Wine-Flo Manual Rev 1.0.2WF - John Brooks Manual Rev 1.0.2WF.pdf · By doing this the pumps outlet flow will end up matching ... recommend that AFLEX EMC Screened 3 Core plus Earth,

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Wine-Flo Flexopal Pump Specifications

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Table of Contents Wine-Flo

Flexopal Pump Specifications 2 Index & Constant Flow Concept 3 Available Models 4 System Components 5-6 Installation Considerations 7 Important Notice & Mounting 8 Wiring Instructions & Diagrams 9-11 Set Up 12-18 Operation 19 Functions List 20 Function Explanations 21 Reinitialising the System 22 Fault Reference Table 23 Warranty Info 24 Supplier Declaration of Conformity (SDoC) 25-26 Notes 27

Constant Flow Technology

As supplied the Wine-Flo is configured to use the “Constant Flow” mode when set to run off the float in “Automatic Probe” mode. This is a new method of controlling the pumping operation and has been developed exclusively by John Brooks Ltd. “Constant Flow” strives to keep the flow of liquid as low and as constant as possible. This is to enable heat exchangers etc. to extract as much heat out of the liquid as possible before it is delivered to the vat etc. The lower liquid delivery temperature results in reduced electricity costs from refrigeration plant etc. “Constant Flow” deliberately allows the level of liquid in the receiving vessel to vary within wide limits, without flooding or running dry, in order to keep the flow as constant as possible. By doing this the pumps outlet flow will end up matching the receiving vessels input flow and ultimately settle into a “Constant Flow”. In some installations, particularly those where there is a lot of froth present, this may be undesirable. In this case the Wine-Flo can be reverted to a conventional mode of operation by changing Function 11 (F011) from the default “Constant Flow” to “Variable Flow”. NOTE: In all other operation modes, i.e Local or Remote Pendant Modes, the Wine-Flo defaults to “Variable Flow”.

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All Single Phase Models are rated for 200 to 240 Vac. All Three Phase Models are rated for 380 to 480 Vac. All Wine-Flo Controllers can be purchased independently of the pump & trolley for custom applications up to 22kW.

Phone: +64 9 274 7114 Fax: +64 9 274 4897

Email: [email protected] www.johnbrooks.co.nz

Model Number Description

BWP-WF1-1.5-102SYST BWP - Wine-Flo 1PH 1.5kW - FP102 Pump - System







All Wine-Flo’s fully comply with EN61800.3 and the drives are covered by C Tick Registration # Z126.

All models can be upgraded with a Bypass to the pump head by adding the letter “B” to the end of the Model Number.

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Controller

Drive

The Wine-Flo cabinet houses all the core Components. There are two main components inside the cabinet - the Drive and the Controller. The Drive is mounted on the back wall inside the cabinet. The drives fully conforms to the following: NZ EMC (Electromagnetic Compatibility) 89/336/EEC Low Voltage Directive 73.23/EEC;EN50081-2 EN 50082-2 EMC Directive. C-Tick # Z126 RoHS Drive Size Range: 1Phase = 1.5kW (2HP) to 2.2kW (3HP) 3Phase = 2.2kW (3HP) to 22kW (30HP)

The Controller is mounted on the door inside the cabinet. It contains the Constant & Variable Flow program algorithms. All user functions are carried out through it’s keypad located on the front side of the door. The controller is fully RoHS compliant.

System Components

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The Probe/Float comes in three lengths, 410, 500 & 585mm. They are all designed to have the same working float stroke movement of 250mm between the lock rings. The stroke can be individually re-scaled through Function F003. The Probe plugs into the 7pin socket on the bottom of the Wine-Flo Cabinet. You must select “Automatic Probe” from within the Wine-Flo’s operating Mode for it to work. The Float is designed to sit on top of the wine, not on froth. The probe/float must be installed vertically in the receptacle through a 25mm hole to accommodate the stainless steel gland. Locate the probe/float away from the wine entry lines, wine pump intakes, and other sources of turbulence in the receptacle.

System Components

The Remote Pendant has all the same functionality as the “Local Mode” The Pendant plugs into the 7pin socket on the bottom of the Wine-Flo Cabinet. You must select “Remote Pendant” from within the Wine-Flo’s operating Mode for it to work.

