LRS Operation Manual

YDQ Series liquid resistor starters
Operation Manual
Xiangfan Dali Industrial Control Co. Ltd.
June, 2006
1. General Description 1 Main use and apply the scope YDQ Series liquid resistor starters (hereinafter referred to as starters) are the new kind of starting devices developed for improving the starting feature of large- and medium sized wire-wound AC asynchronous motors. Having solved the problems of frequency sensitive resistor starters which are high in impact current, difficult in starting and not easy to operate, the starters of this series are suitable for the heavy-load starting of the motors of ball grinding mills, air compressors, crushers, large-sized blast fans and large-sized pumps which are used in the industrial branches of building materials, metallurgy, chemical industry, mining. They are the ideal substitutes for frequency sensitive starters and metal resistor starters.
2 Code Definition
YDQ Auxiliary code of starter Suitable motor Design ordinal number
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Liquid resistor starter Signficance of auxiliary function code: W:Multi-point temperature measurement and glowing alarm function K:Equipped with low voltage motor primary circuit P:Equpped with two AC contactors B:Equpped with vacuum contactors PC:Using programmable controller T:Resistor cabinet Various added codes can be combined to finish relevant functions
2. Fundamental Principle Allow the relative distance between the two parallel plates in the conductive liquid to decrease progressively up to zero through a mechanical driving device and make the resistance value run into the return circuit of motor rotor decrease continuously, so as to realize the heavy-load smooth starting of large- and medium-sized wire-wound motors.
3. Technical Features: 3.1 The starting current is low but constant without impact on power network; the starting current is no more than 1.3 times the rated current. Therefore the requirements of the heavy-load starting of motor for transformer capacity can be decreased, reducing lump sum investment. 3.2 It is smooth in starting, so as to lower its impact on the mechanical
equipment, and the service life of the mechanical equipment and motor can be prolonged by about 30 percent. 3.3 It is high in its heat capacity, and it can start for 5~10 times continuously. 3.4 It can still start under low voltage state. Smooth start can be ensured so long as the voltage of the power network can guarantee the motor to operate normally. 3.5 It is simple in structure, easy to maintain. Its reliability is more superior than that of frequency sensitive, oil-soaked type resistors. 4. Technical parameter (see table 1) Table 1 Model Technical parameter Suitable motor capacity (KW) YDQ5-0.2 YDQ5-0.4 YDQ5-0.6 YDQ5-1 YDQ5-1.5 YDQ5-2 YDQ5-3 YDQ5-4 YDQ5-6 YDQ5-8 Lower than 200 Lower than 400 Lower than 600 Lower than 1500 Lower than 2000 Lower than 3000 Lower than 4000 Lower than 5000 Lower than7000 Lower than 9000 Starting time (S) 20~60 20~60 20~60 20~60 20~60 20~60 20~60 20~60 20~60 20~60 Structure and weight (kg) 200kg 350kg 450kg 500kg 550kg 600kg 720kg 820kg 1050kg 1150kg
Xiangfan Dali Industrial Control Co.Ltd E-mail:daligs@xf.hb.cninfo.net
TEL:0710-3220078 www.dlgs.com.cn
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YDQ5-10
Lower than 11000
20~60
1350kg
5. Profile of Structure The starters of YDQ series are of cabinet type integral style structure. Their protection class can be manufactured up to IP43 according to the need of customers. In addition the structure can be arranged in line with the need of customers. Basic structure and external dimensions are show in Figure 2 and Table 2 .
Elevation
Side elevation figure 2:YDQ5-series
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Table 2 External dimensions and mounting dimensions of YDQ5 series Model External dimensions (mm) A YDQ5-0.2 YDQ5-0.4 YDQ5-0.6 YDQ5-1 YDQ5-2 YDQ5-3 YDQ5-4 YDQ5-6 710 810 910 1010 1110 1210 1540* 2610* B 700 800 860 960 1060 1160 1628 1628 C 1800 2000 2000 2000 2000 2200 2850 2850 Mounting dimensions (mm) E 550 650 750 850 950 1050 ----------F 550 650 710 810 910 1010 ------------ 18 18 18 18 18 18 -----------
Note:1. Take * size at turn the son short connect the machine to choose to use the vacuum chopper the beard add again 1100. 2.The structure of the liquid resistor starter for the motor with even large capacity will be designed and manufactured according to the requirements of customers.
6. Normal Working Conditions Upper limit of ambient temperature is no more than +50 , and lower limit is no less than -5. The relative humidity is no more than 85 percent. The height above sea level is no more than 2000m. It should be placed on an indoor place without obvious shake and impact, without fire and explosive
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dangers and the vertical gradient is no more than 5 . There must be no conductive dust and corrosive gas. Power source is four-wire three-phase system of 380V/220V20A, the undulation of voltage must be guaranteed within 15 percent of rated voltage. The cooling water of resistor is allowed to use the cooling water of circulation, the water pressure is no less than 0.2 MP, water temperature is no more than 30. Note:1 The heater needs to be installed additionally when the ambient temperature is under 0 over a long period of time, the user should explain it while ordering goods. 2 The power supply electric voltage grade special hour, the customer order need to be note.
