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AQUAVAR® CPC - Depco Pump Company

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1. X1 Control Wiring m 1 SCR Terminal for transducer shield Connected internally to chassis ground Shield Analog input channel 1 2nd transducer Default frequency reference 2 Al1 Resolution 0 1 accuracy 1 J1 Al1 OFF 0 10 V Ri 312 kQ EPI J1 Al1 ON 0 20 mA Ri 100 2 2 Switch positions listed on page 25 q 3 AGND Analog input circuit common Connected internally to chassis gnd through 1 MW Jumper wire to X1 11 Jumper Wire 4 10V 10 V 10 mA reference voltage output for analog input potentiometer accuracy 2 Not used Analog input channel 2 Transducer D 5 Al2 Resolution 0 1 accuracy 1 e sr m Transducer input Connection lt White lt 4 20 mA or Black 6 AGND Analog input circuit common Connected internally to chassis gnd through 1 MQ 7 AO1 Analog output programmable Default Not used Current 0 20 mA load lt 500 Q 8 AO2 Analog output programmable Default Not used 0 20 mA Gei load lt 500 Q Transducer Power 9 AGND Analog output circuit common Connected internally to chassis gnd Supply through 1 MQ Brown 10 24V Auxiliary voltage output 24 VDC 250 mA reference to GND Short or Red N circuit protected Transducer digital input power supply 11 GND Auxiliary voltage output common Connected internally as floating Jumper Wire e x Digital input common To activate a digital input there must be 1
2. REM PARAMETERS 2201 VALUE DECREASE 2202 VALUE INCREASE 5 0 PSI 2203 ENABLE SEQUENCE 2204 SWITCH LEAD LAG EXIT EDIT REM PARAMETERS 2201 VALUE DECREASE 2202 VALUE INCREASE 2203 ENABLE SEQUENCE 59 00 HZ 2204 SWITCH LEAD LAG EXIT EDIT when the frequency has reached 59HZ on the lead pump plus value decrease has been met NOTE Always set this parameter at or BELOW the MAXIMUM FREQUENCY If no changes from default are required press the CANCEL key PROGRAMMING MultiPump Constant Pressure Control 18 After 2203 has been selected press the down arrow to 1 2 2 SO o Once 2204 has been saved press the down arrow to Final step is to enter your required system as Optional Step To lock out access to the control REM PARAMETERS 2201 VALUE DECREASE highlight parameter 2204 SWITCH LEAD LAG Press the EDIT key once Using the up or down arrows select the alternating time between lead and lag pumps Once selected press the SAVE key REM PARAMETERS 2204 SWITCH LEAD LAG SYNC LIMIT highlight 2207 PUMP ADDRESS Press the EDIT key once Use the up arrow to select your appropriate address for each pump Always start with address one Once each pump has a different address press the SAVE key pressure After above programming has been completed for each A
3. psa Display Description 2001 Reserved 2002 2003 2004 DIR LOCK The change in direction being attempted is not allowed Either e Do not attempt to change the direction of motor rotation 2005 1 0 COMM Fieldbus communication has timed out Check for and correct e Fault setup 2411 COMM FAULT FUNC and 2412 COMM FAULT TIME e Communication settings Group 31 or 32 as appropriate e Poor connections and or noise on the line 2006 Al1 LOSS Analog Input 1 is lost or value is less than the minimum setting Check e Input source and connections e Parameter that sets the minimum 1604 2007 TRANSDUCER Analog Input 2 is lost or value is less than the minimum setting LOSS Check e Transducer connection and wiring e Input source and connections e Parameter that sets the minimum 1506 2008 PANEL LOSS Panel communication is lost and either e Drive is in local control mode the control panel displays LOC or e Drive is in remote control mode REM and is parameterized to accept start stop direction or reference from the control panel To correct check e Communication lines and connections e Parameter 2401 KEYPAD FAILURE 2009 RESERVED 120 FAULTS ALARMS Alarm Displa Description Code E P 2010 MOT Motor is hot based on either the drive s estimate or on temperature feedback OVERTEMP This alarm warns that a Motor Underload fault trip may be near Check
4. PROGRAMMING Single Pump Programming Pressure transducer 16 Optional Step To lock out access to the control panel keypad refer to page 109 This will prevent unauthorized users from changing programming NOTE If an error or fault occurs refer to the troubleshooting faults section of this manual page 116 When troubleshooting an Aquavar system always break down into the following components 1 Aquavar programming check default settings recommended for single pump multi pump slave pump etc 2 Electrical supply motor wiring grounding check your supply voltage motor wiring transducer wiring and grounding 3 Mechanical Pump Rotation check your pump rotation rubbing or other mechanical problems Pump run out 4 Hydraulic System Piping check to ensure proper suction and discharge piping layout proper NPSHa air entrainment vortex friction loss system curve compensation etc 5 Environment protect from high temperatures direct sun freezing temperatures high altitude dust vibration lack of air flow 77 PROGRAMMING Single Pump Submersible Pump Constant Pressure SINGLE PUMP SUBMERSIBLE CONSTANT PRESSURE LAYOUT Besse AQUAVAR u1 SR U2 U2 vi _ vi v2 WI W2 W2 ae A GND GND s pqs ow UN l Q AQUAVAR CPC F FUSIBLE DISCONNECT n 3 LOAD REACTOR ech amp AIR DIAPHRAGM TANK PRESSURE TRANSDUCER 3
5. W I Reinstall the rubber plugs 4 Non English speaking locations Add a warning sticker in the appropriate language over the existing warning on the top of the module 22 INSTALLATION Frames R1 R6 Install the Wiring Conduit Gland Kit Wiring drives with the IP 21 UL type 1 Enclosure requires a conduit gland kit with the following items e Conduit gland box e Screws e Cover The kit is included with IP 21 UL type 1 Enclosures Overview As you install the wiring observe the following e There are four sets of wiring instructions one set for each combination of drive enclosure type IP 21 UL type 1 and IP 54 UL type 12 and wiring type conduit or cable Be sure to select the appropriate procedure e Connection Diagrams on page 24 shows the connection points on the drive e Power Connections on page 29 describes specific instructions for wiring the power Use in combination with the appropriate general procedure e Control Connections on page 29 describes specific instructions for wiring the control Use in combination with the appropriate general procedure e Cable Terminals on page 135 list the recommended tightening torques e Where applicable observe EMC recommendations For example properly ground the wire screen cable shields 23 INSTALLATION Frames R1 R6 Three Phase Wiring Connection Diagrams The layout of connection terminals is similar for all frame sizes R1 R6
6. NOTE When using relay outputs to activate constant speed pumps in a multi pump application the slave pumps 1 2 and 3 should utilize relay outputs RO1 RO2 and RO3 accordingly Slave 1 gt RO1 Sequence logic is affected by these selections Restart Options Parameter 14 05 See MINIMUM SPEED OPTIONS Low Water Suction Protection The Aquavar provides protection from dry run conditons in pressure level temperature and speed control modes This feature may also be used to provide inter lock capabilities In these cases additional system condition inputs e g level switch pressure switch flow switch etc are used to alert Aquavar of conditions that require protection of the pump Discharge Header mmi j GouLps iN Flow Switch AQUAVAR Centrifugal Pump Controller Speed Signal l Once wired parameter 24 05 LOW WATER must be set to WARNING or WARN AND CONTROL Digital Input 2 DI 2 terminal 14 on the X1 terminal board If this contact is OPEN the response being 1 WARN amp CONTROL In this response Aquavar will issue a warning and then either shut down or reduce speed depending on your settings At this point the pump will behave similar to the description in MINIMUM SPEED Alarm amp Control is the recommended setting 108 FEATURES 2 WARNING ONLY In this response Aquavar will simply issue an alarm warning displayed on the keypad screen but continues
7. 32000 32000 MRev motors accumulated revolutions counter 0 0 disabled Revolution Act 0 65535 Defines the actual value of the MRev motors accumulated revolutions counter The parameter is reset by writing 0 to it 5104 5105 Run Time Trig 0 0 6553 5 Sets the trigger point for the 40 40 40 40 40 kh drive s run time counter 0 0 disabled 5106 Run Time Act Displays actual run time Single Synch Multi Constant Speed Group 99 Pump ronous Control Slave Control Information Range Description 9901 FWVersion AXXX hex Version of the firmware loaded to the AV 9902 Drive Rating XXXY Indicates the drive s current and voltage rating The format is XXXY where XXX The nominal current rating in amps If present an A indicates the decimal point in the rating for the current Y The voltage rating of the drive where Y 2 indicates a 208 240 Volt rating and Y 4 indicates a 380 480 Volt rating 72 PROGRAMMING Single Pump Programming Pressure transducer REM C 0 0 Standard view of display in REM remote mode You will see 40 2 PSI sp the reference pressure REF PRESSURE actual pressure ACT 0 0 PSI ac PRESSURE and motor frequency in HZ 0 0 HZ DIR MENU RECOMMENDED INSTALLATION LAYOUT zm ners l ke SUPPLY POWER emer i Gem VI WI 6 GND A 3 PHASE OUTPUT T
8. Keypad and set point locks Group 11 START UP DATA Provides parameters used for initial start up information e g language application voltage motor current motor RPM horsepower Used for initial motor setup Group 12 START STOP Determines method s of starting and stopping the Aquavar i e Keypad external switch Modbus manual test run and motor jog Group 13 RAMPS amp WINDOWS Parameters used for the acceleration and deceleration of the pump Window and Hysterisis contains modulation of algorithm pressure control regulation Group 14 SPD LIM START LVL Parameters that contain speed control max and min frequency restart value priming delay Group 15 TRANSDUCER VAR Parameters used for the setup and tuning of the pressure transducer flow meter and adjustment of transducer range Group 16 REFERENCE SELECT Parameters that control how the set point is maintained i e Modbus keypad analog input transducer Group 18 RELAY OUTPUTS Parameters that define how the Aquavar output relays are controlled and what delay time is actuated for each relay Three total relays can be used RO1 RO2 RO3 50 PARAMETER LISTINGS Aquavar CPC Parameter List continued Group 19 ANALOG OUTPUTS Defines the analog outputs available on the drive Two possible analog outputs that can be used to monitor various parameters AO1 AO2 Group 21 REGULATE Defines type of control regulation with analog input from
