lev-co 13-12 User manual

User’s Guide
Control Systems for
VFD-Based Fume and Dust Collection Systems
Rev. 06 2016-12-13
©2015 Lev-co Inc. All rights reserved.

i
Table of Contents
1 Introduction ..........................................................................................................................................1
1.1 Scope ............................................................................................................................................1
1.2 System Architectures....................................................................................................................1
1.3 List of Standard Models................................................................................................................2
1.3.1 Model 13-12 –Type 1 –VFD as a Contactor Replacement...................................................3
1.3.2 Model 13-13 –Type 2 –VFD System with Constant Duct Pressure .....................................4
1.3.3 Model 13-14 –Type 3 –Type 2 System with Controlled Electrical Dampers ....................... 5
1.3.4 Model 13-15 –Type 3 VFD System with Blast Gates ............................................................6
1.3.5 Model 13-16 –Enhanced Control System for Wet Collectors .............................................. 7
1.3.6 Model 13-74 –Type 2 System with Vibra-Pulse Cleaning.....................................................8
1.3.7 Model 13-75 –Type 2 System with Shaker Motor Cleaning.................................................9
1.3.8 Models 13-76 and 13-77 –Type 2 System with Sequenced Solenoids Cleaning................10
2 VFD Specifications...............................................................................................................................11
3 Type 1..................................................................................................................................................15
3.1 Mechanical Installation...............................................................................................................15
3.2 Electrical Installation ..................................................................................................................15
3.3 VFD Setup ...................................................................................................................................15
3.4 Operation....................................................................................................................................16
3.5 Troubleshooting..........................................................................................................................16
4 Type 2..................................................................................................................................................17
4.1 Mechanical Installation...............................................................................................................17
4.2 Electrical Installation ..................................................................................................................18
4.3 Pressure Sensor Setup................................................................................................................18
4.4 VFD Setup ...................................................................................................................................18
4.5 Operation....................................................................................................................................19
4.6 Troubleshooting..........................................................................................................................19
5 Type 3..................................................................................................................................................20
5.1 Mechanical Installation...............................................................................................................20

ii
5.2 Electrical Installation ..................................................................................................................20
5.3 Pressure Sensor Setup................................................................................................................20
5.4 VFD Setup ...................................................................................................................................21
5.5 Operation....................................................................................................................................21
5.6 Troubleshooting..........................................................................................................................21
6 Type 3 with Blast Gates.......................................................................................................................22
7 Type 2 with Sequenced Solenoid Filter Cleaning................................................................................22
7.1 Mechanical Installation...............................................................................................................23
7.2 Electrical Installation ..................................................................................................................23
7.3 Pressure Sensor Setup................................................................................................................24
7.4 VFD Setup ...................................................................................................................................24
7.5 Operation....................................................................................................................................25
7.6 Troubleshooting..........................................................................................................................25
8 Type 2 or 3 with Shaker-type Auto Dust Collector .............................................................................26
8.1 Mechanical Installation...............................................................................................................26
8.2 Electrical Installation ..................................................................................................................26
8.3 Pressure Sensor Setup................................................................................................................26
8.4 VFD Setup ...................................................................................................................................26
8.5 Operation....................................................................................................................................26
8.6 Troubleshooting..........................................................................................................................27
9 Wet Cleaning –Enhanced Control System..........................................................................................27
10 Appendix .........................................................................................................................................28

iii
List of Illustrations
Figure 1 –Type 1 Architecture...................................................................................................................... 3
Figure 2 –Type 2 Architecture...................................................................................................................... 4
Figure 3 –Type 3 Architecture...................................................................................................................... 5
Figure 4 –Blast Gate System Architecture ...................................................................................................6
Figure 5 –Enhanced Control System for Wet Collectors - System Architecture..........................................7
Figure 6 –Type 2 System with Vibra-Pulse Cleaning System Architecture ..................................................8
Figure 7 –Type 2 System with Shaker Motor Cleaning System Architecture...............................................9
Figure 8 –Type 2 System with Sequenced Solenoids Cleaning System Architecture ................................10
Figure 9 - Pressure Sensor...........................................................................................................................17
Figure 10 - Pressure Sensor Connections....................................................................................................23
Figure 11 - Pressure Gauge Front Panel......................................................................................................24

iv
Reference Documents
SOURCE
TITLE
DOWNLOAD REF
ABB
ABB ACS250 Users’ Guide
https://library.e.abb.com/public/e26638e1f3cd410e85257db00052f1a2/3AUA0000
137830_REVB.pdf
ABB
ABB ACS550 User’s Guide
https://library.e.abb.com/public/313b6ebaf237059fc1257d0a0048fd68/EN_ACS550
_01_UM_H_A4.pdf
Belimo
FSLF Actuators
https://www.belimo.us/belimo/media/Technical_Documents/Fire_and_Smoke_Act
uators/FSLF_Actuators.pdf
Danfoss
MG11AK22 Danfoss FC102
Instruction Manual
http://drives.danfoss.com/downloads/documents/#/
Danfoss
MG11CD22 Danfoss Pro-
gramming Guide
http://drives.danfoss.com/downloads/documents/#/
Dwyer
616KD Series
http://www.dwyer-inst.com/PDF_files/PDS/DS_616KD.PDF
http://www.dwyer-inst.com/PDF_files/616KD_new.pdf
Invertek
Optidrive Eco User Guide
Rev 2.01
http://www.invertekdrives.com/client-uploads/download-manager/user-
guides/82-HEMAN-
IN%20V2.02%20Optidrive%20Eco%20User%20Guide%20Rev%202.02.pdf
Lev-co
Users’ Guide - Model 13-
16 Enhanced Control Sys-
tem for Wet Collectors
http://www.lev-co.com/attachments/User%20Guides/(13-
16)%20User's%20Guide%20-
%20Enhanced%20Control%20System%20for%20Wet%20Collectors%20R2.pdf
Norgren
V61R517AA213JB
http://cdn.norgren.com/pdf/V60-V62%20Series%20Valves.pdf
Sensocon
A1/A2 Installation & Op-
eration Manual
http://www.sensocon.com/files/PDFs/IOM_A1-A2.pdf

v
Revision Record
DATE
Rev No.
Description
2015-11-19
01
First Release
2015-11-20
02
Updated Spare Parts Numbers
2016-04-29
03
Complete update
2016-06-27
04
Drawing updates; text revisions; addition of sections 7 & 8
2016-08-30
05
Revised Figs 5 & 7, all section 9. Changed title. Text updates.
2016-12-13
06
Revised to included multiple VFD types; extended to include new models
Warranty
This product is guaranteed to be free of defects in materials or workmanship for a period of one (1) year
from date of delivery. Lev-co undertakes to repair and/or replace any such defect within the warranty
period at no cost to the client. Any action by the client involving attempted repair and/or replacement
either by himself or a third party voids this and all warranties.
If such exists, Lev-co extends the warranty of the manufacturer(s) for components used in this product
under the terms stipulated in said warranty(ies). No other warranty is either express or implied.

1
1Introduction
1.1 Scope
This User’s Guide is intended to describe the control systems used in Lev-co fume and dust extraction
systems employing Variable Frequency Drives (VFDs). It does not cover the installation of the ducting,
arms or hose reels, dampers or blast gates, motors, fans, filters or other equipment directly related to
the extraction process. It is limited to the control system only.
Lev-co uses VFDs from various vendors in its systems, dependent on commercial factors or in some cas-
es user preference (familiarity with a given vendor’s product, for example). In essence, all systems func-
tion identically, so only one, based on the Invertek Optidrive, is described herein. Where required, ref-
erences are included to other types, and drawings are provided for all types currently supported.
Items which are critical for safety, performance, or compliance with legal requirements are highlight-
ed in RED and marked with this symbol.
1.2 System Architectures
Lev-co manufactures and distributes local exhaust fume and dust extraction systems. Apart from effec-
tive contaminant removal, one of our major objectives is the minimization of energy consumption, for
both economic and environmental reasons. One of the key methods by which this objective is achieved
is by the use of Variable Frequency Drives to control the operation of fan motors.
The fan motor is invariably a three-phase AC induction motor, which may in some cases be supplied by
single-phase mains power (converted to three-phase by the VFD). Such a motor may be operated in a
variable-speed/constant-torque manner by driving it with a source of variable frequency and voltage.
These two parameters bear a fixed relationship for any given motor; for example, a motor rated for op-
eration at 575 volts and 60Hz has a V/Hz characteristic of 575/60 = 9.583V/Hz. If it is a two-pole motor,
it also has a full rated speed of 3600RPM. Thus, it can be driven at any selected speed by applying a
voltage and frequency along the 9.583V/Hz curve, with the resultant speed being 60RPM/Hz. Thus, half-
speed (for example) is achieved at a voltage of 287.5V and 30Hz, and 90% speed at 517.5V and 54Hz.
(Motor slip is ignored.)
A typical VFD has four main components:
a) A single- or three-phase controlled bridge rectifier which converts the primary AC input voltage
into a semi-regulated internal DC voltage.

2
b) A DC link which smooths the rectified output, usually by means of a large capacitor, and pro-
vides the control feedback to the primary voltage regulator.
c) A DC-to-AC inverter which converts the internal DC bus to the variable-frequency/variable volt-
age output power, usually by means of a high-frequency PWM (pulse-width-modulated) oscilla-
tor. The AC output is in fact a sinusoid synthesized from high-frequency pulses of variable width
and amplitude.
d) A controller which manages the output frequency and voltage as well as many other ancillary
functions.
Lev-co uses VFDs in one of three system architectures:
Type 1 –manually variable duct pressure with optional automatic start/stop
Type 2 –controlled duct pressure with optional automatic start/stop
Type 3 –controlled duct pressure and automatic start/stop with system-powered electrical
dampers.
Any of these basic architectures may be supplemented by options including fire detection and automatic
filter cleaning. These are described below.
1.3 List of Standard Models
Standard available models comprise the following:
Model 13-12 –Type 1 –VFD as a Contactor Replacement
Model 13-13 –Type 2 –VFD System with Constant Duct Pressure
Model 13-14 –Type 3 –Type 2 System with Controlled Electrical Dampers
Model 13-15 –Type 3 VFD System with Blast Gates
Model 13-16 –Enhanced Control System for Wet Collectors
1
Model 13-74 –Type 2 System with Vibra-Pulse Cleaning
Model 13-75 –Type 2 System with Shaker Motor Cleaning
Model 13-76 –Type 2 System with DC Sequenced Solenoids Cleaning
Model 13-77 –Type 2 System with AC Sequenced Solenoids Cleaning
1
This model is not described in this Manual. It has its own User Guide, noted in the Reference Documents table.

3
1.3.1 Model 13-12 –Type 1 –VFD as a Contactor Replacement
In this architecture, the VFD operates simply as an enhanced-performance contactor replacement. The
benefits are the ability to gently ramp motor speed up and down at start and stop, thereby minimizing
motor stresses and extending motor life, as well as eliminating heavy startup surge currents and their
attendant wasteful energy costs. Motor speed may also be adjusted via a supplied speed adjustment
potentiometer to obtain desired extraction performance, reduce noise, or to deliberately reduce energy
consumption during periods when peak demand charges are in effect.
External start/stop interlocking is provided to permit control by one or more external contacts, such as
damper limit switches, foot switches, hood switches, or current-sensing switches. AMU (air make-up
unit) interlocking is also available via this function.
An indicator is provided to show when the motor is running. Options include fused disconnect and duct
pressure indicator.
Figure 1 –Type 1 Architecture

4
1.3.2 Model 13-13 –Type 2 –VFD System with Constant Duct Pressure
In this approach, the Type 1 system is extended to include a pressure sensor in the main duct down-
stream of the fan, which allows the VFD to actively control motor speed as a function of duct (negative)
pressure. This permits constant, effective exhaust at a target duct pressure no matter how many damp-
ers are open or (within limits) the state of the filters. The benefits of the Type 1 architecture also apply.
A MANUAL/OFF/AUTO switch permits the user to override pressure sensing and run the system at max-
imum speed. The same interlocks, indicators and options are available as for Type 1.
Figure 2 –Type 2 Architecture