7. Installation 7.1 It should be best if the liquid resistor cabinet body is to be installed on the concrete platform where can drain. 7.2 The foundation should be level, the cabinet body should be installed in vertical horizon plane. 7.3 Resistor cabinet body can also be installed rightfully above the electric cable chute, if so a channel base should be equipped with. (figure 3) 7.4 The cable of rotor of motor should be connected to the lower end of the short contact of the rear side of resistor cabinet (the lower end of short
contact is connected to the fixed plate of liquid resistor). 7.5 If it is equipped with a phase advancer, the cable of rotor should first run to the phase advancer, and then is connected into the resistor cabinet from phase advancer. 7.6 Liquid resistor starter uses a separate power source in three-phase fourwire system. Lines of 34+12.5mm2 shall be connected to the starter from L1, L2, L3, N on the terminal array IV is zero line., press the diagram paper to connect the good liquid to start the machine with a cabinet, system of DCS or other win to control lock control line between system. 7.7 The earth post should be fitted with green and yellow ground wire.
(figure 3)
8 Adjustment of equipment 8.1 Control wire is connected to the cable of rotor 8.1.1 Check Liquid resistor starter uses a separate power source in threephase 8.1.2 As for connection of control line, allow the liquid starter to be connected to primary cabinet, DCS system or interlocking control line between the medium control system well according to the drawing. 8.1.3 Line of rotor should be connected to lower end of KM2 and join of fixed plate of liquid resistor (line of rotor shall not be fixed until the resistor is tested). 8.1.4 A careful check should be made on whether there are phenomenons of joint leakage, joint mistake and looseness or not before it is powered on. 8.2 Action test of liquid starter 8.2.1 Make the dynamic plate be in the middle position from the upper limit position and lower limit one by using the method running by hand, after the three phases of control power source is confirmed to be in a normal state, let the test knob turn to work position, turn on the air switch in the cabinet, at this moment, if the plate goes upwards it should be in normal mutually preface. 8.2.2 The dynamic plate be in the upper limit position should stop , if the plate goes down, the dynamic phase sequence should be mistaken. At this moment, turn off the power supply and change two phases power source line.
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8.2.3 Then, turn on the power supply of the control and motor and turn test knob rightward to test position, the plate runs down to the lower limit position and stops, and KM2 sucks properly. 8.2.4 Turn test switch leftward to test position, the plate is reset to the upper limit position, using a watch to count out time when the plate runs from the upper limit position to the lower limit position, rectified start protection time is 2 seconds more th0an this time, rectified overtemperature protection time is about 4 seconds. Note: Please determine the phase sequence according to abovementioned method if work needs to change the control power source.
8.3 Preparation of liquid resistor Preparation plan: Preparing the liquid in the light of the resistor of motor rotor. 8.3.1 Water for preparing liquid: It would be the best if the distilled water is used as the water for preparing liquid, soft water can also be used, the lowest limit is to use daily-life water that the deposit has been taken off after purification. The volume of the water should be 10 to 30 percent more than that is required in resistor box. 8.3.2 Resistor solvent, i.e. resistor powder that our company will offer in the amount that is about two times the required volume. 8.3.3 Liquid starting resistor Ro should be determined using the formula:
R0 = 0.577 U 2e k KF t I 2e kM
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where U2e: is the open circuit voltage (V) of the circuit of motor rotor; Ize: is rated current (A) of the circuit of motor rotor; KF: is abundance-capacity multiple of the power of motor. If actual operating value I1 of the current of motor stator is known, you may use K F=
I 1e I1
, where, I1e is the rated current of motor stator, if your equipment is a new one that has not been put into operation, the I 1 is unknown, you may use K F = where, Ne is the rated power of motor and N1 is the power required by load Kt: Temperature multiple, if temperature of the solution prepared is about 30, Kt1.2; KM: is starting torque multiple, that is K M =
MQ Me
Ne , N1
, where MQ is the starting
torque of motor during starting and Me is the rated torque of motor. As for starting the mechanical equipment with full load, such as ball grinding mills, KM1.1~1.3, we normally suggest that you use 1.1, if capacity of power network is large enough and load torque is over large, you may use 1.3 8.3.4 .Preparation of resistor Turn the dynamic plate to the upper limit position first, fill the water prepared to approximately two-thirds of specified level in water tank, you
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should pay attention to that three liquid level marks should be equal basically. Weigh a certain amount of electric liquid powder. Pour the water prepared into a vessel, such as basin or bucket first. The poured water shall be no more than two-thirds of the total volume of the vessel. Take one-third of weighed electric liquid powder and put it into the vessel slowly, and stir continuously till the electric liquid powder is dissolved fully. Then fill the solution into one phase of resistor box, the part of electric liquid powder in block type that has not been dissolved shall be dissolved through adding hot water. If there is still a little undissolved matter, you may give it away. If the vessel is so small that the electric liquid powder cannot be dissolved one time, the electric liquid powder may be dissolved by part to part. Repeat step for filling the dissolved electric liquid powder into other two phases of the resistor box. Add water to each phase of the resistor box respectively to specified level. (The resistor box is about 60mm from liquid level). Turn on and turn off test button to make plate move up and down two or three times and allow resistor liquid in box to be stirred evenly. Use clean cloth to wipe water drops off the external surface of the box. Measuring for the liquid resistor After making its dynamic plate more to starting position, add electricity of
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50Hz to the points between dynamic plate and static plate each phase using a self-coupling transformer. The current I(A) shall be increased from zero to about 5A gradually. Record the readings of ampere A, and measure the voltage-drop V(v) between two plates at the same time. The measuring
liquid resistance is R( ) =
V (v ) and measuring circuit is as following: I ( A)
where Fu: Fuse 2A; A: AC ampere 5A, Grade 0.5; B: voltage adjuster 5KVA; V: AC voltmeter Grade 0.5. The resistance value gained from measuring shall be near the calculation value R0, allowing an error of 0.5 percent. Adjustment of resistance: If the resistance is rather high, the concentration of the resistor liquid shall be increased, otherwise, its concentration shall be decreased. The adjustment method is to take out a part of liquid by using a piece of flexible pipe and add a certain amount of water or electric liquid powder to it. Note: (1) Dynamic plate must be in the upper limit position and rotor
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circuit shall be separated from resistor box when resistance is measured. (2) The resistor liquid shall not be measured until it is stirred evenly. (3) The phase line and zero line of voltage adjuster must not be connected reversely. 8.4 Turn on power for commissioning 8.4.1 Turn on the control power source of the starting cabinet and again do an action test for the starting cabinet. Test knob shall be turned to work position if the action test is in normal condition. 8.4.2 Simulation commissioning Turn on the primary cabinet for the main motor to test position, turn on the control power source for primary cabinet and starting cabinet only. After Allowable starting indicating lamps of the starting cabinet lights, press down the turn-on button of primary cabinet, the switch of primary cabinet is turned on this moment, starting indicating lamp on the surface plate of the starting cabinet lights, at the same time, the plate moves from upper side to lower side to the lower limit position, KM2 sucks properly. The Start indicating lamp goes out and Run indicating lamp goes on. The above-mentioned conditions show that both starting and operation are in normal conditions. Press down the switch-off button of primary cabinet, the switch of primary cabinet is switched off, and KM2 is turned off, Run indicating lamp goes out, the plate moves from upper side to lower side, at the same time, Reset indicating lamp goes on. When the plate moves to upper limit position, Reset indicating lamp goes out, allowable starting
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indicating lamp goes on. You should get ready for next start. 8.4.3 Starting commissioning Turn on the main power source of primary circuit and control power source of primary cabinet and starting cabinet. Start motor in line with the order of simulation commissioning. Observe whether the starting current is in specified range (1.1~1.3 I 1e) or not. If the starting current is too high at the beginning, it shows that the resistor is low. The concentration of resistor liquid shall be decreased. The method is to take a part of liquid out of water tank and fill the same amount of clear water, commission again after the liquid is stirred evenly. If the starting current is too low at the beginning and impact is too high when KM2 circuit breaker (contact) is turned on, it shows that the resistor prepared is too high, so it shall be made lower. The concentration of the resistor liquid shall be increased. The method is to take out a part of liquid and add a suitable amount of electric liquid powder to it. Care shall be taken to that electric liquid powder shall not be added to water too much one time. The electric liquid powder must be fully dissolved in water tank. And adjust the resistor until the starting current is in normal condition. 8.5 Trouble shooting
Trouble Soun Power
Cause Dynamic
Check and treatment method a) Turn off power source, run belt wheel
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d and source light alarms indicating lamp goes out
plate upper lower
is
in or
to allow the dynamic plate to reset to normal position.
limit b) Check for whether main contact KM1 and KM3 are adhered to or not. c)Whether spacing switch SQ1 and SQ3 lose efficacy or not.
position
Power source KT1 functions a. Prolong indicating lamp goes on
rectified
time
of
KT1
appropriately (see Turn on for Commissioning). b. Check whether there are mechanical trouble (belt skids) in driving parts or not KA6 functions a) Check whether the rectified
value (shall be 60to 65) of electric contact thermograph ST1 is correct or not. b) Whether it starts several times continuously or not, to make liquid temperature be too high.
"
Allow
to is
start" Liquid level is If short contact lamp 131 and 133 go on, not too low fill clear water up to specified level.
indicator
bright after reset
KA2 does not a) Check whether spacing switch SQ1
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function
and SQ3 lose efficacy or not. b) Whether there is something wrong with KM2 itself or not.
KA3 does not Check whether KA3 coil and its contact function Temperature is too low Liquid to start easily temperature decreases increase resistance value Temperature of resistor An liquid rises continuously
current through liquid electric passes the resistor
has troubles or not. Heat the liquid resistor to normal atmospheric temperature to
Maintain or replace contact KM2
under operation state. Whether the environment temperature lead or not is high, having
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YDQ Series liquid resistor starters fever source the
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9. Service and maintenance 9.1 Power source of the control cabinet must be turned on first before the equipment is started, it will not be started until allowable start indicating lamp goes on. 9.2 Electrolytic liquid should be generally changed every 4 to 5 years, at the same time clean the plate and insulation cabinet body before filling fresh electrolytic liquid. The plate should be again cleaned with clear water after the conductive surface is first corroded with thin hydrochloric acid, the insulation cabinet body should be dried in the air after it is first washed with clear water, then it will be coated with epoxy resin several times (under general condition, it would be the best if you do not wash the insulation cabinet body through disassembling, you should avoid it from shaking and impacting so as not to make the cabinet body crack when you disassemble it). 10.The conveyance, save 10.1 Packing request according to the customer eligibility use simple packing, domestic packing and export packing request. 10.2 The electric resistance cabinet can't lie to pour the porterage, the in order to prevent damage spreads to move the piece and insulate a box of body.
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10.3 The single cabinet mourns to pack and should avoid bump shot, the packing rises to mourn and should press to keep the luck the marking mourns to pack. 11. Open the box and checks 11.1 Before openning the box should check whether packing is intact or not, the damaged severity should negotiate with the conveyance unit, or contact with my company. 11.2 Open the box to rise to mourn should hang up on the ring,2:00 should hang up to the Cape.( mourn to pack the diagram to see the figure 4) 3, mourn to pack the cabinet body tilt to one side should big in 60 os( figure 5)
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Figure 4 12. Notice to order goods
Figure 5
12.1 Type, standards and quantity of the products to be ordered. 12.2 Type, power, voltage and current of the motor to be fitted with, name and requirements of working system of the equipment to be fitted with. 12.3 Special requirements should be negotiated with manufacturer.
table 1 type weight Resistivity kg 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 2.0 1.75 1.5 1.25 1.0 0.75 0.5 0.45 0.4 0.35 0.3 0.2 0.2 3.5 3.25 3.0 2.75 2.5 2.0 1.5 1.25 1.0 0.7 0.6 0.5 0.45 5.5 5.25 5.0 4.5 4.0 3.75 3.0 2.75 2.5 2.3 2.0 1.8 1.5 8.5 8.0 7.5 7.0 6.5 6.0 5.5 5.0 4.5 4.0 3.5 3.0 2.5 13.5 12.8 12.0 11.5 9.5 8.50 8.00 7.50 7.0 6.5 6.0 5.50 5.00 27.5 20.5 16.5 13.5 11.5 10.5 9.5 8.5 7.5 7.0 6.5 6.0 5.5 45.0 35.0 28.5 23.5 20.0 17.5 15.5 14.0 12.5 11.5 10.5 10.0 9.5 YDQ50.2 YDQ50.4 YDQ50.6 YDQ5 -1 YDQ5 -2 YDQ53 YDQ54 re ma rk
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YDQ Series liquid resistor starters 1.6 1.7 1.8 1.9 2.0
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2.0
4.5 4.0 3.5 3.0 2.5
5.25 5.0 4.5 4.0 3.5
9.0 8.5 8.0 7.5 7.0
Note:Attach the watch in the data means under the condition that normal temperature, go together with the liquid to use the water as distilled water, the electrolysis powder to fuse well of test value.( Provide the reference only
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YDQ Series liquid resistor starters

Xiangfan Dali Industrial Control Co. Ltd.

YDQ Series liquid resistor starters

YDQ Series liquid resistor starters

YDQ Series liquid resistor starters

Xiangfan Dali Industrial Control Co.Ltd E-mail:daligs@xf.hb.cninfo.net

YDQ Series liquid resistor starters

Lower than 11000

Side elevation figure 2:YDQ5-series

Xiangfan Dali Industrial Control Co.Ltd E-mail:daligs@xf.hb.cninfo.net

YDQ Series liquid resistor starters

Xiangfan Dali Industrial Control Co.Ltd E-mail:daligs@xf.hb.cninfo.net

YDQ Series liquid resistor starters

YDQ Series liquid resistor starters

YDQ Series liquid resistor starters

YDQ Series liquid resistor starters

Xiangfan Dali Industrial Control Co.Ltd E-mail:daligs@xf.hb.cninfo.net

YDQ Series liquid resistor starters

, where MQ is the starting

Xiangfan Dali Industrial Control Co.Ltd E-mail:daligs@xf.hb.cninfo.net

YDQ Series liquid resistor starters

Xiangfan Dali Industrial Control Co.Ltd E-mail:daligs@xf.hb.cninfo.net

YDQ Series liquid resistor starters

V (v ) and measuring circuit is as following: I ( A)

Xiangfan Dali Industrial Control Co.Ltd E-mail:daligs@xf.hb.cninfo.net

YDQ Series liquid resistor starters

YDQ Series liquid resistor starters

Trouble Soun Power

Xiangfan Dali Industrial Control Co.Ltd E-mail:daligs@xf.hb.cninfo.net

YDQ Series liquid resistor starters

d and source light alarms indicating lamp goes out

plate upper lower

to allow the dynamic plate to reset to normal position.

Power source KT1 functions a. Prolong indicating lamp goes on

bright after reset

KA2 does not a) Check whether spacing switch SQ1

Xiangfan Dali Industrial Control Co.Ltd E-mail:daligs@xf.hb.cninfo.net

YDQ Series liquid resistor starters

Maintain or replace contact KM2

Xiangfan Dali Industrial Control Co.Ltd E-mail:daligs@xf.hb.cninfo.net

YDQ Series liquid resistor starters fever source the

Xiangfan Dali Industrial Control Co.Ltd E-mail:daligs@xf.hb.cninfo.net

YDQ Series liquid resistor starters

Xiangfan Dali Industrial Control Co.Ltd E-mail:daligs@xf.hb.cninfo.net

YDQ Series liquid resistor starters

Figure 4 12. Notice to order goods

Xiangfan Dali Industrial Control Co.Ltd E-mail:daligs@xf.hb.cninfo.net

4.5 4.0 3.5 3.0 2.5

5.25 5.0 4.5 4.0 3.5

9.0 8.5 8.0 7.5 7.0

Xiangfan Dali Industrial Control Co.Ltd E-mail:daligs@xf.hb.cninfo.net

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