Probe/Float

Remote Pendant

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Installation Considerations Installation It is the installers responsibility to ensure that the wiring in the installation complies with all there Electrical Wiring Regulations and Codes Of Practice that are current at the time of installation. All installation wiring must be performed by a Registered Electrician with a current Practicing License paying extra attention to standard EN61800-3. Cable selection In fixed installations typically the control supply and motor wiring should be a minimum of: Up to 4.0kW - 2.5mm2 5.5 to 11kW - 4.0mm² 15 to 22kW - 6.0mm2 On long cable runs care should be taken to select an appropriate cable size in order to maintain a total voltage drop at the motor of no more than 2.5%. Further, on motor cable runs over 20m the use of a line reactor (sold separately) may be necessary to compensate for cable capacitance. Note: We (the manufacturer) recommend that AFLEX EMC Screened 3 Core plus Earth, of the appropriate size as stated above, be used for all motor wiring. Ambient Temperature The Wine-Flo is designed to work in Ambient temperatures at, or below, 40°C. If the temperature exceeds this then a conditioned environment must be provided. Important The cabinet as supplied is rated to IP54. All wiring into or from the Wine-Flo cabinet must pass only through cable glands & plugs fitted into the bottom of the cabinet. Under no circumstances is anyone to alter or modify the cabinet in any way without prior approval from the manufacturer. This includes drilling extra holes for glands etc. Under no circumstances is anyone to alter any of the parameters on the drive inside the cabinet itself without direct instruction from the manufacturer. The door of the cabinet is to remain closed and sealed at all times during operation and downtime. High voltage levels can be present inside the cabinet even after the power is switched off.

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Mounting Dimensions

When installing the Wine-Flo’s cabinet as a fixed installation it should be secured to suitable metal frame work through the four mounting lugs well clear of the possibility of direct hits from high pressure hoses. The mounting lug holes are 7mm to allow the use of 6mm or ¼inch bolts.

Important Notice!

The Motor MUST be wired with EMC Screened cable. The screen must be earthed at both the drive and motor ends by using EMC Glands. The use of non EMC Screened cable can have very adverse effects on both the drive and controller and, for this reason, the use of non EMC Screened cable or the incorrect earthing of the same voids the Wine-Flo’s warranty! Note: The Wine-Flo’s cabinet comes fitted with an EMC Gland. We do NOT supply the motors EMC Gland when sold independently of our trolley & pump for fixed installations! When not in use the Wine-Flo must have the mains power removed from it, this is to prevent the unit being damaged by power anomalies while non operational. Failure to remove power when the unit is not in use voids the Wine-Flo’s warranty!

1.5 - 3.7kW

15 - 22kW

5.5 - 11kW

WINE-FLO

365m

m

634mm

433mm

335mm

422m

m

530

mm

Not To Scale!

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Note 1:The motor cable must be EMC Screened 3 Core plus Ear th. It must run through and have it’s screen terminated to the cabinets (supplied) & motors (not supplied) EMC Glands. Note 2: Ear th connections are not shown on this diagram. Make all ear th connections to the earth stud located on the bottom of the cabinet and in the motors terminal box. Note 3: Single Phase supplied controller s need to have the pumps motor terminated for 230Volt 3Phase supply as per motor connection instructions.

Note: To comply with EN61800-3 the following MUST be adhered to.

(N) (L)

Teco 7300Cv Drive

L1 L2 L3 T1 T2 T3 BR P1 P

Linked

Cabinet EMC Gland

Motor EMC Gland

Motor

Screened Cable

Motor Connections For:2HP (1.5kW) 1Phase 3HP (2.2kW) 1Phase

3HP (2.2kW) 3Phase up to

30HP (22kW) 3Phase

Wiring Instruction & Diagram

Motor Connection (Single & Three Phase)

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N

Teco 7300Cv Drive

L T1 T2 T3 BR P1 P

Linked

Plug or Isolation Switch

L

N

Teco 7300Cv Drive

L1 L2 L3 T1 T2 T3 BR P1 P

Linked

Plug or Isolation Switch

L1

L3

L2


Mains Connection (Single & Three Phase)

Note 1: Wire the mains power to the controller through a plug, if por table, or isolating switch if to be a fixed installation located close to the controller as shown below. Note 2: Ear th connections are not shown on this diagram. Make all ear th connections to the earth stud located on the bottom of the cabinet.

