ISM-DRD Grade 3 Dry Run Detector ISM-DRD  This unit is designed specifically to detect dry running of any type of pumping system of 30 Kwatt or greater. System management has entered a new era! No other product offers system management, protection and data collection all in one. It’s easy to install with no nonsense wiring. A simple calibration procedure is all that is required. Your system is managed, your equipment protected, should you need it in future, you have a great trouble shooting tool in place. Your ISM-DRD  uses a state of the art microprocessor, programmed with the latest software, designed using the vast field knowledge and experience that has been built up over many years of successful participation in the related field. • • • • • • Easy to install! Simple calibration procedure! Minimized nuisance tripping! Maximum operating range! Auto diagnostics! Peace of mind! ISM-DRD  manages your pumping system by: • • • • • • • Avoiding nuisance tripping Making maximum use of your water reservoir Allowing the widest possible voltage fluctuation Anticipating transient overload conditions Using a simple dry-run management program Limiting the destructive effects of over currents and Reducing rapid cycling automatically when required ISM-DRD  protects pumping system by: • • • • • • • • • Monitoring supply voltage Monitoring current Monitoring shaft load Eliminating rapid cycling which can cause motor overheating Detecting excessive continuous over currents Detecting dry running Logging data during operation for fast and versatile technical support Detecting bad connections Allowing for voltage and current stabilization during start-up 1 With over 15000 units sold in Southern Africa, our engineers have learnt how best to protect your motor. All this knowledge has been built into the ISM-DRD . Rest assured that all the necessary parameters are being monitored to protect your motor effectively. ISM-DRD  does not rely only on current , voltage or power. We have found that a complex combination of these parameters is required to ensure efficient protection with out causing nuisance tripping. If it becomes necessary to do fault finding ISM-DRD  makes it very easy. If it becomes necessary to do fault finding ISM-DRD  makes it very easy. Either use the coloured Led’s on the front panel by interpreting the combination of the lit Led’s, or upload the data using our data reader, and displaying the events on a computer screen. Our qualified staff can offer assistance in interpreting the results. Our web site offers examples of typical installations. ISM-DRD  Grade 3 Technical specifications (Dry run detection) Model Number Voltage Nominal Voltage Running mode Voltage Starting ISM-DRD Grade 3 120V, 230V, 400V, 525V AC 50/60 Hz -20% +15% -15% +20% Voltage response time Voltage trip recovery time 10 seconds 5 minutes Operating Temperature Maximum Current -5° to 60°C Direct 5 amps – other currents with C.T. Relative humidity Relay contact Maximum 75% at 40 degrees Celsius 16 Amps resistive 4 secs for 50% and over 20 secs for 10% and over 15 secs for 15% and over 10 secs for 33% and over 4 secs for 50% and over Overload response on start up Overload response on run Overload recovery time Under Load Control Reset on Dry-Run Rapid Cycle protection Reset On Overload Switch Control 15 minutes App. 75% of nominal shaft power OR 75% of calibrated current Runtime is automatically matched to water available for pumping. Time range 15-240 minutes Maximum of 1starts in a 2 minute run – 5 minute delay before a new rapid cycle period Auto Reset after 1st two overloads with 15 min delay, then reset by power-up with 90 second delay Isolator: Used for applying power to the control box only – not recommended for repeated On/Off switching activity. On/Off, Pressure, Float or other type of switch: Intermittent starting and stopping of the pump/motor unit WARNING! To To avoid possible fatal shock, disconnect power at main power distribution board before installing, wiring or servicing your ISM-DRD  2 For Wiring Diagram see attached appendix We recommend that coloured wire be used in accordance with the three phase colour scheme for ease of fault finding. A successful installation will depend on you paying attention to minor detail at this time. Warning! Installation and maintenance work should only be carried out by technically qualified personnel. Serious or fatal injury could result from tampering by unqualified personnel. Installation in an existing control board. These instructions take the assumption that the control signal to switch the present motor control is from one of the phases. 