9. Not Sel Not Sel Not Sel Not Sel Not Sel 56 PARAMETER LISTINGS Group 12 Start Stop 1203 Test Run continued Range Automatic Description If selected and the drive has not run for the test delay 1205 the drive will start and run at 50 of maximum speed 1401 for 20 seconds and shutdown Auto Restart 1202 must be on Single Synch Pump ronous Defaults Multi Control Constant Speed Slave Control Manual Once manual is selected the drive will start and run at test speed 1204 for 20 seconds and shutdown Once the manual test is complete this parameter will return to Not Sel Not Sel Not Sel Not Sel NotSel Not Gel 1204 Test Speed FL 0 100 Selects the speed the test runs atin manual test mode 1203 25 25 25 25 25 1205 Test Run Delay 0 3600 Hr Selects how long after the drive is idle before it will do a test run 1000 1000 1000 1000 1000 1206 MotorJog Jogs motor for 10 sec 60 RPM to check for motor rotation Disabled Disabled 1209 Manual Override Disabled Default Drive will run at constant speed as set in Parameter 1210 when enabled and contact DI5 is active 1210 Override Freq Ramps Windows Group 13 0 60 Hz Range Sets motor speed when manual override is active Descript
10. Pump Protect The pump protection warning or fault function has been activated Start Slave Used in multipump macro to start slave pump only Stand by Drive is in sleep mode due to no system demand Single Synch Pump ronous Control Run ning Run ning Defaults Multi Run ning Constant Speed Slave Control Start Slave Run ning 1805 RO2 ON Delay 0 3600 s Defines the operation delay for relay output RO2 1806 RO2 OFF Delay 0 3600 s Defines the release delay for relay output RO2 1807 Relay RO3 Output Selects the AV status to be indicated through relay output 3 RO3 The relay energizes when the status meets the setting Relay warnings are reset automatically faults must be manually reset Not Sel default The output is not used Run The output indicates the drive is running Ready The output indicates that power is supplied to the drive and it is awaiting a start command VFD Fault The drive has faulted Not Used Not Used Not Used Not Used Not Used 63 PARAMETER LISTINGS Group Relay 18 Outputs Range Low Water Description The secondary protection warning orfault function has been activated Did is low for the protection delay setting 2404 Closed normal Open Secondary Protect fault function is active Pump Protect Th
11. then press the EDIT key Next use the up arrow to select OPEN then press the SAVE key This group should appear as OPEN if it does not you have entered the pass code incorrectly or it has changed Contact your local Goulds Water Technology representative for the master code Once your group 1001 is showing OPEN you can access all of the pump and drive parameters in the Aquavar After the SAVE key is pressed in the above group press the EXIT key then the down arrow to highlight the group 11 START UP DATA then Press the SEL key once Using the arrows highlight 1102 APPLIC MACRO then press the EDIT key Default is set for SINGLE PUMP Change this group whether your system is Single Pump Multi Pump Slave Pump etc To exit press CANCEL to save this parameter press the SAVE key once Use down arrow until group parameter 1104 MOTOR NOM VOLTAGE is highlighted then press EDIT Use the arrows to enter your motors nameplate voltage then press the SAVE key REM C MAIN MENU 1 PARAMETERS WIZARDS CHANGED PAR REM C PAR GROUPS 10 11 START UP DATA EXIT REM C PARAMETERS 1001 PARAMETER LOCK 1002 PASS ar in 1003 LOCAL LOCK 1004 PARAM SAVE EXIT EDIT REM PARAMETERS 1001 PARAMETER LOCK OPEN 1002 PASS CODE 1003 LOCAL LOCK 1004 PARAM SAVE EDIT REM PARAMETERS 1101 LANGUAGE 1104 MOTOR NOM VOLT 1105 MOTOR
12. 453 6777 Fax 888 322 5877 www xyleminc com brands gouldswatertechnology Goulds is a registered trademark of Goulds Pumps Inc and is used under license Aquavar is a trademark of Xylem Inc or one of its subsidiaries 2012 Xylem Inc IM167 Revision5 July 2012
13. INSTALLATION Frames R1 R6 Check Installation Before applying power perform the following checks 32 V Check Installation environment conforms to the drive s specifications for ambient conditions The drive is mounted securely Space around the drive meets the drive s specifications for cooling The motor and driven equipment are ready for start 3 phase motor For floating networks The internal RFI filter is disconnected The drive is properly grounded along with the pump motor and control panel The input power mains voltage matches the drive nominal input voltage watch for open delta power The input power mains connections at U1 V1 and W1 are connected and tightened as specified Loose connections may cause arcing The input power mains fuses are installed according to NEC The motor connections at U2 V2 and W2 are connected and tightened as specified The motor cable is routed away from other cables and in separate conduit NO power factor compensation capacitors are in the motor cable The control connections are connected and tightened as specified NO tools or foreign objects such as drill shavings are inside the drive NO alternate power source for the motor such as a bypass connection is connected no voltage is applied to the output of the drive Single phase power is connected to U1 and W1 with GND INSTALLAT
14. One of the motor phases is lost Check for and correct e Motor fault e Motor wiring connections e Motor cable fault e Internal fault 35 OUTP WIRING Error in power wiring suspected Check for and correct es Input power wired to drive output e Ground faults 101 SERF CORRUPT Error internal to the drive Contact your local factory 102 SERF IITFILE representative and report the error number 103 SERF MACRO 104 SERF EFBPROT 105 SERF BPFILE 201 DSP T1 OVERLOAD Error internal to the drive Contact your local factory 202 DSP T2 OVERLOAD representative and report the error number 203 DSP T3 OVERLOAD 204 DSP STACK ERROR 205 DSP REV ERROR 206 OMIO ID ERROR Faults that indicate conflicts in th e parameter settings are listed below 1000 PARHZRPM Parameter values are inconsistent Check for any of the following e 2001 MINIMUM SPEED gt 2002 MAXIMUM SPEED e 2007 MINIMUM FREQ gt 2008 MAXIMUM FREQ e 2001 MINIMUM SPEED 9908 MOTOR NOM SPEED gt 128 or lt 128 e 2002 MAXIMUM SPEED 9908 MOTOR NOM SPEED gt 128 or lt 128 e 2007 MINIMUM FREQ 9907 MOTOR NOM FREQ gt 128 or lt 128 e 2008 MAXIMUM FREQ 9907 MOTOR NOM FREQ gt 128 or lt 128 1001 PAR PFCREFNG Parameter values are inconsistent Check for the following e 2007 MINIMUM FREQ is negative 1003 PAR AI SCALE Parameter values are inconsistent Check for any of the following e 1503 TRANSDUCER MIN gt 1502 TRANSDUCER MAX 1004 PAR AO
15. Use a soft damp cloth to clean the control panel Avoid harsh cleaners which could scratch the display window Battery A battery is only used in control panels that have the clock function available and enabled The battery keeps the clock operating in memory during power interruptions To remove the battery use a coin to rotate the battery holder on the back of the control panel Replace the battery with type CR2032 124 MAINTENANCE Frame Sizes R7 R8 Layout The layout stickers of the drive are shown below The stickers show all possible components concerning maintenance activities Not all of them are present in each delivery 3 V21 V23 A11 A12 A15 Code 64572261 Code 64601423 Designation Component A49 Control Panel A41 Motor Control and I O Board OMIO Y41 Cooling Fan C Capacitors 125 MAINTENANCE Frame Sizes R1 R6 Heatsink The heatsink fins pick up dust from the cooling air The drive runs into overtemperature warn ings and faults if the heatsink is not clean In a normal environment not dusty not clean the heatsink should be checked annually in a dusty environment more often Clean the heatsink as follows when necessary 1 Remove the cooling fan see section Fan below 2 Blow dry clean compressed air from bottom to top and simultaneously use a vacuum cleaner at the air outlet to trap the dust Note Prevent dust from entering adjoining equipment 3 Replace the cooling fa
16. e IP 54 ULtype 12 enclosure indoor use only This enclosure provides protection from airborne dust and light sprays or splashing water from all directions e UL Type 3R Enclosures are intended for outdoor use to provide a degree of protection from falling rain Undamaged by the formation of ice on the enclosure May be cooled by forced air and louvers for vents e P 56 UL type 4 enclosure Constructed for outdoor use or hose down applications Provides a degree of protection against falling dirt rain sleet snow windblown dust and splashing water Not suitable for direct sun A sun shield or canopy may be required Suitable Mounting Location Confirm that the mounting location meets the following constraints e The drive must be mounted vertically on a smooth solid surface and in a suitable environment as defined above e The minimum space requirements for the drive are the outside dimensions see Outside Dimensions on page 141 and 143 plus air flow space around the unit see Cooling on page 137 e The distance between the motor and the drive is limited by the maximum motor cable length See Motor Connection on page 136 e The mounting site must support the drive s modest weight and noise output See Dimensions and Weights on page 141 Wiring and EMC Considerations Determine electromagnetic compliance EMC requirements per local codes In general always follow the NEC in the absence of a local code
