Tornado F-5 Motor Backspin Detect Relay And Probe For F-5 Motor Controller
Tornado F-5 Motor Backspin Detection Relay And Probe Revision 8.1 Change Log: Rev 8.1 Apr 24 2012 JNesbitt@GPS-US.co GPS updates 2
Table of Contents C H A P T E R 1 Specifications 4 C H A P T E R 2 Safety Overview 6 C H A P T E R 3 Introduction 7 C H A P T E R 4 Installation and Wiring 8 C H A P T E R 5 Backspin Detection Setup 10 C H A P T E R 6 Stand Alone Backspin Setup 11 A P P E N D I X Appendix A 13 3
Chapter 1 Specification Relay Unit Size: (w x h x d) 5.125" x 5.25"(4.25") x 2.00" (Height excluding base plate) Weight: 1.6 pounds NEMA Rating: NEMA 1 Power: Derives power through the communication link, or externally powered by 120VAC for stand-alone operation. Auxiliary output contacts, NO and NC High Voltage (HV) Probe input connection for interface to HV Probe. Communications: Two connectors for using RS/485 protocols (RJ45 type connectors). This is connected to any of the RJ45 type connectors on the unit system modules. RX and TX LEDs for indicating transmit and receive on the communication link. Blue LED for an indication that the motor is currently spinning. 4
High Voltage Probe Unit Size: (w x h x d) 8.75"(7.75") x 4.625" x 2.375" (Width excluding base plate) Weight: 3.7 pounds NEMA Rating: NEMA 1 Low Voltage Connection: One Phoenix connector for interface to the Backspin Relay. High Voltage connection: Three high voltage wires for connection to the motor T-leads, up to 5kVAC. 5
Chapter 2 Safety Warnings Overview Read and follow all Warnings, Precautions, Notes, and Instructions included in this document. A Warning identifies an immediate hazard that exists that poses some probability of causing death or serious injury. A Caution identifies potential conditions and actions that have the possibility of death or severe injury. A Note identifies the need for general safety practices which, if violated, could cause injury to personnel or damage to equipment. High voltages are exposed during operation. Do not touch exposed surfaces during test. Caution Verify wiring connections prior to applying power to the system. Damage to the equipment could result from incorrect connections. Note Inspect system ground and bonds prior to power application. Shock hazard could exist if proper ground is not maintained. Motor Control Unit The High Voltage Probe unit is connected directly to the high voltage output of the main contactor, which can be up to 5000 Volts. These High Voltages may be present during operation and set-up, and should be considered hazardous. 6
Chapter 3 Introduction The Backspin Relay and HV Probe is an optional part of the Motor Controller system. The backspin equipment is generally used in electric submersible pump applications in the oilfield or water well applications where detection of the backward spin of the pump is desired. When the motor is shutdown or turned off, the existing fluid in the production tubing causes the pump/motor to turn backwards as the fluid is falling back into the well. If the motor is started while this backspin is happening, this could cause damage to the equipment. The Backspin Relay can detect this backspin and prevent the manual or automatic starting of the pump until the back spinning has stopped. 120VAC Line 120VAC Neutral Relay N/O Relay Common Relay N/C A Phase Sensing B Phase Sensing C Phase Sensing Backspin Probe Connection Only Tornado F-5 Backspin Relay Module Backspin Alarm Active TX RX DRAWN BY: Global Production Solutions GPS SIZE: DATE: DWG NO REV N/A April 24 2012 TORNADO F-5 CONNECTION DIAGRAM N/A PROJECT: TORNADO F-5 OPERATOR MANUAL SCALE: N/A Backspin Unit Connections SHEET 1 OF 1 7
Chapter 4 Installation and Wiring The HV Probe unit is connected directly to the high voltage output of the main contactor, which can be up to 5000 Volts. These High Voltages may be present during operation and set-up, and should be considered hazardous. High Voltage Probe The High voltage probe has two sets of connections. The high voltage connection consists of three high voltage wires that are connected directly to the output of the 3-phase voltage of the contactor or motor leads. This HV connection is rated up to 5000 volts AC. A small cable fitted with a connector is used to connect the probe to the backspin relay unit. Mounting holes on the probe allow the probe to be mounted to the inside of the switchboard panel. Backspin Relay The backspin relay is connected to the Motor Controller system via the provided patch cord with the RJ-45 type connectors. All parts of the controller units are tied together in a daisy chain fashion using these patch cords. Each module on the controller units are equipped with two receptacles for the RJ-45 connectors to allow this to be done easily. This provides communication to the controller in order for the controller to prevent starting when backspin is in motion. A connector on the backspin relay marked Backspin