1. 2. 3. 4. 5. 6. 7. 8. TURN OFF AC POWER AT THE SOURCE (DB BOARD) Find a suitable location for the ISM-DRD , close to the main contactor, for convenient wiring. Connect the ISM-DRD  incoming supply (L1, L2, L3) to the supply side of the contactor, ISMDRD  to always have power. Observe the sequence from the supply to the ISM-DRD  terminals “L1, L2, L3”. Connect the C.T. to L3 line either on the incoming or load side of the contactor. Observe the label on the C.T. if supplied with ISM-DRD . In the case that you are using your own C.T., ensure that the P1 side of the C.T. faces the load side. This is important, as the ISM-DRD  uses the phase angle during monitoring, and if incorrectly wired will cause nuisance trips. Connect the S1, S2 of the C.T. to the respective terminals on the ISM-DRD . Trace the control line going to the main contactor, and if at all possible change the source supply to “L2”,(Using “L2” as the source for control, will ensure optimum protection for possible phase failure on “L2”). Disconnect the control line going to the main contactor auxiliary coil, and take this wire to the ISM-DRD  “A1” terminal. Place a wire from the ISM-DRD  “A2” terminal to the open contactor auxiliary coil disconnected in step 6. Your ISM-DRD  is ready for final calibration. Warning! The Current transformer S1 and S2 terminals are at line potential. Please ensure that these terminals are insulated to prevent accidental shock! 3 Installation in a new control box, using a 400V coil contactor. 1. 2. 3. 4. 5. 6. 7. 8. 9. TURN OFF AC POWER AT THE SOURCE (DB BOARD) Find a suitable location for the ISM-DRD , close to the main contactor, for convenient wiring. Connect the ISM-DRD  incoming supply (L1, L2, L3) to the supply side of the contactor, ISMDRD  to always have power. Observe the sequence from the supply to the ISM-DRD  terminals “L1, L2, L3”. Connect the C.T. to L3 line either on the incoming or load side of the contactor. Observe the label on the C.T. if supplied with ISM-DRD . In the case that you are using your own C.T., ensure that the P1 side of the C.T. faces the load side. This is important, as the ISM-DRD  uses the phase angle during monitoring, and if incorrectly wired will cause nuisance trips. Connect the S1, S2 of the C.T. to the respective terminals on the ISM-DRD . Connect a wire from “L2” to your control line, (On/Off switch, float switch, pressure switch, timer switch, etc). Using “L2” as the source for control, will ensure optimum protection for possible phase failure on “L2”. Connect the return line from the control device to the ISM-DRD  “A1” terminal. Connect a wire from the ISM-DRD  to the “A1” terminal of the contactor coil. Place a wire from the ISM-DRD  “A2” terminal to the “A2” terminal of the contactor coil. Connect your motor wires to the load side of the contactor. Your ISM-DRD  is ready for final calibration. Warning! The Current transformer S1 and S2 terminals are at line potential. Please ensure that these terminals are insulated to prevent accidental shock! Installation in a new control box, using a 230V coil contactor. 1. 2. 3. TURN OFF AC POWER AT THE SOURCE (DB BOARD) Find a suitable location for the ISM-DRD , close to the main contactor, for convenient wiring. Connect the ISM-DRD  incoming supply (L1, L2, L3) to the supply side of the contactor, ISMDRD  to always have power. Observe the sequence from the supply to the ISM-DRD  terminals “L1, L2, L3”. 4. Connect the C.T. to L3 line either on the incoming or load side of the contactor. Observe the label on the C.T. if supplied with ISM-DRD . In the case that you are using your own C.T., ensure that the P1 side of the C.T. faces the load side. This is important, as the ISM-DRD  uses the phase angle during monitoring, and if incorrectly wired will cause nuisance trips. 5. Connect the S1, S2 of the C.T. to the respective terminals on the ISM-DRD . 6. Connect a wire from “L2” to your control line, (On/Off switch, float switch, pressure switch, timer switch, etc). Using “L2” as the source for control, will ensure optimum protection for possible phase failure on “L2”. Connect the return line from the control device to the ISM-DRD  “A1” terminal. 7. Connect a wire from the “Neutral” bar to the “A1” terminal of the contactor coil. 8. Place a wire from the ISM-DRD  “A2” terminal to the “A2” terminal of the contactor coil. 9. Connect your motor wires to the load side of the contactor. 10. Your ISM-DRD  is ready for final calibration. Warning! The Current transformer S1 and S2 terminals are at line potential. Please ensure that these terminals are insulated to prevent accidental shock! 