 8 Foot (not always) 24 Screw or nut 25 Washer 26 Key 40 Shaft seal 50 O-ring or gasket 60 Screw or nut 67 Screw 80 Pipe union (L- and ALH -serie) 81 Pipe union (L- and ALH -serie) 86 Cooling pipe (L- and ALH -serie) 103 Frequency converter 111 Fixing plate (FCB, FCC) 112 Pipe joints (FCB, FCC) 113 Pipes (FCB, FCC) 114 Transmitter for pressure, pressure

dierence or temperature (FCB, FCC,FCD, FCF)

115 Cable (FCB, FCC, FCD, FCF) 117 Screws (FCB, FCC)

WHEN ORDERING SPARE PARTS, PLEASE SPECIFY THE TYPE IDENTIFICATION, SERIAL NUMBER, THE SIZE OF THE IMPELLER, THE MOTOR TYPE AND POWER AND THE POSITION NUMBER OF THE SPARE PART.

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6.3 Troubleshooting

Trouble

Shaft seal is

Wearing.

Fault Fixing

leaking.

Pump has run dry.

Pump don’t run. The shaft of the pump is blocked.

Fuses have worked.

No electricity.

The disorder has stopped the pump.

Change the seal.

Check the free rotation of the shaft by turning the motor fan. If required, loosen the motor unit from the pump housing and repair the cause of the block.

Repair the cause of the fault. Change the fuses. If necessary, call the expert.

Check and repair connections. If necessary, call the expert.

Reset the pump by disconnecting the supply voltage at least for 10 seconds.

Pump stops by itself or runs irregular and noisy.

Control wiring is not correct.

The parametres of the frequency converter are changed or the pump is stopped with local control panel.

The frequency converter or electric motor is damaged.

If the pump is operated when cover of the frequency converter is open, the special carefulness must be observed.

The supply voltage is defective. One phase is possible missing.

The frequency converter or electric motor is damaged.

Check the wiring in accordance with the control diagram. Between terminals 4-6 must be jumper or closed switch.

Correct the parameters or start the pump with the local control panel (not included in standard delivery). If necessary, call the expert.

Replace the frequency converter and/or electric motor with a new one. Contact to Kolmeks.

Check the supply voltage. Check and repair fuses and connections of the cables.

Replace the frequency converter and/or electric motor with a new one. Contact to Kolmeks.

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Trouble

Fault

Fixing

The pump is running with minimum frequency.

The reference value is missing or in minimum.

The pipes of the pressure or dierential pressure transducer are blocked or incorrectly connected.

The signal of the feedback transmitter (pressure or temperature) is too high. Possible short circuit.

The mechanical or electrical connections of the temperature transmitter of the FCF -pump are incorrect or the transmitter is damaged.

Adjust the correct value with the potentiometer (if intention to use the potentiometer as source of the reference signal). Check the wiring of the potentiometer. Check and correct the reference if the reference is given by external controller.

Check and repair the connections and blockings of the pipes. Open the possible valves, which are installed to the pipes.

Disconnect the cable from the transmitter, the speed should increase, if there is a fault in transmitter or the signal. Check the connections, transmitter. If necessary, replace the transmitter with the new one.

Check and repair of the connections or the transmitter.

The pump is running only with the maximum frequency, which don’t vary in accordance with the requirements of ﬂow changes.

Parameters of the FCF -pump are wrong. ( cooling and heating pumps have dierent parameters)

The incorrect setup selection or wrong parameters.

Reference signal is too high.

Feedback transmitter is missing or the signal is wrong.

Check and correct the parameters with the local control panel. If necessary, call the expert.

Check the selected setup. Terminals 6-3 closed = setup2, opened = setup1. Check and correct the parameters with the local control panel. If necessary, call the expert.

Adjust the correct value with the potentiometer (if intention to use the potentiometer as source of the reference). Check the wiring of the potentiometer. Check and correct the reference if the reference is given by external controller.