Probe Connection Only is where the matching connector is plugged in from the HV probe. A third connector on the backspin relay is used for external connection and/or stand-alone operation of the backspin detection. For stand alone operation, the 120VAC power, neutral, and ground pins must be connected to an external power source. External devices for detection of the backspin can use the relay common, relay NC, and relay NO pins. When the motor is turning, the contacts will switch. This is not a standard configuration. There is one each of RX and TX LEDs for indicating transmit and receive status on the communication link. One blue LED lights to indicate motor spin, which will blink at the frequency of the motor spin whether it is running or in backspin. 8
Main Power (1100 3300 Volts AC) 50 / 60 Hz Input L 1 L 2 L 3 Fuse 1 Fuse 2 Fuse 3 ISOLATION SWITCH Fuse 4 Fuse 5 H1 Primary Voltage PT X2 X1 120 V AC Fuse 7 Fuse 1 : App Specific Fuse 2 : App Specific Fuse 3 : App Specific Fuse 4 : 2E 4.8 kv (39551) Fuse 5 : 2E 4.8 kv (39551) Fuse 6 : 2E 4.8 kv (39551) Fuse 7 : 6 Amp 500 Volts AC Fuse 8 : 2 Amp 600 Volts AC Fuse List ***NOTE Plug in an RJ45 cable from the Motor Controller into the Display and plug in another RJ45 cable from the Motor Controller to the Backspin Relay for power. RX TX Tornado F-5 Backspin Relay Module Backspin Probe Connection Only C Phase Sensing B Phase Sensing A Phase Sensing 120VAC Neutral Relay N/O Relay Common Relay N/C H1 X2 Sensing Voltage PT Fuse 6 Fuse 8 X1 120 V AC (1) 120 VAC INPUT (2) VAC NEUTRAL (3) CT - A (4) CT - COMMON (5) CT - B (6) RELAY COMMON (7) CT - C (8) DI - 2 (9) RED LIGHT CONTACTOR (11) 120 VAC (12) START INPUT (13) DI 1 (14) SENSING VOLTS (15) AUTO INPUT (16) 120 VAC (17) MANUAL INPUT (18) ANALOG INPUT #1 (19) G (10) AMBER LIGHT ANALOG INPUT #2 (20) CT-A G CT-B G CT-C COMM 2 TX COMM 1B COMM 1A TX Tornado F-5 RX RX ESP MOTOR Backspin Alarm Active 120VAC Line Recording Ammeter MOTOR CONTACTOR BACKSPIN PROBE DRAWN BY: Global Production Solutions GPS SIZE: DATE: DWG NO: REV: N/A 24 April 2012 TORNADO F-5 CONNECTION DIAGRAM N/A PROJECT: TORNADO F-5 OPERATOR MANUAL SCALE: N/A Typical Backspin Connection SHEET 1 of 1 Figure1. Typical Connection of the Backspin Probe
Chapter 5 Backspin Detection Setup The backspin detection is setup using the motor controller display parameters. Under the Fault Activations Menu, the Backspin Enable parameter is set to yes if backspin detection is desired. Once the backspin has been detected, after a motor stop command or shutdown fault, the Motor Controller Display will show direction CBA/ABC and RPM in HZ this is held in the controller memory until updated approx every 2 sec, or until the backspin relay detects that the motor has stopped turning and lockout is cleared. This means if communication between motor controller and backspin relay is lost it will not reset the backspin speed or direction and you will be unable to clear lockout without changing the backspin Fault Activation Menu Enable to NO.
Chapter 6 Stand Alone Backspin Setup The backspin relay system can be used to prevent starting pumps while spinning, using the 120VAC input, the backspin relay output, and a motor controllers Digital or aux input and an N/C contact on the contactor. The Backspin relay output changes state only while backspin is present the N/O becomes closed and the N/C becomes open. Using the N/O and common contacts and going thru the N/C contacts on the contactor into the digital/aux input to the motor controller, this will allow the unit to start and run if the digital input/aux is set to N/C to shut down. Once the contactor is pulled the backspin alarm becomes active but the signal will not go thru the N/C contacts of the contactor until a shut down occurs, then the backspin alarm will remain closed until the spin stops. 11
Main Power (1100 3300 Volts AC) 50 / 60 Hz Input L 1 L 2 L 3 Fuse 1 Fuse 2 Fuse 3 MOTOR CONTACTOR ISOLATION SWITCH ***NOTE VSD pulls K-1 in when unit is stopped connecting Backspin Relay to stop on customer interface board. When Backspin stops VSD will be allowed to start. This will drop K-1 and opens Backspin Relay output until VSD stops again. COMMON VSD RUN COMMAND N/O N/O N/C K-1 RELAY K-1 RELAY CONTACTS Fuse 120 VAC BACKSPIN PROBE RX TX Backspin Relay Module Tornado F-5 Backspin Alarm Active Backspin Probe Connection Only C Phase Sensing B Phase Sensing A Phase Sensing Relay N/C Relay Common Relay N/O 120VAC Neutral 120VAC Line Fuse 120 VAC VSD STOP COMMAND ESP MOTOR DRAWN BY: Global Production Solutions GPS SIZE: DATE: DWG NO: REV: N/A 24 April 2012 TORNADO F-5 CONNECTION DIAGRAM N/A PROJECT: TORNADO F-5 OPERATOR MANUAL SCALE: N/A Stand Alone Backspin Connection SHEET 1 of 1 Figure 2. Typical Connection: Stand-Alone Backspin Probe Option
