Installation & Operation Manual

DECLARATION OF CONFORMITY
Application Of Council Directive(s) Manufacturers Name \ Address: 89/336/EEC Electromagnetic Compatibility 73/23/EEC Low Voltage Franklin Electric Co., Inc. 100 Schaefer Dr. Gas City, IN 46933 Dieter Schuch Franklin Electric Europa GmbH Gutenberg Strasse 8 D-54516 Wittlich Germany EU Directive 89/336/EEC using: EN 55011:1998, A1:1999 & A2:2002 emissions (See Note 1) EU Directive 73/23/EEC using: EN 61010-1:2001 Equipment Type/Environment: Equipment for Measurement, Control & Laboratory use Light \ Heavy industrial

European Representative Name: European Representative Address:

Model Name: SubMonitor Conformance to Directive(s) Product Standard:

Note(s) (1) Product meets emission limit/methods of EN 55011 Class B. Product meets the immunity levels/methods of EN 61326 Year of Manufacture: 2005 We, the undersigned, hereby declare that the equipment specied above conforms to the above Directive(s). Manufacturer Franklin Electric Co., Inc. Full Name Quinn Wise Position Sr. Project Engineer Place Bluffton , IN, USA Date March 28, 2005 Legal Representative in Europe Franklin Electric Europa GmbH Full Name Dieter Schuch Position Product Manager Place Wittlich Germany Date March 28, 2005

www.franklin-electric.com

Contents
To Set SubMonitor Language ................................................2 SubMonitor Submersible Pump Motor Protection System ............................................3 Components ...........................................................................4 Installation............................................................................5-6 Quick Guide to Setup .............................................................7 Additional Programmable Options .......................................8 Password.................................................................................9 Event History......................................................................... 10 Key Parameters in Event History ........................................ 11 Other Features ...................................................................... 12 Special Conditions ............................................................... 12 Programmable Options ........................................................ 13 Troubleshooting .................................................................... 14 Maintenance ..........................................................................15 Specications ....................................................................... 16 Mounting Dimensions .......................................................... 17 Notes ..................................................................................... 18

To Set SubMonitor Language:

After data sync, from monitoring screen, Select Menu, press button Select 5 Detailed Setup, press button Select K Change Password, press button Select English, press button Turn knob until the desired language is displayed, press button to set Select OK to exit

SubMonitor Submersible Pump Motor Protection System

Franklins SubMonitor is an easy to use, programmable protection device for Franklin Electric three-phase submersible motors. SubMonitors features provide advanced protection of submersible motors: SubMonitor operates over the full range of three-phase motor voltages, 200 - 575 volts, 50 and 60 Hz. Operates on motors with service factor current rating of 5 amps through 350 amps - no external current transformers required. Protects motors and pumps from overloads, underloads, overvoltage, undervoltage, unbalanced currents, phase loss*, chattering contacts, and phase reversal. Operates with a Subtrol-equipped submersible motor to provide motor overheat protection. Monitors and displays three-phase voltages, three-phase currents, and pump status. When a fault occurs, displays the fault conditions and status. Records and displays the history of up to 502 fault trip events, plus records changes to programmable parameters. Records total pump operating time. Features a detachable display unit which may be mounted on the front of a panel for viewing operating status. Includes the option of password protection to avoid tampering. Easy mounting with DIN rail mounts. Totally integrated unit - current transformers are built in. Simple Programming SubMonitor has been pre-programmed with default settings for submersible motors and pumps. Set-up is as simple as setting the motor ratings - voltage, Hertz, and SF max amps. Additional programming options can be selected if desired to customize the features and levels of protection. See page 7 for an overview of the menu structure and page 12 for a full list of programmable options. All programming set-up can be made prior to installing at the eld site by connecting 230 volts single-phase between voltage inputs L1, L2 and L3 of SubMonitor (jumper between L2 and L3) and entering the motor data and any other options.
* Phase loss is a severe case of current unbalance. Reported unbalance trips are due to phase loss when current on one of the legs (noted in the data log) is very small, or when the current unbalance function has been disabled.