Mains Connections For: 2HP (1.5kW) 1Phase 3HP (2.2kW) 1Phase

Mains Connections For: 3HP (2.2kW) 3Phase Up to

30HP (22kW) 3Phase

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Jumper for

future use

Cabinets 7 Pin Panel

Socket

Cabinets Protective

Earth


Remote Plug & Relay Connections

The bottom connector on the controller is a set of 6 Relay Outputs, each with a Maximum Capability of 24Volt 5Amps R1, R2 and R4 are signal inputs to the drive and should be pre-wired. R3 turns on and of in unison with the drive and can be used to operate any external equipment that needs to start and stop in sync with the Wine-Flo. R5 and R6 are for future development.

Relay Connections:

B 0 C A 10 9

SCN PUR BRN YEL BLK BLU RED

24VDC 24V DC 10VDC

Wine-Flo’s Control Board

Remote Plug Connections:

All control connections to the bottom of the terminal strip mounted to the inside of the door for the remote equipment should be pre-wired to the 7pin panel socket on the bottom of the Wine-Flo’s cabinet.

SCN BLU YEL PUR RED BRN BLK

1 2

3 6

4 5

7

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Set Up

When you power up for the first time. The controller communicates with the drive and sees that it has not been set up. The Wine-Flo will not run until the setup wizard has been completed.

See Page 2 for our FLEXOPAL Pump specifications needed at specific stages throughout the setup procedure.

Press

During setup the indicated keys are used on the Key Pad.

Used to DECREASE the value of the digit which is above the

cursor

Shifts the CURSOR one position to the left, reverses Motor

Rotation or changes the drive into Volts/Hz Mode

Used to READ a function value or

ENTER data

Used to INCREASE the value of the digit which is above the cursor

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Select the Type of Wine Pump.

There are 5 options- Centrifugal, Impeller, Lobe, Progressive Cavity or Other.

Press the or arrows to change the selection. Press to confirm the selection.

Set Up

Obtain the voltage from the motors nameplate.

Enter the Motor Rated Voltage.

Note: Enter the exact current figure that appears on the Motors Nameplate. In the past, with older controllers, it has been common practice to raise this figure but if this is done with the Wine-Flo the Auto-Tune will not work correctly. The Wine-Flo will automatically apply a 10% margin to this figure after the Auto-Tune is complete to help eliminate nuisance tripping .

Obtain the current from the motors nameplate.

Enter the Motor Rated Current (in Amps).

Press the or arrows to alter the value. Press the to change the position of the cursor. Press to confirm the value.


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Set Up

Enter the Motor Rated Power (in kW).

Obtain the power rating from the motors nameplate.

Enter the Motor Rated Speed (in RPM).

Obtain the speed rating from the motors nameplate.


Enter the Motor Rated Frequency (in Hz).

Obtain the frequency rating from the motors nameplate.

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Set Up

Select the Maximum Float Height.

This MAXIMUM Float Level defaults to 100% and should initially be left as is unless you specifically know that it needs to be lowered. It’s possible to change this from function (003) within the function list once the Wine-Flo has been fully commissioned. Note: This also scales the pot on the Remote Pendant by the same percentage.

Select the Maximum Speed (in RPM).

Choose the Maximum desired Operating Speed you want the pump to run at.

An informational message will now be shown on the Screen for a few seconds showing what the Maximum Wine Level will be set to. No action is required.


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Press to continue.



Set Up

Select the Minimum Speed (in RPM).

Choose the Minimum desired Operating Speed you want the pump to run at.

Select the Drain Interval (in minuets).

This function is used in conjunction with Constant Flow while running in “Automatic Probe” mode. Initially leave this as the default of “0” as it can be changed and fine tuned via Function (010) in the Function list at a later date. If you choose to set the number of minutes between each Drain Interval:

The default of “0” minutes means that this function is turned off.

Run Auto-Tune.

When running in Vector Mode, the drive needs to measure the resistance and inductance of the motor to give it greater control while running.

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Set Up

If the Auto-Tune is unsuccessful, you will see this screen. You MUST recycle the power for the setup to continue! When the controller comes back on line you will be directed back to Re-Enter Data to confirm you initially entered correct values. Then the controller will run the Auto-Tune procedure again. At the third attempt to Auto-Tune you will be given the option to convert to Volts/Hz Mode to enable you to carry on with the set-up procedure. Press to change mode. Else Press to continue.

Auto-Tune Failed.

The Auto-Tune procedure takes between 10 and 30 seconds to complete. When finished there are 2 possible results. Passed or Failed.

Auto-Tune Passed.

If the Auto-Tune is successful, you will see this screen. The setup wizard will resume after a short delay.

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Set Up

Setup is now Complete. Wait until an informational message appears on the screen telling you to Press The Wine-Flo will automatically go to it’s READY to run mode.

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Indicates the type of pump that the controller is programmed to run.

Displays the speed that the motor is

running at

Shows the controller

status

Shows the Current that is being drawn by the motor while

running

The Software Version which is installed in

this controller

The Level of the float, in Automatic Probe mode,

or percentage that the pot is set to in Remote

Pendant mode.

Used to START and STOP the pump in

Local Mode

Shifts the CURSOR one position to the left.

Manually RESETS faults & clears fault history.

Also FWD/REV’s selective pumps in Local

Mode.

Used to READ a function value or

ENTER data

Used to enter the MODE function list to enable switching

between Local, Remote Pendant & Automatic Probe .

Used to INCREASE the

speed of the pump in Local Mode. Also to scroll up through functions etc.

Used to switch between the

DISPLAY and FUNCTION menus

Normal Operation

Keypad Operation

Indicates the mode that the controller

is operating in.

Used to

DECREASE the speed of the pump

in Local Mode. Also to scroll down through functions etc.

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Function Number Description Range Password

Protected

000 Control Reset Yes/No Yes

001 Acceleration Time (Seconds) 0.1–120.0 No

002 Deceleration Time (Seconds) 0.1-120.0 No

003 Float Level (%) 10-100 No

004 Minimum Speed (RPM) 0–Max No

005 Maximum Speed (RPM) 2 x Normal No

006 Password Entry 0–9999 No

007 Fault History N/A No

008 Timer (Run After Empty) 0-120 No

009 Motor Current (Amps) 0.3–100.0 Yes

010 Drain Interval (Minutes) 0-15 No

011 Mode Of Operation CF/VF No

012 RPM Display Normal/Large No

Key:

No password required to access and change

Password required to access and change

Only visible when “Automatic Probe” Mode is selected from the main running screen.

Function Listing The Wine-Flo allows you to change a number of functional parameters relating to the operation of the system. For security reasons some are password protected to prevent systems from being accidentally reset. (see page 21) The parameters are accessible by pressing the key on the main display screen. Scroll through

the function parameter numbers using the or arrow keys. Select using the key.

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Explanation of Functions

F000: If the correct password is entered at 006 this parameter becomes visible and allows the Controller memory to be erased and the Controller made to think that it is a new installation which will cause it to guide the user through a full setup procedure again. F001: Adjusts the Acceleration rate of the pump. (In Seconds) F002: Adjusts the Deceleration rate of the pump. (In Seconds) F003: This sets the Maximum level that the wine should ever reach in the receiver. (In %) F004: Sets the Minimum running speed of the pump. (In RPM) F005: Sets the Maximum running speed of the pump (In RPM). This figure is limited to double the normal full speed of the motor. (This is the only function that can not be changed while the unit is running) F006: Unlocks locked parameters when correct password is entered. (The password to activate locked functions is 9999) F007: Displays the last 10 faults (Refer to Page 23 for Explanations). The history can be cleared by pushing the button when you are in this function. F008: Sets the (“run on” at minimum speed as set in function 004) time that the unit will continue to run after it receives a stop signal from the probe/float. (In Seconds) F009: If the correct password is entered at 006 this parameter becomes visible and allows the motors overload current to be adjusted. F010: Sets the interval (In Minutes) between receiver drain outs, for assistance with froth removal. 0 = off / 15 = Max F011: When the Wine-Flo is being operated in “Automatic Probe” mode this function allows the operating mode to be changed from “Constant Flow”, which is the default and explained on page 2, to “Variable Flow” which a more conventional method of pumping. F012: When set to “LARGE” the main running screen will display only the RPM of the pump when its running. Then revert back to the standard informational screen when the pump is stops.

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Reinitialising the Operating System

The operating system will need to be reinitialised when: 1. The type of wine pump or motor is changed. 2. The Drive needs to be swapped out for a new one. 3. The Controller needs to be swapped out for a new one. 4. If the Wine-Flo is installed as a fixed installation and needs to be relocated. 5. You may have reason to think the program is incorrect. Follow the following procedure! 1. Turn on the power 2. Push 3. Arrow to F006 Push 4. Arrow to 9999 Push 5. Arrow to F000 Push Follow the prompts on the display 6. Arrow to read YES Follow the prompts on the display again 7. Arrow to read YES 8. Follow the prompts on the display. 9. Turn off the power at the mains. 10. Turn on power at mains after 30 sec. 11. Follow the prompts on the display. 12. New Controller Push to configure.

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# Fault Fault Explanation

1 Drive Program Abnormality Refer to John Brooks

2 Drive EEPROM Error Drive hardware fault

3 Over Supply Voltage Refer power supply Co. Potential for serious damage

4 Low Supply Voltage Refer power supply Co. Fix and drive will restart

5 Drive Overheated Check cabinet & ventilation. Potential for serious damage

10 Overcurrent at Deceleration Refer to John Brooks. Increase deceleration time

11 Overcurrent at Acceleration Refer to John Brooks. Increase acceleration time

12 Overcurrent at Constant Speed Refer to John Brooks. Mechanical pump fault

13 Over Voltage at Constant Speed Refer to John Brooks. Mechanical pump fault

14 Drive Heatsink Overheated Check cabinet & ventilation. Potential for serious damage

15 Drive Overspeed Deceleration time too short

16 Drive CTER Error Refer to John Brooks

17 Overcurrent at Start Pump seized

20 Overcurrent at Stop Refer to John Brooks

21 Motor Overloaded Motor overloaded. Turn Off/On

22 Inverter Overloaded Refer to John Brooks. Motor overloaded

23 Over Torque Refer to John Brooks

24 Low Voltage while Running Refer power supply Co. Fix and drive will restart

29 Factory Setting Error Refer to John Brooks

30 Zero Speed Stop STP0 No action required

31 Fail To Start Directly STP1 No action required

32 Keypad Emergency Stop Run/Stop button on drive unit has been pushed. Turn power Off/On

33 External Emergency Stop Refer to John Brooks

34 External Base Block Refer to John Brooks

36 Drive PID Error Refer to John Brooks

37 Comms (EFO) Error Refer to John Brooks

38 Encoder Signal Lost Refer to John Brooks

39 Illegal Interrupt of Drive CPU Refer to John Brooks. Drive hardware error

40 Access to Parameter Denied Refer to John Brooks

41 Disallowed Use of Drive Keypad Drive keypad operated. Turn power Off/On

42 Parameter Setting Error Drive keypad operated. Turn power Off/On

43 Communications Error Check Communication cable is connected on Drive & Controller

99 No Float Connected Check the float, cables and all connections

Fault History Reference Table The fault history records the last 10 faults during operation.

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Warranty It has become apparent that on occasions insufficiently qualified personnel are installing and commissioning electronic drive systems which are beyond their technical knowledge. This is often done without fully reading the technical literature accompanying the equipment. These systems are test run prior to leaving the factory by the manufacturer. For reasons of validity of warranty it is important that the drive is installed and commissioned by a qualified technician. If a warranty problem occurs, John Brooks Ltd will inspect and test all equipment to assess the validity of the claim based on the above conditions being met. Equipment to be assessed for warranty must be returned, freight paid, to John Brooks Ltd in Auckland. If the equipment has failed under a warranty condition, the system will be repaired or replaced and returned freight free. The warranty offered from John Brooks Ltd is directly related to the manufacturers warranty of controls and motors. All units are warranted for a period of twelve months from the date of delivery. No costs other than those specifically related to the repair of the unit will be met under a warranty claim.

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NOTES

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5 Andromeda Crescent East Tamaki Auckland, 2013 Ph: +64 9 274 7114 Fx: +64 9 274 8497 Web: www.johnbrooks.co.nz Email: [email protected]

Documents

Wine-Flo Manual Rev 1.0.2WF - John Brooks Manual Rev 1.0.2WF.pdf · By doing this the pumps outlet flow will end up matching ... recommend that AFLEX EMC Screened 3 Core plus Earth,