17. modes and instrument type selected during programming Values may be adjusted in parameter 13 06 EXAMPLE if the Aquavar unit was in pressure control with the set point at 100 psig the regulation window would be factory preset at 8 of the set point This would result in an 8 PSIG window 4 PSIG above the set point and 4 PSIG below the set point Parameter Name Value Range Note s 13 06 REG 0 100 Constant Pressure 8 WINDOW Flow Direct 30 Suggested settings are above in the notes Sometimes the REGULATION WINDOW will have to be adjusted to smooth out the system pressure Default setting is 8 NOTE If the system pressure drops below or goes above the hysteresis limits DASHED lines then the Aquavar control software will adjust the speed with the fast ramps This would occur if you have a rapid demand of water in your system Normally it takes a few seconds to level off 112 FEATURES Hysteresis Set Point Hysteresis Al I I I I I p I I I I I I I I I I I I I w I D I Ka I I OpuIAA 1S210 SA gt qulog3 S luloq 185 40 Buim s Aopu AA R1 Ramp 1 Fast Acceleration R2 Ramp 2 Fast Deceleration R3 Ramp 3 Slow Acceleration Set Point Scale e g Pressure PSIG Flow GPM etc R4 Ramp 4 Slow Deceleration Time
18. the drive 70 PARAMETER LISTINGS Modbus Setup Group ER Protocol ID Range 0 0xFFFF Description is required by the user unless desired Refer to the fieldbus manual This parameter configures the module type automatically by the fieldbus adapter No action changes to default settings are Single Synch Pump ronous Control Multi Defaults Constant Speed Slave Control 3202 Station ID 0 247 1 1 1 1 1 3203 Baud Rate 1 2 57 6 9 6 9 6 9 6 9 6 9 6 kbits s kbits s kbits s kbits s kbits s kbits s 3204 Parity Defines the data length parity 8N2 8N2 8N2 8N2 8N2 and stop bits 8N1 8 data bits no parity and one stop bit 8N2 8 data bits no parity and two stop bits 8E1 8 data bits even parity and one stop bit 8 data bits odd parity and one stop bit 3205 Selects the communication ABB ABB ABB ABB ABB Profile profile Drives Drives Drives Drives Drives 3207 CRC Errors ABB Drives ABB Drives control word and Status Word AV Alternate Profile 3206 OK Messages 0 65535 Read only counter of good Modbus messages Read only counter of CRC errors 3208 EFBUART Errors Read only counter of UART errors 3209 EFB Status protocol Contains the status of Modbus Idle Drive is configured for Modb
19. to your constant speed pump starter sized for the appropriate horsepower and voltage The relay outputs located on the terminal control board X1 SEE DIAGRAM FROM PREVIOUS PAGE will actuate when programmed according to the operators desired output The lag pumps will turn on when the Aquavar controlled pump cannot keep up to the required demand The lag pumps will be operated by across the line starters and signaled to start via the Aquavar relays located on terminal s 19 through 27 of the X1 terminal block The lag pumps are referred to as SLAVE pumps because they operate with commands from the Aquavar controlled LEAD pump The Aquavar controller will actuate the relays and provide a time delay for ON OFF on each relay Lag Pump Starts Head Value Decrease Capacity GPM The figure shows Pump 1 when it cannot maintain the system pressure value decrease Next Pump 1 lag pump 2 will operate as a lead and lag system If Pump 1 2 cannot maintain system flow then lag 2 pump will turn on then you will have all three pumps 1 2 3 operating in the system You can operate up to 3 slave pumps with 1 Aquavar controlled pump NOTE Each lag pump is controlled by the speed of the lead Aquavar pump system pressure drop value decrease and a delay time in seconds Do not set the pressure drop too close to operating system pressure or pump cycling will occur 95 PROGRAMMING MultiPump Slave Pump Con
20. 0 0 4 10 0 0 4 13 0 0 5 13 0 0 5 14 0 0 55 14 0 0 55 c 55 0 2 5 5 E 8 0 0 3 8 0 0 3 8 5 0 3 8 5 0 3 d 5 5 0 2 5 5 RE 65 10 25 65 0 25 65 0 25 9 0 0 35 Center to center dimension Weight UL Type 1 Weight for each Frame Size Ib Ib Ib Ib Ib Ib Sa E Em E 142 TECHNICAL DATA Units with IP 54 UL Type 12 Enclosures Outside Dimensions IP 54 UL Type 12 Dimensions for each Frame Size Ref R1 R2 R3 R4 R5 R6 mm in mm in mm in mm in mm in mm in W 215 8 5 215 85 257 10 1 257 10 1 369 14 5 410 16 1 W2 225 8 9 225 89 267 10 5 267 10 5 369 14 5 410 16 1 H3 441 17 4 541 21 3 604 23 8 723 28 5 776 30 5 924 36 4 D 238 9 37 245 9 6 276 10 9 306 12 0 309 12 2 423 16 6 Mounting Dimensions Mounting dimensions are the same as for the IP 21 UL Type 1 Enclosure See Mounting Dimensions on page 144 Weight IP 54 UL Type 12 Weight for each Frame Size 8 4 186 11 5 25 4 18 1 40 0 26 6 58 7 42 93 86 190 143 TECHNICAL DATA Weights and Dimensions W i A 1 n 1 Q Frames R7 R8 r i 1 ai JI G
21. 4 Max characteristic being monitored 64 PARAMETER LISTINGS Analog Outputs Group 19 Range Description Single Synch Defaults Multi Pump ronous Control Constant Slave Speed Control 1904 MinimumAO1 0 0 20 0mA_ Defines the minimum value of 0 1 0 1 0 1 0 1 0 1 AO1 Default 4 mA 1905 MaximumAO1 0 0 20 0mA_ Defines the maximum value of 20 20 20 20 20 AO1 Default 20 mA 1906 AO2 Content Sel Connects a AV signal to analog Not Not Not Not Not output 2 AO2 Used Used Used Used Used Not Sel default Not in use Frequency Output frequency 20 mA motor nominal frequency 1106 Current Output current 20 mA motor nominal current 1105 Torque Motor torque 20 mA 100 of motor nominal rating Power Motor Power 20 mA 100 of motor power rating Proc Var Actual value of process variable Actual Al2 20 mA Reference 1 Max 1603 Energy Saving Calculated energy savings option 1 or 2 over a conven tional fixed speed system 20 mA Savings scale 2603 1907 AO2 Content Various Selects the minimum value of the Min characterisitc being monitored 1908 AO2 Content Various Selects the maximum value of the Max characteristic being monitored 1909 MinimumAO2 0 0 20 0mA_ Defines the minimum value of 4
22. 4 4 4 4 AO2 Default 4 mA 1910 MaximumAOQ2 0 0 20 0mA_ Defines the maximum value of 20 20 20 AO2 Default 20 mA Group oC Single Synch Multi Constant Speed 21 SEES Range dek Pump ronous Control Slave Control Regulation Mode Selects the type of AV control with Normal falling process variable signal Normal Increases the output speed with Default falling process variable signal For level control applications the tank is on the discharge side Inverse Decreases the output speed with falling process variable signal For level control applications the tank is on the suction side 65 PARAMETER LISTINGS Group 21 Regulate 2102 Press Incr Speed Range Description Sets the speed for which additional pressure is added to compensate for system frictional losses at increased flow Used for single pump and backup modes only Default 20 Hz Single Synch Pump ronous Control Defaults Multi Constant Speed Slave Control 2103 Press Incr Group Multipump 22 Control Value Decrease 0 10000 The pressure increase in selected units point which is added to the set point pressure to compensate for frictional losses at the pressure increase speed Used for single pump and backup modes only Note the full set point pressure increase is achieved at maximum speed 1401 Description Defines how much the actual
23. 5 Description This is the protection limit in PSI for the process value at which Pump Protect Ctrl 2402 activates when pump is at max speed for the protection delay Single Synch Pump ronous Control 0 0 Defaults Multi 0 Constant Speed Slave 0 Control 0 2404 Protection Delay 0 200 s This is the protection delay period prior to activation of Pump Protect Ctrl 2402 Default setting is 0 sec 2405 Low Water Loss of digital input 2 DD for protection delay 2404 Disabled Default Protection is disabled Warn The AV generates a warning only Secondary Protect A no other action is taken Warn and Control Parameter 1202 Auto Restart must be set to On to automatically restart once fault has been reset Dis abled Dis abled Dis abled Dis abled Dis abled 2406 Error Reset 0 9999 Indicates number of fault resets Note parameter 1202 Auto Restart must be set to on When set to 0 Error Reset is disabled Time between resets ig parameter 2407 Reset Delay Manual intervention is required if fault is still active after set number of resets has been achieved The drive reaction to the fault will be according to parameter 1405 Config Speed Min setting Reset is applicable to parameters 2404 and 2405 2407 Reset Delay 1 250s Defines the time that the AV will wait after an alarm
24. 60 000 operating hours at maximum rated operating temperature and drive load The expected life span doubles for each 10 C 18 F drop in the fan temperature fan temperature is a function of ambient temperatures and drive loads Fan failure can be predicted by the increasing noise from fan bearings and the gradual rise in the heatsink temperature in spite of heatsink cleaning If the drive is operated in a critical part of a process fan replacement is recommended once these symptoms start appearing Replacement fans are available from the factory Do not use other than factory specified spare parts 122 MAINTENANCE Frame Sizes R1 R6 Frame Size R1 R4 To replace the fan 1 Remove power from drive 2 Remove drive cover 3 For Frame Size e R1 R2 Press together the retaining clips on the fan cover sides and lift e R3 R4 Press in on the lever located on the left side of the fan mount and rotate the fan up and out 4 Disconnect the fan cable X0021 5 Install the fan in reverse order 6 Restore power Frame Size R5 and R6 2 99 To replace the fan 1 Remove power from drive 2 Remove the screws attaching the fan 3 Disconnect the fan cable 4 Install the fan in reverse order 5 Restore power Internal Enclosure Fan Replacement IP 54 UL Type 12 enclosures have an additional internal fan to circulate air inside the enclosure Frame Size R1 to R4 To replace the internal enclosure fan in frame sizes R1