4 External switch – Rapid Cycle Protection. Your electric motor accumulates a certain amount of heat each time it is switched on. It must run for a period of time during which it has the opportunity to dissipate the heat. The ISM-DRD  will do the necessary calculations and management of the switching process. If too many starting cycles are called for, a 5 minute waiting period will be applied. The water distribution system must be designed to allow the pump to run for as long as possible before switching off. When a pressure switch is connected as an external switch, the rapid cycle protection function of the ISMDRD  is activated, Rapid cycling will now be prevented. Try to set your system parameters so that the motor will run for about 2 minutes before stopping. Warning! Motor size will depict the minimum run period for that motor. Ensure that the pressure system is suited to motor size for optimum rapid cycle protection! The ISM-DRD  does not know your motor size! The ISM-DRD  uses a general algorithm for rapid cycling! Calibration of the ISM-DRD  Before calibration of the ISM-DRD , ensure that all valves are in an open position. Ensure there are no blockages in the pipeline. Ensure there is water in the bore hole, well, reservoir. 1. 2. 3. 4. 5. 6. ENSURE THAT AC POWER IS TURNED OFF AT THE CONTROL BOX ISOLATOR. Ensure that your wiring is according to the specific wiring diagram Before connecting the motor, use a 500V insulation tester (megger) to test the insulation resistance of each motor lead to earth. Lightly press and hold the water drop on the ISM-DRD  . Switch the mains on. The ISM-DRD  flashes a Green-Red-Green+Red sequence three times. Release the water drop after the first sequence has flashed. The motor starts up, if control circuit is on, (400V coil), in the case of a 230V coil the motor will start even if the control circuit is On or not. ISM-DRD  now allows you the opportunity to confirm that the amperage drawn is with in the motor manufacturers specifications and rotation is correct. IMPORTANT! Make use of a tong tester (amp meter) and volt meter to confirm that the electrical supply is with in specifications. Readings outside these specifications must be correct before proceeding. 7. Once the running readings have been confirmed as acceptable, press and release the water drop. ISMDRD  stops the motor and flashes the Green-Red-Green+Red sequence three times, and adds the volts and amperage readings to memory.It is for this reason that the amps and volts are measured. ISM-DRD  takes these readings as being acceptable. Failure to measure the running amps and volts could lead to motor failure. 5 8. After approximately 5 seconds, ISM-DRD and Green light glows.  restarts the motor in normal running mode. The Red Your ISM-DRD  is now on guard!! 9. Should you have any problems in setting up your ISM-DRD further assistance.  please contact your supplier for Operation. Under normal conditions, switching on will result in a click (relay activating), or a clunk (contactor activating) being heard and water being discharged. No special attention is required under normal running conditions. The ISM-DRD  acts as a controlling switch that will interrupt power to your motor if all is not well. The ISM-DRD  checks for voltage variation and continuously measures various parameters of the motor. Operation with Mains Switch. In some cases it may be necessary or desirable to use a Mains Switch, which will interrupt power to the ISM-DRD  completely. In such a case the ISM-DRD  protects the motor although it cannot store some of the operating data. Light indicators. The ISM-DRD  has two coloured LED’s which indicate the state of the unit. LED sequence is deciphered under the trouble shooting table. External LED display. The ISM-DRD  can extend the LED’s to a control box front panel, eliminating the need to open a control box to see the LED status on the ISM-DRD . Ask for ISM-DRD  LED extension kit, P/N 151600XXX. This kit will interface to the DB15 header at the top side of the ISM-DRD . WARNING! Under no circumstances connect a cable other than from the ISM-DRD  external LED extension kit to the DB15 header. THERE ARE DANGEROUSLY HIGH VOLTAGES WHICH ARE AT LINE POTENTIAL PRESENT ON THIS CONNECTOR WHICH CAN CAUSE FATAL HARM TO THE USER. 6 Trouble Shooting. Light indication or Symptom (See Fig. 2) Unit appears dead Flashing RED-GREEN RED and GREEN light on while pump is running RED light on and GREEN light flashing while pump is running GREEN light on and RED light flashing while pump is running Lights flashing RED-RED-GREEN and pump not running