Components
Reset Switch Inputs (L1, L2, L3) Fault Light (Base)

Base Unit

Control Circuit Terminals

Alarm Circuit Terminals

Integrated Sensor Coils Fault Light (Display) 4 Line Digital Display

Menu Selector Switch

Detachable Display Unit

Plug-in Wiring Connectors

Installation
WARNING: Hazardous Voltage. Electrical shock can cause death or serious personal injury. This equipment should be installed by technically qualied personnel. Failure to install in compliance with national and local electrical codes and within Franklin Electric recommendations may result in electrical shock or re hazard, unsatisfactory performance, or equipment failure.
SubMonitor L1, L2 and L3 Connections must be made on the line side of the contactor as shown L1 L2 L3

  

FIGURE 1

FIGURE 2

Internal Circuit

A2

Start
Off

Stop

A2

FIGURE 3

SubMonitor Wiring 1. Read this section of the manual thoroughly. 2. Disconnect power & verify that power is off before installing SubMonitor. 3. Install SubMonitor as illustrated in the wiring diagram in Figure 1. SubMonitor may be mounted above or below the contactor as shown. To use the DIN rail mount, rst attach the DIN rail clip to the bottom of the base unit. Then secure the SubMonitor to the DIN rail. Attach the top rail rst, then apply downward pressure until the bottom rail snaps into place. 4. Connect three phase power leads to the plug-in connector L1, L2, and L3 terminals as shown in Figure 2. Wire strip length is 5/16 (8mm). The L1, L2, L3 connections must be made to the line side of the contactor passing through the sensor coils as shown in Figure 2. (This is because the overheat signal from the motor must rst pass through the sensor coils, then into the L1, L2, and L3 terminals of SubMonitor). 5. Connect the control circuit wires to the M1 and M2 plug-in connector terminals, and signal circuit wires to the A1 and A2 plug-in connector terminals (Figure 3). Tighten all terminals to 4.5 in-lbs and install the plugin connectors into SubMonitor (plugs are keyed to avoid misconnection). 6. Pass the T1, T2, and T3 motor power leads through the sensor coils in the base unit. 7. NOTE: 6-lead Wye-Delta motors - for a 6-lead motor with a Wye-Delta control panel, each sensor coil must encircle a pair of leads which connect to the same line in the delta connection, such as T1-T6; T2-T4 or T3-T5. 8. As an option, the SubMonitor display unit is detachable and can be mounted on the exterior of the panel door (requires a small punch-out and two screw holes). Use the extension cable provided in the kit to connect the base unit to the display unit. Lightning Arrestor 1. Install the lightning arrestor and connect line leads to the line side of the contactor as shown in Figure 4. 2. The lightning arrestor ground lead must be connected to water strata ground to provide suitable surge protection. Connect metal-to-metal to well casing, drop pipe, or to the submersible motor with wire the same size as drop cable wires.
NOTE: Refer to Franklin Electric Submersible Motor Application, Installation and Maintenance (AIM) manual for further discussion of lightning protection.

FIGURE 4

Quick Guide to Setup

Points 1 through 3 below describe navigation: how to get around among the two menus and several screens. Point 4 describes how to change a parameter. 1. On initial power-up, the control circuit will be locked out until the motor voltage and SF Amps are set. After a 30 second delay while data sync is completed, the monitor screen will report SF Amps Set Too High: Locked Out*. Notice MENU in the lower right cornerthe arrow indicates that pressing the knob will take you to the menu Basic Setup. 2. From Basic Setup, rotate to Select Motor and press, and you will arrive at the Select Motor screen where you can set motor Hz, volts, and SF Amps (read point 4 below). Set the SF Amps to match the motor SF Max Amps by adjusting each digit individually. When you are done with this screen, rotate to OK and press, thereby going back to Basic Setup. 3. Note that selecting Detailed Setup takes you to a longer menu with items that are lettered. Select Back: Basic Setup to return to Basic Setup. Refer to charts on page 7 and page 12 for structure and available options of menus. 4. When you are on a selected screen of either Basic Setup or Detailed Setup and you want to change a setting: a. Rotate the knob until the arrow points to the item to be changed. b. Press the knob and the arrow will blink. Turning the knob now changes the value of the item. c. When the item is correctly adjusted, press the knob and the arrow stops blinking. d. You can now rotate the knob to another item on the screen. Selecting OK returns you to the parent menu. SubMonitor is now set up to protect your motor and pump, and will allow the motor to start when you return to the Monitor screen and select Manual Reset. After any Manual Reset there is a one minute off-time delay before the motor starts. Note that the signal circuit and red Fault LED are ON until the motor data is entered and Manual Reset is pressed. * Phase ReversalSubMonitor has a built in phase sequence meter. If initial power up displays Phase Reversal, the incoming voltage at SubMonitors L1,L2, L3 terminals is negative sequence, and the contactor is locked out until the phase sequence is corrected. Figure 2 on page 4 shows SubMonitor inputs L1, L2, and L3 connected to motor leads T1, T2, and T3 respectively. While this order is not critical for operation of SubMonitor, it should provide proper motor rotation with positive sequence line voltage.