25. E EEE E r E LEET TETEE RRRLKIN APON NI 102 addy Nd 300 0001 0 F 2672F00 noe SIEPA DoS E 267F00 329F00Y7 600 0 2 268F00V 16EG Je Se3F00V 26 F00V 32e3F00V ON Lad ON Lavd gu 3BnSs3j84 33200SNV3l ON L Yd IZHOOY e APPENDIX tion ifica Transducer Cable Spec EO AON O a MER el A Hl DIE Sam ma YVAVNOV ZENZ TR dd JOAC esesjey Au IoPON 371 308d SS3N1Y13 ALEDFYLNIDNOJ X11 LNONAY Io 100 NAY FQUd JIONY 09181 NOLLISOd 3081 SOUYONVIS LID 1umew id TT TONVGHODSY Y HL MAKE NI S338V893101 2138138039 LSANOT NOdN QINYNLIY 38 OL OMA bat WW CS 1300N ONI ATIAX ADOTONHOAL YALA S719NV EY YOSNIS ISSN ZE sare an soo F a 18Vd Yos zer 3d NI ATIAX ADOTONHDAL KEE Ee en 5 U i Leewe 0021 d9 voov 0021 9636 009 mr 009 ss oge J9EPOOV ur Die 00 d9Evoov 00E iis og oer 08 YIAWNN E SL CR LHM e d1HS NU gt Le osi Ni any 4d Io SCT OD 40 NOISSINY Ad N3LLDA HOI NOdN 143OXd LON TIVHS ANY YSN AN STIV4V93N3S ONI WFIAX ADO TONHOAL Y3 LYM SCINOD dO AldadOud JHL SI SNIAAVYC SIHL SUSLINETTIA SJH NI 3SIWU3HIO GILON SST INN S39NV83101 1V43N39 saopjd Z 9N I 0IOWY JAO IQEPOOV POW O L2 8 HIN dZIS 09E JVBVD OL NOIldl85S30 0131HS JLON du dil 9 1109 318V2 YOd N d NV HOQNJA dpuM o1 Pld 9 14902 109 2 0 pu WON DIP D19A0 13
26. HZ Default is 10 of the parameter 1106 MOTOR NOM FREQ which is 6 HZ For a submersible motor or suction lift situation this would be set to at least REM PARAMETERS 1101 LANGUAGE 1102 APPLIC MACRO 1104 MOTOR NOM VOLT 1105 MOTOR ADM CURR REM PARAMETERS 1104 MOTOR NOM VOLT 1105 MOTOR NOM CURR 1106 MOTOR NOM FRE OTOR NOM RP LA EXIT EDIT REM C PARAMETERS 1105 MOTOR NOM CURR 1108 MOTOR NOM POW 1 0 HP REM PARAMETERS 1111 MOTOR ID RUN 1201 START STOP KEYPAD 1202 AUTO RESTART 1203 TEST RUN REM PARAMETERS 1401 MAXIMUM FREQ 1402 MINIMUM FREQ 30 0 HZ 1403 CONFIG SPEED MIN 1404 STP DELY MIN SPD EDIT 30 HZ For a positive suction booster system leave at the default setting Once changed press the SAVE key to store the setting 75 PROGRAMMING Single Pump Programming Pressure transducer 12 From group 1402 press the down arrow until group 1502 TRANSDUCER MAX is highlighted then press EDIT Default pressure transducer setting is 300 psi Adjust this based on your maximum rating for a new transducer NOTE Goulds Water Technology provides a 0 300 psi transducer as standard Select the appropriate range then press SAVE If no changes are necessary press CANCEL REM PARAMETERS 1410 UNDERVOLT CTRL 1411 PRIMING DELAY 1501 TRANSDUCER UNIT 1502 TRANSDUCER MAX 13 Use the down arrow to highl
27. IS MOTOR CURRENT 0 20mA input MOTOR POWER THIS IS THE DEFAULT PRESSURE MOTOR PROC VAR TRANSDUCER INPUT 4 20Ma MOTOR ENERGY SAVNGS 21 01 REGULATION NORMAL DEFAULT SELECTS THE TYPE OF AQUAVAR MODE INVERSE CONTROL AS THE ANALOG SIGNAL RISES OR FALLS SET TO INVERSE FOR DECREASED MOTOR SPEED BASED ON SUCTION LEVEL TRANSDUCER 26 03 SAVINGS 0 65535 If ENERGY SAVNG is selected as an SCALE Default 10 000 output this parameter must be set to scale the signal 4 mA 0 00 and 20 mA equals this amount For example 20 mA 10 000 Auto Restart The Aquavar drive can be configured to start automatically following a power failure Changing the value to ON will enable auto restart Selecting OFF disables the auto restart AUTO RESTART is also used with ERROR RESET for automatic restarts following a shutdown due to a pump fault AUTO RESTART will also restart the pump once a secondary protection fault is reset Parameter Name Value Range Note s 12 02 AUTO OFF When this is set to ON the Aquavar RESTART ON DEFAULT will automatically re start after a power failure or fault reset 25 04 AR OVER ENABLE Allows the drive to restart after a motor CURRENT overcurrent error 25 05 AR OVER ENABLE Allows the drive to restart after an VOLTAGE INPUT OVERVOLTAGE error 25 06 AR UNDER ENABLE Allows the drive to restart after an VOLTAGE INPUT UNDERVOLTAGE error 25 07 AR AI lt ENABLE Allows the drive to res
28. PHASE OUTPUT ALWAYS D DISCHARGE CHECK VALVE GATE VALVE HIGHLY RECOMMENDED SUBMERSIBLE PUMP END SUBMERSIBLE MOTOR 3 PHASE 78 PROGRAMMING Single Pump Submersible Pump Constant Pressure It is possible to utilize the Aquavar Centrifugal Pump Controller on commercial industrial well and submersible turbine applications Submersible pumps and motors require specific installation programming and pipe layout compared to above ground booster pump systems However specific programming must be followed to meet minimum requirements set forth by the motor manufacturer i e Franklin Electric Always consult with the appropriate motor technical manual for motor compatibility and requirements when using a Variable Frequency type drives NOTE THE AQUAVAR IS NOT RECOMMENDED FOR RESIDENTIAL WELL APPLICATIONS CONSULT GOULDS WATER TECHNOLOGY FOR SUITABLE VARIABLE SPEED CONTROLLERS DESIGNED FOR RESIDENTIAL WELL PUMPS e g BF15 series Service Factor Amps The submersible pump will sometimes utilize the motor service factor or MAX AMPS Therefore during peak use times it is recommended to select the appropriate Aquavar based on the MOTOR MAXIMUM AMPS or service factor amps Normally this can be found on the motor nameplate or the AIM application installation manual This will avoid nuisance tripping or current overload by the Aquavar The Aquavar is designed to protect the motor on overcurrent Compare the motor max amps wi
29. Programming on page 73 e Additional refinements can be made using the control panel to manually select and set individual parameters See Complete Parameter Descriptions on page 50 Assistant Control Panel Display Features The AQUAVAR CPC Control Panel features e Alphanumeric control panel with a LCD display e Language selection for the display e Drive connection that can be made or detached at any time e Start Up Wizard to ease drive commissioning e Copy function Parameters can be copied to the Control Panel memory for later transfer to other drives or for backup of a particular system e Context sensitive help Control Panel Keypad The following table summarizes the button functions and displays on the Control Panel LCD Display Divided into three main areas Top line variable depending on the mode of operation For example see Status Information Middle area variable in general shows parameter values menus or lists Bottom line shows current function of the two soft keys and the clock display if enabled Soft key 2 Function varies and is defined by the text in the lower right corner of the LCD display Soft key 1 Function varies and is defined by the text in the lower left corner of the LCD display REM 50 40 2 PSI sp Down Arrow Up Arrow Scrolls down through a menu or list displayed in the middle of the LCD Display Scrolls up t
30. RAMP HYSTERESIS Ramp hysteresis is the point at which the Aquavar controller changes over from the fast ramp to the slow ramp Default values of Ramp Hysteresis are in of the regulation window The values for RAMP HYSTERESIS are automatically selected based upon the control mode selection made during programming EXAMPLE Using the same example above the Regulation Window was 8 psig An 80 ramp hysteresis would be 3 2 PSIG Note from the graph this is 1 6 PSIG on the upper half of the regulation window and 1 6 PSIG on the lower half of the regulation window Parameter Name Value Range Note s 13 05 RAMP 0 100 Pressure 80 HYSTERESIS Flow Direct 5 As the figure shows Aquavar attempts to keep the actual process reading within the Setpoint Hysteresis Window using the slow acceleration and deceleration ramp rates When the process reading exceeds this window it will compensate using the fast acceleration or deceleration ramp rates Adjusting Ramp Rates Ramp 1 Fast Acceleration This ramp is the fast run up time used when the pump first starts and is trying to reach the setpoint A setting too fast may overshoot the set point while a setting too slow may cause the drive to respond too slowly to set point changes NOTE FOR AQUAVAR UNITS ABOVE 10 HP SET RAMP 1 AND RAMP 2 TO AT LEAST 8 10 SECONDS Parameter Name Value Range Note s 13 01 RAMP 1 0 1800s Pressure default 5 seconds FAST ACCEL Lev
31. Run would be applied is when a standby pump is infrequently used the test run would allow lubrication of bearings and help verify if the unit is ready for operation The TEST RUN DELAY sets the interval that automatic test runs will occur at Test runs are factory programmed for 20 seconds This duration cannot be changed If Automatic test run is selected the test run is at 50 of maximum speed NOTE Once manual test is selected and the test is complete parameter 12 03 will return to NOT SEL Parameter Name Value Range Note s 12 02 AUTO OFF Default Must be set to ON for test run function to RESTART ON operate 12 03 TEST RUN NOT SEL default AUTOMATIC MANUAL 12 04 TEST SPEED 0 100 The speed as a percent of maximum speed FL 50 Default which the test run will occur at if MANUAL is selected 12 05 TEST RUN 0 3600 hours This is the period of pump inactivity before the DELAY 1000 Hrs Default test run will begin based on power up time Tuning System Pressure If the pump appears to oscillate in speed e g Hunting cannot maintain a uniform set point or shuts off too quickly or too slowly the ramp rates and regulation window settings may need to be modified or adjustments When an operating mode is selected i e Flow Pressure Level etc Aquavar engages factory default settings for the rate that the drive adjusts at to meet the set point demand In most cases these settings will n
32. SCALE Parameter values are inconsistent Check for any of the following e 1904 AO 1 MIN gt 1905 AO 1 MAX e 1909 AO 2 MIN gt 1910 AO 2 MAX 118 FAULTS ALARMS Fault Fault Name Code In Panel Description and Recommended Corrective Action 1005 PAR PCU 2 Parameter values for power control are inconsistent Improper motor nominal kVA or motor nominal power Check for the following e 1 1 lt 1104 MOTOR NOM CURR 1103 MOTOR NOM VOLT 1 73 Pn lt 2 6 e Where Py 1000 1107 MOTOR NOM POWER if units are kW or Py 746 1107 MOTOR NOM POWER if units are HP e g in US 1007 PAR FBUS Parameter values are inconsistent Check for and correct e A parameter is set for fieldbus control e g 1201 START STOP Fieldbus but 3001 COMM PROT SEL 0 1009 PARPCU 1 Parameter values for power control are inconsistent Improper motor nominal frequency or speed Check for both of the following e 1 lt 60 1105 MOTOR NOM FREQ 1106 MOTOR NOM SPEED lt 16 e 0 8 lt 1106 MOTOR NOM SPEED 120 1105 MOTOR NOM FREQ Motor Poles lt 0 992 Fault Resetting The AQUAVAR can be configured to automatically reset certain faults Refer to parameter Group 24 Fault Functions and Group 25 Automatic Reset Warning If an external source for start command is selected and it is active the AQUAVAR may start immediately after fault reset Flashing Red LED To reset the drive for faults