Appendix A Product Warranty Warranty coverage: Global Production Solutions ( GPS ) warrants GPS manufactured products ( Product ) to be free of workmanship and material defects for a period of eighteen (18) months from the date of shipment to Buyer or twelve (12) months from the date of installation. GPS, at its option, will at no charge either repair, replace, or refund the purchase price of the Product during the warranty period, provided it is returned in accordance with the terms of this warranty to 35431 Hardesty Road, Oklahoma USA 74801, at GPS option, may include the replacement of parts or boards with functionally equivalent reconditioned or new parts or boards. Replaced parts or boards are warranted for the balance of the original applicable warranty period. All replaced parts, boards or Product shall become the property of GPS. Shipping costs are to be borne by the purchasing party. This express warranty is extended by GPS to the party purchasing the Product ( Buyer ) and is not assignable or transferable to any other party. This is the complete warranty for the Products, except as modified by separate agreement between GPS and Buyer. GPS is not responsible under this warranty for ancillary equipment, whether or not manufactured by GPS, which is attached to or used in connection with the Product, nor for operation of the Product with any such with any such ancillary equipment. Because each Product system is unique, GPS disclaims liability for range, coverage, or operation of the system as a whole under this warranty. This warranty applies within the fifty (50) United States and the District of Columbia. WHAT THIS WARRANTY DOES NOT COVER: Defects or damage resulting from use of the Product in other than its normal and customary manner, (b) Defects or damage from misuse, accident or neglect, (c) Defects or damage from improper testing, operation, maintenance, installation, alteration, modification or adjustment, (d) Product disassembled or repaired in such a manner as to adversely affect performance or prevent adequate inspection and testing to verify any warranty claim, (e) Product which has had the serial number removed or made illegible.
GENERAL PROVISIONS: This warranty sets forth the full extent of GPS responsibilities and liability regarding the Product, and repair, replacement, or refund of the purchase price, at GPS option, is Buyer s exclusive remedy. THIS WARRANTY IS GIVEN IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, WHICH ARE SPECIFICALLY EXCLUDED INCLUDING, WITHOUT LIMITATION, IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN NO EVENT SHALL GPS BE LIABLE FOR DAMAGES IN EXCESS OF THE PURCHASE PRICE OF THE PRODUCT, FOR ANY LOSS OF USE, LOSS OF TIME, INCONVENIENCE, COMMERCIAL LOSS, LOST PROFITS OR SAVINGS OR OTHER INCIDENTAL, SPECIAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE USE OR INABILITY TO USE SUCH PRODUCT. PATENT AND SOFTWARE PROVISIONS: GPS will defend at its own expense any suit brought against Buyer to the extent that it is based on a claim that the Product or parts infringes a United States patent, and GPS will pay those costs and damages finally awarded against Buyer in any such suit which are attributable to any such claim, but such defense and payments are conditioned on the following: (i) that GPS will be notified promptly in writing by Buyer of any notice of such claim; and (ii) that GPS will have sole control of the defense of such suit and all negotiations for its settlement or compromise; and (iii) should the Product or parts become, or in GPS opinion be likely to become, the subject of a claim infringement of a United States patent, that Buyer will permit GPS, at its option and expense, either to procure for Buyer the right to continue using the Product or parts or to replace or modify the same so that it becomes non-infringing or to grant Buyer a credit for the Product or parts as depreciated and accept its return. The depreciation will be an equal amount per year over the lifetime of the Product or parts as established by GPS. GPS will have no liability with respect to any claim of patent infringement, which is based upon the combination of the Product or parts furnished by GPS, nor will GPS have any liability for the use of ancillary equipment or software not furnished by GPS, which is attached to or used in connection with the Product. The foregoing states the entire liability of GPS with respect to infringement of patents by the Product or any parts thereof. Laws in the United States and other countries preserve for GPS certain exclusive rights for copyrighted GPS software such as the exclusive rights to reproduce in copies and distribute copies of such GPS software. GPS software may be copied into, used in and redistributed with only the Products associated with such GPS software. No other use, including without limitation disassembly, of such GPS software or exercise of exclusive rights in such GPS software is permitted. No license is granted by implication, estoppel or otherwise under the patent rights of GPS or any third party. 14