Additional Programmable Options

The table on page 12 shows the parameters that may be changed in the Basic Menu and Detailed Menu screens, including the default settings.
Volts 460 Amps 62 Pump Running 462 63 460 61 Menu

Monitor Display

Basic Setup 5 Detailed Setup 6 Return to Monitor 1 Enter Password 2 Select Motor 3 Underload Trip 4 Overload Trip

Basic Setup Display

Detailed Setup L Restore Defaults M Back: Basic Setup A Underload Trip B C D E F G H I J K Overload Trip Unbalance Trip Overheat Trip Overvoltage Trip Undervoltage Trip False Start Trip Restarts Time Delays Data Logging Changes Password

Detailed Setup Menu

Basic Setup 5 Detailed Setup 6 Return to Monitor 1 Enter Password 2 Select Motor 3 Underload Trip 4 Overload Trip Volts 460 Amps 62 Pump Running 462 63 460 61 Menu

Basic Setup Display

Monitor Display

Password
1. The password is factory preset to 0 0 0, which disables the password protection. With the password protection disabled, all functions in the menus can be changed by any user. 2. If the password protection is enabled, all parameters in the menus can be viewed but not changed until the correct password is entered. 3. Using the password function: a. Go into the Detailed Setup menu and select Change Password. Enter the three digits of the password sequentially left to right, just like a combination lock. Select >OK to return to the Detailed Setup menu. b. Go to the Basic Setup menu and select Enter Password. Enter the password sequentially left to right. 4. If you forget your password, refer to the Enter Password screen which shows a password code. You may call the FE Hotline at 1-800-348-2420 to convert the code into your three digit password. 5. The password resides in the Base Unit. If you change display units, you will need to know the password that was used with the base unit. 6. If you wish to disable the password protection: a. Go to Enter Password in the Basic Setup menu. Enter the correct password. b. Go to Change Password in the Detailed Setup menu. Enter the password 0 0 0 sequentially left to right. 7. When a correct password has been entered, changes can be made for the next 20 minutes. To get another 20 minutes, re-enter the password. 8. The 20 minute valid password interval is terminated if power is disconnected. 9. If the password protection is enabled, the Event History can be reviewed after entering the correct password.

Event History
Information Logged Up to 502 events can be logged and stored in the display unit in a rolling data set. Information stored includes: Event (trip fault, power interruption, etc) Time of event (pump run time) 3 motor currents 3 line voltages Reviewing Events Before events can be reviewed, a valid password must be entered (if the password is other than 0 0 0). Each event is represented by one screen of information. Each event is numbered (0-511). Each event has a time stamp displayed in days (0-1165), hours (0-23), minutes (0.0-59.9).The time stamp displayed is the total pump run time. You can sequence through the events by turning the knob; CCW goes backward in time, CW goes forward in time. Entering the Event Review system is itself an event that is logged. This event provides the Total (pump) Run Time. This will be the rst event shown upon entry into the Event History, and is identied as Total Run Time. Events Logged Total Run Time (always the most recent event) Power Up Delay (records power interruptions) Tripped : Underload Tripped : Overload Tripped : Unbalance Tripped : Overheat Tripped : Overvolt Tripped : Undervolt Tripped : FalseStart Manual Reset Protection Change (Trip Point, etc.) (New protection data recorded) Defaults Restored (New protection data recorded) Motor Change (Hz, Volt, SFA) (New motor data recorded) When detailed logging mode is selected, every switch event and timed reset is recorded. This mode is typically used only for detailed system troubleshooting. Additional events logged: Timed Reset (Motor Start by SubMonitor) Switch On (Motor Start by External Control) Switch Off (Motor Stop by External Control)

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Key to Parameters in Event History

Whenever a setting is changed in the menu, the change is recorded in the event history as a Parameter Change. The parameter that was changed is identied with a parameter number per the following table, and the new setting is recorded.
Parameter Number 0 1 2 3 4 5 7* 8* 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Description Motor Rated Frequency Motor Rated Voltage Motor SFA - hundreds digit Motor SFA - tens digit Motor SFA - ones digit Motor SFA - tenths digit Trip Enable Flags Auto Restart Flags Number of Underload Restarts Number of Other Restarts Time Between Starts Power-Up Time Delay Underload Trip Point Timeout for Underload Trip Overload Trip Point Timeout for Overload Trip Unbalance Trip Point Timeout for Unbalance Trip Timeout for Overheat Trip Overvoltage Trip Point Timeout for Overvoltage Trip Undervoltage Trip Point Timeout for Undervoltage Trip Number of False Starts Timeout for False Start Trip

* Flags are binary format (ie. 1101001) where 1=enabled; 0=disabled. Order of ags: underload, overload, unbalance, overheat, overvoltage, undervoltage, false start. For example, for ags 1101001: Underload, overload, overheat, and false start trips are enabled. Unbalance, overvoltage, and undervoltage trips are disabled.

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Other Features
Reset The SubMonitor will not allow a reset for several minutes after a fault trip, depending on the programmed reset time and fault mode. This allows time for the motor to cool before it is restarted after a problem has occurred. Any Manual Reset causes the motor to restart in exactly one minute. Operation without the Display Unit After the Select Motor parameters are entered (volts, Hz, and SF Amps), the base unit of SubMonitor provides full motor protection even when the Display Unit is disconnected. When operating with a Base Unit only: A run enable condition is indicated by a green LED A trip condition is indicated by a red Fault LED Manual reset is initiated by pressing the Reset Switch The Event History is not recorded (total run time is recorded).

Special Conditions
Note: The SubMonitor is not compatible with variable frequency drives, electronic phase converters, or solid state soft starters. These devices will cause nuisance tripping of the motor overheat fault, or may cause damage to SubMonitor components. Reduced voltage starters may be used with SubMonitor if they are bypassed during normal running condition (Figure 5), and if the starting time does not exceed 3 seconds. Power Factor or Surge Capacitor across-the-line capacitors for either power factor correction or surge protection may be used with SubMonitor. If used, these capacitors must be connected to the power supply lines before these lines pass through the SubMonitor sensor coil windows or motor overheat protection may be lost. Note: At installations where the line voltage is typically 100 to 110% of nominal, it may be necessary to increase the default underload trip setting to fully protect the system against underload conditions.

FIGURE 5

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Trip Point Settings Adjustable Range Adjustable Range

Timeout Settings

Min

Min

Default (On / Off)

Max

Max

Default Setting

Increment

Default Setting

Increment 1 10

Programmable Options
minutes / seconds min sec 10 5 1 1 5 5 1 min min min min min min min

General Parameters Restart Attempts - Underload Restart Attempts - All Other Time Between Starts Power Up Delay 3 3 1 30 0 10 0 0 10* 10* 1 1 Restarts Restarts

On On

10 120

Specic Parameters Underload Overload Undervoltage Overvoltage Current Unbalance Overheated Motor False Start (Chattering) 75% 115% 90% 110% 5% 10 3 15 1 30% 100% 80% 125% 80% 90% 110% 120% 2% 10% 5% 5% 2% 2% 1%

On On On On On On On

30 10 1 1 10 10 starts in 10 sec. 1

of SFA of SFA of Vrated of Vrated

10 5 1 1 5 5 1

120 60 15 15 60 60 15

* Unlimited restarts (**) may also be selected.

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Troubleshooting
Fault Message SF Amps Set Too High Phase Reversal Problem / Conditions SF Amps setting above 350 Amps Reversed incoming voltage phase sequence Measured voltage or current is exceeding the selected motor settings Normal line current Possible Cause Motor SF Amps not entered Incoming power problem Wrong Motor Voltage or SFA Setting Excessively high line voltage or motor current Wrong SF Max Amps setting Over pumping well Clogged pump intake Underload Low line current Closed valve Loose pump impeller Broken shaft or coupling Phase loss Normal line current Overload Wrong SF Max Amps setting High or low line voltage High line current Ground fault Pump or motor dragging Motor stalled or bound pump High or low line voltage Motor is overloaded Overheat Motor temperature sensor Excessive current unbalance has detected excess Poor motor cooling motor temperature High water temperature Excessive electrical noise (VFD in close proximity) Unbalance Overvoltage Undervoltage Current difference between Phase loss any two legs exceeds Unbalanced power supply programmed setting Open delta transformer Line voltage exceeds Line voltage below programmed setting Unstable power supply Poor connections in motor power circuit Unstable or weak power supply

Overrange

False Starts

Chattering contacts Power has been Loose connections in motor interrupted too many times power circuit in a 10 second period Arcing contacts

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Maintenance
Symptom
SubMonitor Dead SubMonitors Screen Does Not Change from Franklin Electric Screen

Possible Cause or Solution

If the line voltage is correct at the SubMonitors L1, L2 and L3 terminals and the display is blank, remove display and check cable connections. If cable connections are ok, then SubMonitor is malfunctioning. Check for a broken or disconnected communications cable from base to display. If cable is ok, then SubMonitor is malfuctioning. SubMonitor has a built-in phase sequence meter to assure once properly installed, a change in incoming power sequence cannot cause the pump to run backwards. If the display reads Phase Reversal the SubMonitor thinks the motor will run in the wrong direction.

Display reads Phase Reversal

On a new installation, after verifying proper motor rotation, switch power leads L1 and L2 on top of the SubMonitor. DO NOT CHANGE THE MOTORS LEADS. On an old installation that was working ne, verify proper motor rotation and/or switch motor leads T1 and T2 at the starter as needed. DO NOT CHANGE THE SUBMONITOR POWER LEADS.

Tripped Light On

Whenever the pump is off as a result of SubMonitor protective function, the red tripped LED (light) on the display and base will turn on. With power turned off, check for a shorted contractor coil or a grounded control circuit lead. The coil resistance should be at least 10 ohms and the circuit resistance to panel frame should be over 1 megohm. A standard or delay-type 1.5 Amp fuse should be used. If proper voltage is at the control coil terminals when controls are operated to turn the pump on, but the contactor does not close, turn off power and replace the coil. If there is no voltage at the coil, trace the control cirucit to determine if the fault is in the fuse, wiring or panel operating switches. This tracing can be done by rst connecting a voltmeter at the coil terminals and then moving the meter connections step by step along each circuit to the power source, to determine at which component the voltage is lost. Check that coil voltage is within 10% of rated voltage. If voltage is correct and matches line voltage, turn off power and remove the contactor magnetic assembly to check for wear, corrosion or dirt. If voltage is erratic or lower than line voltage, trace the control circuit for faults similar to the previous item, but looking for a major drop in voltage rather than its complete loss.

Control Circuit Fuse Blows

SubMonitor Contactor Will Not Close

Contactor Hums or Chatters

Check that the small interlocks switch on the side of the Contactor Opens When contactor closes when the contactor closes. If the switch or Start Switch is Released circuit is open, the contactor will not stay closed when the selector switch is in HAND position. Contactor Closes But Motor Doesnt Run Turn off power. Check the contactor contacts for dirt, corrosion and proper closing when the contactor is closed by hand.

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Specications
Electrical
Input Voltage Frequency Motor SF (Max) Amps Range Maximum Conductor Size Through Sensors Measurement Accuracy * Voltage Current Trip Time - Locked rotor, underload, overload, overheat, unbalance, overvoltage, undervoltage Input Current, L1, L2, L3 Control Circuit Rating Signal Circuit Rating Agency Approvals Standards Met Surge Electrical Fast Transient ESD ANSI/IEEE C62.41 IEC 1000-4-4 Level 4, 4kV IEC 1000-4-2 Level 3, 6kV 3-Phase 190-600 VAC 50 Hz or 60 Hz 5 amps to 350 amps 0.92 diameter, #0000 AWG Max 23 mm diameter, 95 mm2 gauge max 1% 1 digit 1% 1 digit 3 seconds 0.15 amps 1.5 amp AC, up to 600 volts 1 amp AC, up to 250 volts Incandescent lamp, 100 watts max UL 508 classication NKCR, NKCR7 le E160632 cUL

Mechanical
Dimensions (WxHxD) Base Unit Display Unit Total Unit Weight Base Unit Display Unit Total Unit Operating Temperature Range Storage Temperature Range Relative Humidity Protection Class Display Unit Base Unit 8.0 x 5.35 x 4.3 (20.3 x 13.6 x 10.9 cm) 7.0 x 3.0 x 1.4 (17.8 x 7.6 x 3.6 cm) 8.0 x 5.35 x 5.7 (20.3 x 13.6 x 14.5 cm) 46 oz (1.3 kg) 7 oz (0.2 kg) 53 oz (1.5 kg) -20 C to +60 C -30 C to +80 C 10-95% non-condensing NEMA 3R NEMA 1

* When Strong radio frequency energy is present, SubMonitor measurement accuracy (voltage and current) is 3%. Contact Franklin Electric technical support for assistance with these types of installations.

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Mounting Dimensions
(171.45 mm)

4.72
(119.89 mm)

Slot (6.35 mm) Dia. Max. 4 Places

(146.05 mm) (73.03 mm)

2 /8
7

#8 Flathead Screw 1 (19.05 mm) Long 2 Places

(19.05 mm)

Install Gasket Between the Panel and the Back of the Display Unit

1 (19.05 mm) Dia. Clearance Hole in Control Panel Cover for RJ Cable

For Mounting Detachable Display Unit on the Cover of a Control Panel

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TOLL-FREE HELP FROM A FRIEND Franklin Electric Submersible Service Hotline 800-348-2420