33. Synch ronous Multi Control Constant Slave Speed Control 0202 Actual 0 max scale Actual feedback unit determined by parameter 1501 0203 Pump Speed 0 60 Hz Actual frequency of motor Hz 0204 Wire to Water Power 0 Hp Overall hp includes pump motor and VFD 0205 SetPoint 1 0 max scale Set Point reference 1 unit determined by parameter 1501 0206 Set Point 2 0 max scale Set Point reference 2 unit determined by parameter 1501 0207 Energy Savings 0 65353 USD Calculated AV savings option 1 or 2 since last reset Savings are compared to conventional system Re settable by parameter 26 05 0208 Pump Number Stopped Pump 1 Pump 4 Actual pump number in multi pump control mode 0209 Used Set Point Status Words FB CMD Word 1 0 max scale Range Same value as in 0205 or 0206 depending on which is in use Description Low word of drive s control word Single Synch Pump ronous Multi Control Constant Speed Slave Control 0302 FB CMD Word 2 High word of drive s control word 0303 FBSTS Word 1 Low word of drive s status word 0304 FBSTS Word 2 High word of drive s status word 0305 Fault Word 1 Fault word 1 ofth
34. Water Technology distributor from whom the controller was purchased and furnish complete details regarding the claim The distributor is authorized to adjust any warranty claims utilizing the Goulds Water Technology Customer Service Department The warranty excludes a Labor transportation and related costs incurred by the dealer b Reinstallation costs of repaired equipment c d e Reimbursement for loss caused by interruption of service Reinstallation costs of replacement equipment Consequential damages of any kind and For purposes of this warranty the following terms have these definitions 1 Distributor means any individual partnership corporation association or other legal relationship that stands between Goulds Water Technology and the dealer in purchases consignments or contracts for sale of the subject controllers 2 Dealer means any individual partnership corporation association or other legal relationship which engages in the business of selling or leasing controllers to customers 3 Customer means any entity who buys or leases the subject controllers from a dealer The customer may mean an individual partnership corporation limited liability company association or other legal entity which may engage in any type of business THIS WARRANTY EXTENDS TO THE DEALER ONLY Xylem yeme 2881 East Bayard Street Ext Suite A EE Seneca Falls NY 13148 Phone 800
35. and control condition before attempting an error reset 60s 60 60 60 60 2408 Run Enable DI1 has to be closed for drive to be able to run Disable Enable Run Enable is not in use DI1 is used for Run Enable Function 68 PARAMETER LISTINGS Group 24 Fault Functions Comm Fault Function Range Description Selects how the drive reacts ina fieldbus comm break i e if the drive fails to receive command word or reference The time de lays is given by parameter 2410 Single Synch Pump ronous Speed Speed Not Selected No response Fault Drive Faults and coasts to stop Last Speed Drive displays a warning and remains running at last speed reference Defaults Multi Control Speed Constant Slave Speed Speed Control Speed 2410 Group 25 Comm Fault Time Automatic Reset NR of Trials 0 60 0s Range Defines the time delay for the control word or reference supervision Description Sets the number of allowed automatic resets within a trial period defined by parameter 2502 3 05 Synch ronous Multi Control Constant Slave Speed Control Energy Savings Energy Cost Disable 0 000 1 000 signal loss Description Cost
36. arrow Drive is stopped Upper right 50 shows the percentage of full scale the transducer is operating Middle The middle of the LCD display will display REM c 50 For Single Pump 40 2 PSI sp Reference or set point Pressure SP 0 0 PSI ac 0 0 HZ Actual set point Pressure AC DIR 12 45 MENU Frequency in HZ NOTE The AQUAVAR display will show SET PRESSURE ACTUAL PRESSURE and Frequency Hz in single pump mode Bottom The bottom of the LCD display shows Lower corners show the functions currently assigned to the two soft keys Lower middle 12 45 displays the current time if configured to show the time Operating the Drive LOC REM The very first time the drive is powered up it is in the remote control REM mode and is controlled from the Transducer and Control Panel To switch to local control LOC and control the drive using the Control Panel press and hold the button The drive must be stopped e The Remote REM Mode uses the transducer and set point to control the speed output to the pump e The Local LOC Mode uses the control panel for manual control of the drive output Speed up or down To switch back to remote control REM press and hold the button until REMOTE CON TROL is displayed Start Stop To start and stop the drive press the START or STOP buttons 46 START UP Other Modes Besides the Output Mode the Control Panel has e Other op
37. base sob No terminals Connection 1 4 MNPT 0 875 HEX LABEL CentriPro www centripro com C US PART PRTO300SB1P LISTED PRESSURE 0 300PSI 79BN INPUT 10 28VDC MADE IN USA OUTPUT 4 20mA SERIAL AXXXXXX YYMMDD SPECIFICATIONS Parameter Value Parameter Value Pressure Range 300 PSI Operating Temp Range 40 to 85 C Output 0 100 4 20 mA Compensation Temp Range Oto 55 C Supply Voltage 10 28 VDC Zero Thermal Error Maximum lt 035 of FS Burst Pressure Minimum 5x rated Span Thermal Error Maximum lt 035 of FS Pressure Overload Maximum 2x rated Pressure Port Material 17 4 PH Supply Current Maximum lt 22mA Housing Material 304 stainless steel Pressure Cycles Minimum 100 million Isolation Voltage Minimum 500VDC Accuracy combined lin hyst rep lt 0 5 BFSL Seal Material N A Zero Offset Maximum lt 1 of FS C Listinas UL cUL 508 lt 2 of ES C 2 CE ENG 326 Span Tolerance Maximum 148 APPENDIX ions icat if Transducer Data Spec SHDI8YA Te da LYN ETEMITE 111513 1833805 3Z9Pr00 E DIE RN MOILISOd NHL SUNRONIE LME EU b i Ligue 118491 dd JHH PAIE PII JADY d AL TaN Wa EN AMS HLIM JJNWQJSDD36 HOEMOH Al BIO 01 DIHLIMOTA WEE VIN LEIDER Co HINT Aere thay ASSY ZEN H390CSNVHI 3Hd0SS3HJ osuymwaamamas nu sag yari KM a NV HDH CS 33 N FEL SE e POORA EIA STT KO D eru ur POS eed 18 MOSEL CN Mi k n SUSAR TTT S3H281 LON TIS CHE SCAN STR eS i i 21093 ILON SSIINN
38. by e Enabling the red LED on the drive LED is either steady on or blinking e Setting an appropriate bit in a Fault Word parameter 0305 to 0307 e Overriding the control panel display with the display of a fault code e Stopping the motor if it was on The fault code on the control panel display is temporary Pressing any of the following buttons removes the fault message MENU ENTER UP button or DOWN button The message reap pears after a few seconds if the control panel is not touched and the fault is still active Flashing Green Alarms For less severe errors called alarms the diagnostic display is advisory For these situations the drive is simply reporting that it had detected something unusual The drive signals that it has detected an alarm by e Flashing the green LED on the drive does not apply to alarms that arise from control panel operation errors Alarms 1 to 7 e Setting an appropriate bit in an Alarm Word parameter 0308 or 0309 See Group 03 FB Status Words on page 50 for the bit definitions e Overriding the control panel display with the display of an alarm code and or name The alarm messages disappears from the control panel display if when any of the following are pressed on the control panel MENU ENTER UP button or DOWN button 115 FAULTS ALARMS Correcting Faults The recommended corrective action for faults is e Use the Fault Listing table below to find and address the
39. can drop before the next lag pump is started Used for multicontrol synchronous control and slave modes only Single Synch Pump ronous Control Multi Constant Speed Slave Control 2202 Value Increase 0 1000 Defines the increase in set point when a lag pump starts This value is cumulative with each lag pump that turns on Used for multicontrol synchronous control and slave modes only The default setting for 2202 is equal to the value set in 2201 2203 Enable Sequence 0 60 Hz Defines the speed the drive must be at before multipump operation is allowed Applies to synchronous multicontrol and slave modes only Default 98 of 1401 Maximum Speed 59 59 59 59 59 2204 Switch Lead Lag 100 h Defines the time the lead unit will run before a new unit is deemed the lead unit Note if setto 1001 Not SEL the switching function is disabled including switching during a fault Default setting is 48 hrs 48 48 48 48 48 66 PARAMETER LISTINGS Defaults Group Multipump 22 Control 2205 Sync Limit Single Synch Multi Constant Speed J SE ange EEN Pump ronous Control Slave Control Selects the speed at which lag pump 1 or slave 1 RO1 should be turned off Applies to synchronous multicontrol and slave modes 2206 SyncWindow 0 60 Hz The speed step ab
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41. dangerous voltages near the OMIO board when the drive is powered Separating the Drive and Extension Modules The drive module is mounted on a trolley that straddles a pedestal The following procedure removes mechanical connections so that the drive module and trolley can roll forward for service access R7 1 Disconnect all power sources from the drive extension modules and wait at least 5 minutes for internal capacitors to fully discharge 2 Remove all front covers from the drive module 3 Disconnect the control panel cable 4 Remove the upper side plate from the drive module if convenient 5 Remove screws if any that fasten the drive module to the wall 6 Inside the pedestal toward the rear are screws that attach the drive bus bars to the pedestal bus bars The connections are staggered for easy access using a wrench with an extension Remove these screws 6 Torque when re assembling e R7 M8 5 16 in screws 15 22 Nm 11 16 Ib ft e R8 M10 3 8 in screws 30 44 Nm 22 32 Ib ft WARNING Be careful not to drop screws inside the pedestal Loose metal pieces inside the unit may cause damage 7 The following cables between the drive and the extension module are split by a connector located at the front of the drive Disconnect both cables at this location e The power supply cable to the OMIO board e The power supply cable to the extensionmodule cooling fan 8 At the OTIF board disconne
42. following components 1 Aquavar programming check default settings recommended for single pump multi pump slave pump etc N Electrical supply motor wiring grounding check your supply voltage motor wiring transducer wiring and grounding WP Mechanical Pump Rotation check your pump rotation rubbing or other mechanical problems Pump run out 4 Hydraulic System Piping check to ensure proper suction and ischarge piping layout proper NPSHa air entrainment vortex friction loss system curve compensation etc Wu Environment protect from high temperatures direct sun freezing temperatures high altitude dust vibration lack of air flow 101 FEATURES Analog Outputs The Aquavar CPC has two 4 20 mA analog outputs as standard These outputs may be configured by the user to output from a selection of nine actual pump signals Parameter group 19 is used to configure these outputs Analog Outputs are found on X1 Terminal Block 2 and 5 pins Reference the terminal block diagram on pages 24 31 for detailed wiring connections Parameter Name Value Range Note s 19 01 AO 1 Not SEL default CONNECTS an ANALOG SIGNAL TO Content Sel MOTOR FREQUENCY THE ANALOG OUTPUT RANGE IS MOTOR CURRENT 0 20mA input MOTOR POWER MOTOR PROC VAR MOTOR ENERGY SAVNGS 19 06 AO 2 Not SEL default CONNECTS an ANALOG SIGNAL TO Content Sel MOTOR FREQUENCY THE ANALOG OUTPUT RANGE
43. motor shut down when demand is reduced Parameter Name Value Range Note s 13 04 RAMP 4 0 1800s Pressure default 60 seconds SLOW DECEL Flow magnetic flow meter default 50 sec Level Temperature default 200 seconds 114 FAULTS ALARMS Warning Do not attempt any measurement parts replacement or other service procedure not described in this manual Such action will void the warranty may endanger correct operation and increase downtime and expense Warning All electrical installation and maintenance work described in this chapter should only be undertaken by qualified service personnel The Safety instructions on the first pages of this manual must be followed Diagnostic Displays The drive detects error situations and reports them using e The green and red LED on the body of the drive e The status LED on the control panel if a control panel is attached to the drive e The control panel display if a control panel is attached to the drive e The Fault Word and Alarm Word parameter bits parameters 0310 to 0311 See Group 03 FB Status Words on page 50 for the bit definitions The form of the display depends on the severity of the error You can specify the severity for many errors by directing the drive to e Ignore the error situation e Report the situation as an alarm e Report the situation as a fault Red Faults The drive signals that it has detected a severe error or fault
44. next pump will automatically turn on in its place Each Aquavar controlled pump will provide a fully functional lead lag and automatic alternation system with automatic back up control when required System Curve Friction Compensation It is possible to program the Aquavar to maintain a constant pressure and compensate for increasing friction loss according to a system curve As the flow rate increases in the system the friction loss will increase as well The Aquavar can compensate for this friction loss with the simple adjustment of the parameter 2202 VALUE INCREASE When each Aquavar unit enables the pump it will increase the system pressure by the programmed amount This pressure is additive with each additional pump Therefore if you set this parameter for 3 psi and you initial constant pressure is 50 psi and you have 4 pumps total 50 psi 3 psi 3 psi 3 psi 59 psi when all 4 pumps are operating at full speed This final system pressure should be enough to overcome your calculated head and friction loss and to provide constant pressure at the end of the pipe run NOTE This program function is not intended for substitution of proper pipe layout and sizing according to Hydraulic Institute Standards This feature may not work for excessive friction losses Pump Sequencing The Aquavar CPC has the ability to operate in a multiple pump with lead and lag pumps Each Aquavar will be given an address then operate as Pump 1 Pum
45. or HZ 1403 Contig Speed Min Defines the reaction of the drive when the AV tries to regulate at a speed at or below minimum frequency 1402 0 Default The drive will stay at Minimum Frequency until Sto Delay Min Spd 1404 times out the unit will then shutdown Min Freq The AV will stay at this speed until the transient clears or unit is manually shutdown unless a fault occurs 1404 Stp Delay 0 1800 s Min Spd The time period the drive will stay at MinSpd 1402 before stopping Functions when 1403 is set to 0 Becomes active if set point would result in regulation below min spd closed valve condition in pressure control and Secondary Protect A amp B 1405 Restart Value 0 150 If the drive is shutdown by Contig speed min 1403 due to no system demand pressure control and level control only the drive will sleep until the process actual value drops below a set restart value 1405 for longer than the restart delay 1406 If operating in inverse mode 2101 the drive will sleep until the process variable rises above the restart value Wake up level in of set point value To disable the Restart Value function in both normal and inverse settings enter 0 Auto Restart parameter 1202 does not influence the restart function Default 0 1406 Restart Delay 0 1800 s Time delay for restart value 1405 Default 0 sec 58 PARA
46. pressed in the above group press the EXIT key then the down arrow to highlight the group 11 START UP DATA then Press the SEL key once Using the arrows highlight 1102 APPLIC MACRO then press the EDIT key Using the UP arrow highlight CONSTANT SLV option then press SAVE key 6 Use down arrow until group parameter 1104 MOTOR NOM VOLTAGE is highlighted then press EDIT Use the arrows to enter your motors nameplate voltage then press the SAVE key Use the down arrow until group parameter 1105 MOTOR NOM CURRENT is highlighted then press EDIT Using the arrows enter your motor s maximum allowed amp draw at full speed or Service Factor Amps NOTE Enter motors service factor from nameplate or motor manual Once you have entered the amps press the SAVE key 8 Use down arrow until you highlight group parameter 1107 MOTOR NOM RPM then press the EDIT key Use arrows to enter the RPM from the motor nameplate default is 3450 RPM Press the SAVE key to store setting 9 Use down arrow until you highlight group parameter 1108 MOTOR NOM POW then press the EDIT key Use arrows to enter the otors Horsepower rating from nameplate then press the SAVE key 98 REM PAR GROUPS 11 REM PARAMETERS 1101 LANGUAGE 1104 MOTOR NOM VOLT 1105 MOTOR NOM CURR EXIT ED REM C PARAMETERS 1101 LANGUAGE 1102 APPLIC MACRO 1104 MOTOR NOM VOLT 2
47. provides Aquavar CPC rating information and recommended wire sizing for the input and output cables GWT AQUAVAR CPC NORMAL Output Input NEMA 1 Full Frame Voltage Phase Base Load DUTY gt Cable Size Cable Size Model Amps HORSEPOWER 2 amp Min AWG Min AWG CPC40061 6 9 3 R1 14 14 CPC40081 8 8 5 R1 14 14 CPC40121 11 9 7 5 R1 14 14 CPC40151 154 10 R2 12 12 CPC40231 23 15 R2 12 12 CPC40311 31 20 R3 10 8 CPC40381 38 25 R3 8 8 CPC40451 45 30 R3 8 6 CPC40591 59 40 R4 6 4 CPC40721 72 50 R4 4 3 CPC40771 77 60 R4 4 3 460 CPC40971 97 75 R4 3 1 CPC41251 125 100 R5 1 2 0 CPC41571 157 125 R 2 0 3 0 CPC41801 180 150 R 3 0 4 0 CPC42451 245 200 R7 350MCM 350MCM CPC43161 316 250 R7 2X250MCM 2 X250MCM CPC43681 368 300 R8 2X300MCM 2 X 300MCM CPC44141 414 350 R8 2X400MCM 2 X400MCM CPC44861 486 400 R8 2X500MCM 2 X 500MCM CPC45261 526 450 R8 2X350MCM 2 X 350MCM CPC46021 602 500 R8 2X500MCM 2 X 500MCM CPC46451 645 550 R8 2X500MCM 2X500MCM 1 Recommended AWG Size based on NEC table 310 16 40 C ambient 90 C UL type copper wire For other wire sizes or types consult local state or NEC codes 2 Frame sizes R7 and R8 the Aquavar CPC will have multiple conductor terminals for each phase Consult technical section CABLE TERMINALS for maximum wire diameter and torque values 132 TECHNICAL DATA Fuse Sizing Rat
48. refer to either e Serial number label attached on upper part of the chokeplate between the mounting holes ACS550 01 08A8 4 Gu asss HIR Py Pra 4 3kW Ser no 2030700001 e Type code label attached on the heat sink on the right side of the unit cover Input U 3 380 480 V lin 8 8A f 48 63 Hz C Input U 3 0 U V LISTED gee oC Si JIDD Input P P 4 3kW Ser no 2030700001 ACS550 01 08A8 4 Type Code CPC 4 370 1 FD AQUAVAR Series Voltage 2 208 240 Volt 4 480 Volt 5 575 Volt Amps 370 Amps See Technical Section NEMA Enclosure Rating 1 NEMA 1 2 NEMA 12 Fused Disconnect Options Consult factory for other options if available Not all combinations may be available Standard equipment on 200 HP and above 460 volt models INTRODUCTION Ratings and Frame Size The chart in Ratings on page 131 lists technical specifications and identifies the drive s frame size significant since some instructions in this document vary depending on the drive s frame size To read the Ratings table you need the Output current rating entry from the type code Also when using the Ratings table note that the table is broken into sections based on the drive s Voltage rating Motor Compatibility The motor drive and supply power must be compatible Motor Specification Verify Reference Motor type 3 phase induc
49. required press the CANCEL key then EXIT and go to the LEXIT EDIT next step From group 12 press the down arrow until group 14 SPD REM C PARAMETERS LIM STRT LVL is highlighted and then press SEL Use down 1401 MAXIMUM FREQ arrows to highlight group 1402 MINIMUM FREQ then 1402 WENIDIUM FAEG press EDIT Using the arrow keys select the appropriate 1403 CONFIG SPEED MIN minimum speed in HZ Default is 10 of the parameter 1106 1404 STP DELY MIN SPD MOTOR NOM FREQ which is 6 HZ For a submersible motor SCH or suction lift situation this would be set to at least 30 HZ Depending upon the static water level and pipe distance to the transducer you may have to increase this setting up to 40HZ Once changed press the SAVE key to store the setting PROGRAMMING Single Pump Submersible Pump Constant Pressure 12 Next step will set the appropriate time delay in seconds at the MINIMUM FREQUENCY Use the down arrow until you highlight parameter 1404 STP DELY MIN SPD and then press the EDIT key Use the UP ARROW to select a time in seconds A suggested delay time is 5 seconds When the pump reaches the minimum frequency it will have a delay of 5 seconds before shutting down Once entered then press the SAVE key 13 From group 1404 press the down arrow until group 1502 TRANSDUCER MAX is highlighted then press EDIT Default pressure transducer setting is 300 psi Adjust this based on your maximum ratin
50. root cause of the problem e Reset the drive See Fault Resetting on page 119 Drive not ready fault Check supply voltage DC Bus 1 35 x input voltage Comm fault drive not responding Internal communication lost e Cycle Power Remove and reinstall panel Replace panel Fault Listing Fault Fault Name Code In Panel 1 OVERCURRENT Description and Recommended Corrective Action Output current is excessive Check for and correct e Excessive motor load pump overload e Insufficient acceleration time parameters 1301 Ramp 1 and 1302 Ramp 2 e Faulty motor motor cables or connections 2 DC OVERVOLT Intermediate circuit DC voltage is excessive Check for and correct e Static or transient overvoltages in the input power supply e Insufficient deceleration time parameters 1302 Ramp 2 increase to at least 8 seconds 3 DEV OVERTEMP Drive heatsink is overheated Temperature is at or above 115 C 239 F Check for and correct e Fan failure e Excessive ambient temperature e Obstructions in the air flow e Excessive motor load e Dirt or dust coating e Ambient temperature on the heat sink e Altitude 4 SHORT CIRC Fault current Check for and correct e A short circuit in the motor cable s or motor e Supply disturbances 5 OVERLOAD Inverter overload condition The drive output current exceeds the ratings given in Ratings on pages 131 134 of this manual 6 DC UNDERVOLT
51. shows the transfer status as a percent of completion 4 Press EXIT to step back to the Output Mode Clock Set Mode Use the Clock Set Mode to e Enable disable the clock function e Set date and time e Select display format 1 Select CLOCK SET in the Main Menu 2 Press UP DOWN to step to the desired option 3 Press EDIT 4 Press UP DOWN to select the desired setting 5 Press SAVE to save setting 49 PARAMETER LISTINGS Aquavar CPC Parameter List The Aquavar CPC parameter list contains all of the necessary pump drive fault and control parameters needed for programming this unit Each group indicates a certain function and control for the Aquavar in order to set up single or multipump control To view the available parameter list on your keypad press the MENU button to access the parameter list The parameters are write protected with a password Please contact your Aquavar representative for more information on this password located in GROUP 10 LOCKS PASSWORDS Group 01 VFD SIGNALS This set of parameters sets up the drive and motor These parameters can only be adjusted and changed when the motor has stopped Monitoring of motor output and various analog and digital outputs Group 02 PUMP SIGNALS Provides output set points energy savings and wire to water power Group 03 STATUS WORDS Provides status of drive and alarm condition Group 10 LOCKS PASSWORDS Provides password and parameter save information
52. the same time sets a parameter to its default value 6 Press SAVE to save the new parameter value If the new value is the default value the pa rameter will no longer appear on the Changed Parameters listing Par Backup Mode The Control Panel can store a full set of drive parameters If two sets of parameters are de fined both are copied and transferred when using this feature The Par Backup Mode has three functions e Upload to Panel Copies all parameters from the drive to the Control Panel The Control Panel memory is nonvolatile and does not depend on the panel s battery Restore All Download To Drive All Restores the full parameter set s from the Control Panel to the drive Use this option to restore a drive or to configure identical drives NOTE The Restore All function writes all parameters to the drive including motor param eters Only use this function to restore a drive or to transfer parameters to systems that are identical to the original system Download Application Copies partial parameter set s from the Control Panel to a drive The partial set does not include internal motor parameters Use this option to transfer pa rameters to systems that use similar configurations the drive and motor sizes do not need to be the same 1 Select COPY in the Main Menu 2 Press UP DOWN to step to the desired option 3 Press SAVE The parameter set is transferred as directed During the transfer the display
53. to R4 1 Remove power from drive 2 Remove the front cover 3 The housing that holds the fan in place has barbed retaining clips at each corner Press all four clips toward the center to release the barbs 4 When the clips barbs are free pull the housing up to remove from the drive 5 Disconnect the fan cable 6 Install the fan in reverse order e The fan air flow is up refer to arrow on fan e The fan wire harness is toward the front e The notched housing barb is located in the right rear corner e The fan cable connects just forward of the fan at the top of the drive 123 MAINTENANCE Frame Sizes R1 R6 Frame Size R5 and R6 To replace the internal enclosure fan in frame sizes R5 or R 1 Remove power from drive 2 Remove the front cover 3 Lift the fan out and disconnect the cable 4 Install the fan in reverse order 5 Restore power Capacitors The drive intermediate circuit employs several electrolytic capacitors Their life span is from 35 000 90 000 hours depending on drive loading and ambient temperature Capacitor life can be prolonged by lowering the ambient temperature It is not possible to predict a capacitor failure Capacitor failure is usually followed by a input power fuse failure or a fault trip Contact factory if capacitor failure is suspected Replace ments for frame size R5 and R are available from the factory Do not use other than factory specified spare parts Control Panel Cleaning
54. will sleep until the process variable rises above the restart value Wake up level in of setpoint value 0 150 Default is 0 To disable the Restart Value function enter 0 14 06 RESTART 0 3600 Sec This is the length of time the drive waits DELAY 0 default between starting the pump according to 1405 value 12 02 AUTO OFF default This enables the drive to restart on its own RESTART ON following a power failure or ERROR RESET 24 06 ERROR 0 Default If the Aquavar unit faults on Pump Protection RESET 1 9999 this parameter will reset the fault up to the selected number of times before completely shutting off the drive 24 07 RESET 0 250 seconds The automatic reset of protection faults can be DELAY 60 seconds Default delayed Default value is 60 seconds Restart Value Allows a pressure or value drop before the Aquavar starts to maintain system pressure Units are in of set value e g If set pressure is 100 PSI and 14 05 is set for 90 then the Aquavar will wait until system pressure drops to 90 PSI before starting Priming Delay This feature will override the PUMP PROTECT feature and is designed to allow self priming pumps sufficient time to prime before the Aquavar Pump Protection logic becomes active The delay period is applied only if the pump is being started from a zero speed condition Once the priming delay is complete the PROTECTION DELAY 24 06 becomes active if set Parameter 14 07 Name PR
55. 0 TECHNICAL DATA Cable Sizing Ratings 208 240 Volt Drives The following tables provide current horsepower frame size and recommended cable sizes for the Aquavar CPC GWT AQUAVAR CPC NEMA 1 Full NORMAL care Output Input Voltage Phase Base Load DUTY gt Cable Size Cable Size Model Amps HORSEPOWER SiZ Min AWG CPC20171 8 5 R1 CPC20241 12 3 R2 12 8 CPC20311 15 5 5 R2 12 8 CPC20461 23 7 5 R3 10 6 CPC20591 29 5 10 R3 8 4 230 1 CPC20881 44 0 15 R4 6 2 CPC21141 57 0 20 R4 4 1 0 CPC21431 71 5 25 R6 3 3 0 CPC21781 89 0 30 R6 2 4 0 CPC22211 110 5 40 R6 1 0 300MCM CPC22481 124 0 50 R6 2 0 350MCM CPC20121 11 8 3 R1 14 14 CPC20171 16 7 5 R1 10 10 CPC20241 24 2 7 5 R2 8 8 CPC20311 30 8 10 R2 8 8 CPC20461 46 2 15 R3 6 6 CPC20591 59 4 20 R3 4 4 230 3 CPC20751 74 8 25 R4 3 3 CPC20881 88 0 30 R4 2 2 CPC21141 114 0 40 R4 1 0 1 0 CPC21431 143 0 50 R6 3 0 3 0 CPC21781 178 0 60 R6 4 0 4 0 CPC22211 221 0 75 R6 300MCM 300MCM CPC22481 248 0 100 R6 350MCM 350MCM 1 Recommended AWG Size based on NEC table 310 16 40 C ambient 90 C UL type copper wire For other wire sizes or types consult local state or NEC codes 2 Frame sizes R7 and R8 the Aquavar CPC will have multiple conductor terminals for each phase Consult technical section CABLE TERMINALS 131 TECHNICAL DATA Cable Sizing Ratings 380 480 Volt Drives The following table