Lights flashing GREEN-GREEN-RED and pump not running RED light on constantly Red light flashing GREEN light on constantly GREEN light flashing Possible Cause No power to the unit ISM-DRD  needs to be calibrated All OK Solution Check wiring. AC power should be applied to L1 and L2. In some cases the pressure switch or other control device may be wired to the power input. Check that the control switch is wired according to the instructions. See Figure 2. Follow the calibration procedure - Supply voltage is less than 90% nominal Supply voltage is more than 110% of nominal Supply voltage exceeded 115% of nominal Supply voltage below 80% of nominal. If condition occurs intermittently installation will work satisfactorily. If condition remains, contact electrician to investigate supply. If condition occurs intermittently installation will work satisfactorily. If condition remains, contact electrician to investigate supply. Wait 3 minutes for retry. If condition prevails, contact electrician to attend to AC supply. Wait 3 minutes for retry. If condition prevails, contact electrician to attend to AC supply. Remove power from the ISM-DRD  for at least 5 seconds. Pump will restart with in 90 seconds of re-applying power. If fault persists, call an electrician to check the motor The motor will auto restart within 15 minutes. Overload condition has been To reset manually, switch external switch off detected and external switch and on again. Do not do this more than twice. in on position Correct the fault before attempting any further starts A dry run has been detected Switch on and resume pumping. A float and the On/Off switch or switch or other external control switch may external control switch has have opened. Check for external switches or opened control devices The motor will restart automatically with in 15-240 minutes. Flash rate is proportional to A dry run or under load has the amount of time left. Slow indicates up to 4 been detected hours waiting time. A fast flash rate indicates a few minutes 3 overloads in a row caused a lock-out condition 7 Calibration Mode Trouble shooting Light indication or Symptom (See Fig. 2) RED-GREENRED/GREEN sequence flash GREEN flashing RED flashing Possible Cause Start or end of calibration procedure The ISM-DRD  has not detected any current flowing in S1 and S2 The ISM-DRD  has detected that the current flowing in S1 and S2 is greater than 5 amps Solution Switch On external switch. Contactor not pulled in OR C.T. to large for motor size, get smaller ratio C.T. (NOTE! Secondary ratio must always be 5 amps) OR motor not connected OR wiring incorrect – check wiring according to Figure 1 Use a larger ratio C.T. NOTE! C.T. secondary ratio must always be 5 amps Data Reader Option While the ISM-DRD  is on guard, it records various pump parameters. Switching events are also recorded. Fault diagnosis has never been easier!. It is now possible to get to the root of an installation problem before serious damage occurs. The data can also be emailed anywhere in the country or the world. This means that the best possible technical backup is as far as your telephone. Contact your supplier for more information on the ISM  Data Reader 381000500 and how to use it. Figure 3: ISM © Data Reader 8 Figure 4: Sample data extracted from a ISM-DRD  E Limited Warranty The manufacturer of ISM-DRD  warrants to the original equipment manufacturers and authorized ISM-DRD  dealers and service centers that each ISM-DRD  unit sold will be free from defects in workmanship and materials and will perform consistent with samples previously supplied and will conform to specifications published or mutually established for a period of one year from date of installation but not more than two years from date of manufacture in water pumping applications. Any ISM-DRD  unit which fails to conform to the sales contract, including the above warrant, will be replaced at the option of the ISM-DRD  manufacturer. The remedy of repair or replacement is the sole and exclusive remedy afforded for breach of the above warranty. Warranty on the repaired or replaced equipment will be for the time remaining under the terms of the original warranty. Under no circumstances shall the ISM-DRD  manufacturer be liable for any special, incidental or consequential economic or other damages resulting from the failure of the ISM-DRD  manufacturer to comply with the contract of sale or breach of the above warranty, negligence or otherwise. This warranty is applicable only for water well installations. The ISM-DRD  and specifications are subject to change without notice 9 ISM-DRD  Notes. 10