Check and repair the feedback signal and/or connections. If necessary, replace the transmitter with the new one.

The pipes of the pressure or dierential pressure transducer are blocked or incorrectly connected.

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Check and repair the connections and blockings of the pipes. Open the valves, which may be installed to the pipes.

Subject to change without prior notice

Trouble

Fault

Fixing

The pump is running only with the maximum frequency, which don’t vary in accordance with the requirements of ﬂow changes.

The mechanical or electrical connections of the temperature transmitter of the FCF -pump are incorrect or the transmitter is damaged.

Parameters of the FCF -pump are wrong. (cooling and heating pumps have dierent parameters)

The incorrect setup selection or wrong parameters.

The maximum speed is required by the system.

Check and repair of the connections or the transmitter.

Check and correct the parameters with the local control panel. If necessary, call the expert.

Check the selected setup. Terminals 6-3 closed = setup2, opened = setup1. Check and correct the parameters with the local control panel. If necessary, call the expert.

Check the adjustments and the need of the pumping in the system. Balance the parallel circulations. It can be the normal situation, then there is no need for any further measures. Solve the actual rotation speed by measuring or with the local control panel. Contact to Kolmeks. Maximum frequency is not allowed to change (factory default).

Green LED 302

Yellow LED 301

Red LED 300

Operation

o o o Connect the supply voltage. on o o Connect the start and reference signal on o on Disconnect the supply voltage as long as all LEDs are o.

on on on Disconnect the supply voltage as long as all LEDs are o.

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Trouble

Fault

Fixing

The pump is not pumping.

The pump is noisy.

There is air in the pump or the system.

The suction pressure is too low.

Circulation is closed with the valves

Cavitation.

The pressure dierence of the pump is too high.

There is a faulty shaft seal or bearings.

Deairate the system. Fill the pumps and the pipes with the ﬂuid. Try to run the pump a moment with the high speed, then possible air pockets leave the system easier.

Increase the suction pressure.

Open the valves.

Increase the suction pressure. Decrease the ﬂow.

Decrease the pressure reference. If possible, open the control valves and decrease the pressure reference, then the head of the pump is lower and the ﬂow remains the same.

Continuous rough noise refers to the faulty bearings. High noise, few seconds long, occasionally refers to the faulty shaft seal. Replace faulty bearings and shaft seal with the new ones. If necessary, contact Kolmeks.

Electrical noise from the frequency converter or electric motor.

Replace the motor with the new one. If necessary, correct the parameters of the frequency converter. Contact Kolmeks.

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7. Declaration of Conformity

We, OY KOLMEKS AB, P.O.Box 27 FI-14201 Turenki, FINLAND

declare under our sole responsibility that the products

FC_ - PUMP SERIE,

types AE, AEP, L, LH, LP, LS, AL, ALH, ALP, ALS, T and AT,

to which this declaration relates, are in conformity with the

– Council Directive 98/37/EY on the approximation of the laws of the Member States relating to machinery – Low voltage directive 2006/95/EY – Pumps and pump units for liquids. Common safety requirements. EN 809.

EMC STANDARDS

Generic standards

The generic standards are stated in the EMC directive (89/336/ETY).

FC_ -pump complies with:

EN 50081-11), EN 50082-1.

Residental, commercial and light industrial environment.

EN 50081-2, EN 50082-2.

Industrial environment.

Emission levels stated by EN 50081-1 are only fulﬁlled by FC_ -pumps with class B-1 optional ﬁlter. Class

B-1 ﬁlter is included in FC_ -pumps as a standard.

Turenki 02.05.2008

Kimmo Issakainen Managing Director

OY KOLMEKS AB

P.O.BOX 27 FI-14201 TURENKI, FINLAND tel. +358 20 7521 31 fax +358 20 7521 200 www.kolmeks.ﬁ export@kolmeks.ﬁ

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Kolmeks AE-25/4FC, AE-26/2FC, AE-26/4FC, AE-32/4FC, AE-33/2 Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual