Operating Manual -ENGLISH- Page 1 KWG-ISO

Transcription

1 Page 1 KWG-ISO Operating manual English- Status May 2013

2 Page 2 Manufacturer address KW-Generator GmbH & Co.KG Bänglesäcker Schwäbisch-Gmünd / Lindach Phone: +49 (0) Fax: +49 (0) info@kw-generator.com About this manual This manual refers to insulation monitors of series KWG-ISO. The notes on safety and risks as well as the general data shall be applicable to all KWG- ISO modules and shall be complied with in any case for reasons of liability. No part of this operating manual shall be copied, published or disclosed irrespective of the type and means unless the express consent of KW-Generator GmbH & Co. KG has been obtained. Modifications after printing have not been taken into account. Right to technical modifications reserved. Status of manual: V12. Norms and regulations KWG-ISO modules are in conformity with RoHS and comply with the regulations according to IEC , IEC61326 and are intended for mains in accordance with DIN VDE bestimmt. Application and use of KWG-ISO modules KWG-ISO modules are components of machines and system intended for industrial and professional use and thus cannot be treated as retail goods. The ISO monitors shall be used only according to the technical data of the nameplate and/or the data sheet or a specific release. They are protected from vibration and moisture by special sealing compound; however, shall be operated only in water-protected (IP54) switching boxes and switching cabinets. They shall not be operated in the open, and the switching box and/or switching cabinet shall not be cleaned by means of high-pressure cleaners. KWG-ISO modules shall be used only for the applications specified here and only in compliance with this operating manual. Any other use is deemed misuse and thus not allowed. Improper or unauthorized use is not allowed. No liability will be accepted by KW-Generator GmbH und Co. KG in this case. The KWG-ISO module monitors the insulation value of a non-earthed AC system with DC portions in the wide voltage range from 100V to 300V towards earth which is supplied by a KWG generator. One insulation module only shall be connected in each system which is connected in a conducting manner.

3 Page 3 Warranty Unless specific warranty regulations are defined in writing for type-related applications and customers, we will grant a warranty according to the general European regulations. General Safety Instructions DANGER Electric machines include dangerous components which are either live or rotate during machine operation. Except the switching relays, the KWG-ISO is wear and maintenance-free Repairs are excluded due to the complete sealing of the unit. Thus: - Improper use, - Demounting protective lining, disconnecting safeguards, - Poor inspection and maintenance, may cause serious personal and property damage. The safety officer shall convince himself and ensure that transport, installation, commissioning, operation, inspection, maintenance and repair of the machine are carried out by qualified personnel with the following qualifications: - Specific technical qualification and experience - Knowledge of technical norms and applicable laws - Knowledge of the general national and local system-specific safety regulations - Ability to detect and avoid dangerous situations. Work at electric machines shall not be carried out without the approval given by the safety officer; this is applicable to vertical machines where all poles are separated from the mains and the machine is secured against re-connection (including auxiliary circuits). The generator shall not be operated in environments subject to explosion hazards. The relevant regulations shall be followed! Earthing of the neutral conductor is prohibited for operation with the KWG-ISO module.

4 Page 4 General structure The KWG-ISO module is a single-circuit board solution and can thus be sealed. Control and evaluation are carried out by a controller. All connections are of the plug connector type. Later DIN- (top-head) bus assembly of chassis assembly is possible by 2 or 4 plug-in fastening flanges. Screw fasting is possible by means of M3 or M4 screws. The housing consists of impact-resistant black plastic material. Description of function The KWG-ISO generates a pulse-shaped measuring voltage. This superimposed to the IT system to be monitored via the terminals L1 and N. Ohmic insulation faults between IT system and earth close the measuring circuit. If the pre-warning value is less then specified, relay AL1 switches. If the switch-off value is less than specified, relay AL2 switches. On connection of the supply voltage, the device carries out a self-test. Connection faults or mal-function, if any, are determined. Then a self-test is carried out automatically every hour. The relay are not switched during all self-tests. If a fault is found out, this is indicated by AL1 and AL2 relays. The self-test can be initiated manually by pressing the test button (T input) for at least 1.5 seconds. The internal fault memory can be deactivated by bridging the R input. Technical data and specific features Supply voltage from 95V to 264V AC, intrinsic consumption < 3VA Monitored IT network 95V to 300V AC / 22Hz to 125Hz (triggering accuracy up to 65Hz +/- 15% of RRated) Pulse-shaped measuring voltage allows measurements in mains with DC portions such as, for instance, inverter welding machines and frequency converters for motors. max. admissible external DC voltage: 300V max. admissible mains discharge capacity 5uF Response times at 0.5 x Ran and 1uF : < 1s Relay change-over contact when reaching the pre-warning limit (typically 46kOhms) Relay change-over contact when reaching the switch-off limit (typically 23kOhms) Additional opto-coupler output max.24v when reaching the switch-off limit Sensitivity which can be changed over x2 (pre-warning 80kOhms, switch-off 40kOhms) Insulation value is put out via opto-coupler, pulse width-modulated (analog out) TEST and RESET buttons can be designed for signal voltages (24V) Mode can be changed over, rest/working principle Integrated fault memory, clearing by RESET button or switching of the supply Automatic self-test after switching on and every hour (relays are not switched) Universal fastening possibility, top-head rail and screwed assembly can be selected Module embedded completely to seal and protect the components All connections are of the plug-connector type EMC according to IEC61326

5 Page 5 Insulation coordination according to IEC , surge voltage: 2.5kV, test according to IEC :2,21kV COMMISSIONING After the installation of the system refer also to Operating manual KWG generators test also the KWG-ISO module for proper functioning. Depending on the application, the tripping unit or the main contactor must respond after manual self-test. After reset, the main contactor and/or the tripping unit can be reset to ON. If not, check the installation and contact KWG, if necessary. If an insulation fault occurs during start-up and/or at a later time, we recommend the following procedure to find out the cause of fault. 1. Remove the complete load from terminal box, switching box or generator and switch off the external devices. 2. Start system. If no fault occurs, contact the load again at the terminal box, switching box or generator. 3. If an insulation fault occurs, either the supply line or extension line to the devices is defective. If no insulation fault occurs, connect the different devices one after the other. Mark the device which causes the insulation fault during connection as defective and have it checked in a specialized workshop. 4. If an insulation fault occurs after point 1) without connected load, the generator system is defective. -> Contact KWG.

6 Page 6 PLUG ASSIGNMENT Plug assignment 6pol-AMP 1= Supply and measuring circuit N 2= Supply and measuring circuit L1 3= free 3= Relay AL2 Error contact 12- normally closed 3= Relay AL2 Error contact 14- normally open 6= Relay AL2 Error contact 11- change-over 3pol-AMP 1= Relay AL1 pre-warning contact 24- normally open 2= Relay AL1 pre-warning contact 21- change-over 3= Relay AL1 pre-warning contact 22- normally closed 8pol-AMP 1= Signal output fault 2= Signal reason for fault and controller out 3= Signal output controller out 4= Signal input RESET 5= Signal input TEST 6= common for RESET and TEST 7= PE connection MUST BE CONNECTED! 8= PE connection MUST BE CONNECTED! Programming feature Bridge L open = Mode of functioning of tripping unit bridged = mode of functioning of main contactor

7 Page 7 Bridge W open = pre-warning value 40kOhms, fault value 23kOhms bridge t= pre-warning value 80kOhms, fault value 40kOhms Interface to KWG generator controller In addition to the independent mode, the KWG insulation monitor offers the feature of communication with the KWG generator controller. The insulation value is put out via the controller CAN-BUS. At the same time, the insulation value can be processed further in the KWG generator controller and, for instance, control relays. Examples for connection

8 Page 8

9 Page 9 Dismantling Prior to demounting the KWG-ISO module make sure that the unit cannot be started automatically or manually. In addition, the system must be disconnected and dead. The KWG-ISO module can be disconnected electrically simply by pulling out the AMP plugs. Disposal hints For proper waste disposal follow the local regulations for electronic scrap.