56. 0 V Mand 12 Te 12 DCOM or 10 V between that input and DCOM The 24 V may be provided by 10 15 the AQUAVAR X1 10 or by an external 12 24 V source of either polarity E stop H lt 3 Dl Digital input 1 programmable Default run enable Group 24 or Jumper d 14 DI2 Digital input 2 programmable Default low water Group 24 oh 15 DI Digital input 3 programmable Default2 E stop or jumper s 16 DI4 Digital input 4 programmable Default set point selection to 24V for 17 DIS Digital input 5 programmable Default HOA Group 12 SEET 18 DI Digital input 6 programmable Default not used Jumper 19 ROIC Relay output 1 programmable Default drive ready a 20 ROIA ZN Maximum 250 VAC 30 VDC 2A 5 21 RO1B Minimum 500 mW 12 V 10 mA 22 RO2C Relay output 2 programmable Default pump run O 23 RO2A Maximum 250 VAC 30 VDC 2A gt 24 RO2B i Minimum 500 mW 12 V 10 mA 25 RO3C Relay output 3 programmable Default fault P 26 RO3A Maximum 250 VAC 30 VDC 2A 27 RO3B Ss Minimum 500 mW 12 V 10 mA 1 Digital input impedance 1 5 kQ Maximum voltage for digital inputs is 30 V 2 Default values depend on the macro used Values specified are for the default macro single multipump NOTE Jumper Wires between 3 and 11 10 and 15 11 and 12 NOTE Terminals 3 6 and 9 are at the same potential NOTE For safety reasons the fault relay sign
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58. 16 03 SET POINT 2 KEYPAD Default This selects where the value for SEL ANALOG INPUT Set Point 1or 2 is coming from FIELDBUS e KEYPAD a number e g 100 will be manually entered via the keypad Selecting ANALOG INPUT will require entry of parameters 16 03 16 04 22 08 SET POINT 2 OFF 1 4 Must select source SOURCE during the daytime normal water pressure is set for 60 psi FEATURES Parameter Value Notes 16 01 DI4 A switch would be wired into DI4 and the DCOM on the X1 terminal to toggle between set point 1 and set point 2 16 02 KEYPAD The setpoint would be manually entered using the Aquavar keypad When the switch D14 is set to 0 Open the set point would be entered as 110 psi using the keypad REF button 16 03 KEYPAD The set point would be manually entered using the Aquavar keypad When the switch D14 is set to 1 Closed the set point would be entered as 60 psi using the keypad REF button WARNING Parameter 16 01 16 02 and 16 05 can only be changed when the motor is not running Most parameters require you to stop the pump before programming System Curve Compensation The AQUAVAR CPC system can automatically compensate for system friction losses due to increased flow in single pump operation or multi pump backup modes Tables are available in most pump catalogs to assist in determining the amount of friction loss that can be expected for various pipe
59. 3 phase 1 phase 10 15 for CPC2XXXX Maximum allowed prospective short circuit current in the supply is 65 kA in a second providing that the mains cable of the drive is protected with appropriate fuses US 65 000 AIC Frequency 48 63 Hz Imbalance Max 3 of nominal phase to phase input voltage Fundamental Power Factor cos phi 0 98 at nominal load Cable Temperature Rating 90 C 194 F rating minimum Motor Connection Voltage U2 Motor Connection Specifications 0 U 3 phase symmetrical Umax at the field weakening point Frequency 0 500 Hz Frequency Resolution 0 01 Hz Current See Ratings on pages 131 134 Power Limit 1 5 x Rated HP Field Weakening Point 10 60 Hz Switching Frequency Selectable 1 4 or 8 kHz Cable Temperature Rating 90 C 194 F rating minimum Maximum Motor Cable Length Maximum Motor Cable Length Frame Size f 1 or 4 kHz fav 8 kHz R1 100 m 50m R2 R4 200 m 100 m R5 R 300 m 150 m R7 R8 300 m NA WARNING Using a motor cable longer than specified in the chart above may cause permanent damage to the drive or motor WARNING Use of an output load filter or reactor is required when motor leads exceed the above recommendations Consult motor manufacturer on required use of inverter drives 136 TECHNICAL DATA Control Connect
60. 30V 1105 MOTOR NOM CURR REM PARAMETERS R PARAMETERS 4 MOTOR NOM VOLT 1 5 MOTOR NOM CURR EM C PARAMETERS 05 MOTOR NOM CURR 6 MOTOR NOM FREQ OM RPM G MOTOR NOM POW 1 0 HP EXIT EDIT PROGRAMMING MultiPump Slave Pump Control 10 After saving your motor horsepower press the EXIT key Use the down arrow until you highlight the group 15 XDUCER VARIABLES then press EDIT 11 Press the down arrow until parameter 1502 TRANSDUCER MAX is highlighted then press EDIT Default pressure transducer setting is 300 psi Adjust this based on your maximum rating for a new transducer NOTE Goulds Water Technology provides a 0 300 psi transducer as standard Select the appropriate range then press SAVE If no changes are necessary press CANCEL 12 Use the down arrow to highlight 1503 TRANSDUCER MIN 0 0 then press EDIT Default should be 0 psi Press CANCEL to advance to the next step If this group needs to be changed based on another type of transducer value press SAVE to store 13 Use the down arrow to highlight 1506 SENSOR MIN then press EDIT Use the up arrow until the TUNE value is displayed press the SAVE key This provides the transducer a tuned value of 0 ZERO psi NOTE Make sure that your transducer is wired to the Aquavar but free from any pressure in the system The transducer must be exposed to 0 psi when this step is performed Pres
61. 36 ft e 76 cm 30 in frame size R1 e 61cm 24 in frame size R2 Free Fall M tallowed e 46 cm 18 in frame size R3 e 31 cm 12 in frame size R4 e 25 cm 10 in frame size R5 e 15 cm in frame size R 1 Consult factory above 6600 altitude 2 Derate drive one HP size from motor for higher temperatures e g motor HP 10 HP use 15 HP Aquavar in temperature up to 122 F 3 R7 R8 not allowed for free fall any distance 145 TECHNICAL DATA Materials Materials Specifications e PC ABS 2 5 mm color NCS 1502 Y RAL 90021 PMS 420 C and 425 C Drive e Hot dip zinc coated steel sheet 1 5 2 mm thickness of coating 100 micrometers Enclosure e Cast aluminium AIS e Extruded aluminium AIS Package Corrugated board drives and option modules expanded polystyrene Plastic covering of the package PE LD bands PP or steel The drive contains raw materials that should be recycled to preserve energy and natural resources The package materials are environmentally compatible and recyclable All metal parts can be recycled The plastic parts can either be recycled or burned under controlled circumstances according to local regulations Most recyclable parts are marked with recycling marks Disposal If recycling is not feasible all parts excluding electrolytic capacitors and printed circuit boards can be landfilled The DC capacitors contain electrolyte and the printed circuit board
62. 4 Press EDIT 5 Press UP DOWN to step to the desired parameter value NOTE To view the parameter default value In the set mode press UP DOWN simultaneously e Press SAVE to store the modified value or press CANCEL LOC 2 PAR EDIT to leave the set mode Any modifications not saved are 4102 EXT1 EXT2 SEL cancelled EXT1 e Press EXIT to return to the listing of parameter groups and again to return to the main menu CANCEL SAVE 47 START UP Wizard Mode When the drive is first powered up the Start Up Wizard guides you through the setup of a few basic parameters For example at the first start the drive automatically suggests entering the first task password The Start Up Wizard is divided into tasks You may activate the tasks one after the other as the Start Up Wizard suggests or independently You are not required to use the assistant you may use instead the parameter mode to set the drive parameters The order of the tasks presented by the Start Up Wizard depends on your entries The task list in the following table next page is typical Start Up Wizard The start up wizard is a tool that can be used to quickly program an Aquavar with the most commonly used single mult pump parameters The wizard will prompt the programmer to enter the required parameters by automatically bringing them to the screen To enable the wizard following the steps below 1 In the main screen select MENU Then press en
63. 6 25 CPC21781 89 0 R6 30 CPC22481 124 0 R6 40 CPC22481 124 0 R 50 CPC20041 4 6 R1 1 CPC20071 7 5 R1 2 CPC20121 11 8 R1 3 CPC20171 16 7 R1 5 CPC20241 24 2 R2 7 5 CPC20311 30 8 R2 10 CPC20461 46 2 R3 15 230 3 CPC20591 59 4 R3 20 CPC20751 74 8 R4 25 CPC20881 88 0 R4 30 CPC21141 114 0 R4 40 CPC21431 143 0 R 50 CPC21781 178 0 R 60 CPC22211 221 0 R 75 CPC22481 248 0 R 100 CPC40061 6 9 R1 3 CPC40081 8 8 R1 5 CPC40121 11 9 R1 7 5 CPC40151 15 4 R2 10 CPC40231 23 R2 15 CPC40311 31 R3 20 CPC40381 38 R3 25 CPC40451 45 R3 30 CPC40591 59 R4 40 CPC40721 72 R4 50 CPC40781 78 R4 60 460 3 CPC40971 97 R4 75 CPC41251 125 R5 100 CPC41571 157 R6 125 CPC41801 180 R6 150 CPC42451 245 R7 200 CPC43161 316 R7 250 CPC43681 368 R8 300 CPC44141 414 R8 350 CPC44861 486 R8 400 CPC45261 526 R8 450 CPC46021 602 R8 500 CPC46451 645 R8 550 CPC50031 2 7 R2 2 CPC50041 3 9 R2 3 CPC50061 6 1 R2 5 CPC50091 9 R2 7 5 CPC50111 11 R2 10 CPC50171 17 R2 15 CPC50221 22 R2 20 575 3 CPC50271 27 R3 25 CPC50321 32 R4 30 CPC50411 41 R4 40 CPC50521 52 R4 50 CPC50621 62 R4 60 CPC50771 77 R6 75 CPC50991 99 R6 100 CPC51251 125 R6 125 CPC51441 144 R6 150 _ HP classifications are for reference purposes only always size the Aquavar according to the output amps and the service factor amps of the motor 14 INTRODUCTION Preparing for Installation Drive Identification Drive Labels To determine the type of drive you are installing
64. 6 450 R8 7600 25946 721 CPC46021 602 500 R8 8100 27653 721 CPC46451 645 550 R8 9100 31067 721 139 TECHNICAL DATA Air Flow 208 240 Volt Drives The following table lists heat loss and air flow data for 208 240 Volt drives GWT AQUAVAR CPC NEMA1 Full NORMAL Frame wan Voltage Phase Base Load DUTY Size Model Amps HORSEPOWER Watts BTU HR CPC20171 CPC20241 12 3 R2 227 776 52 CPC20311 15 5 5 R2 285 373 52 CPC20461 23 7 5 R3 420 1434 79 CPC20591 29 5 10 R3 536 1829 79 230 1 CPC20881 44 0 15 R4 786 2685 165 CPC21141 57 0 20 R4 1014 3463 165 CPC21431 71 5 25 R6 1268 4431 238 CPC21781 89 0 30 R 1575 5379 238 CPC22211 110 5 40 R 1952 6666 238 CPC22481 124 0 50 R6 2189 7474 238 CPC20121 11 8 3 R1 116 404 26 CPC20171 16 7 5 R1 161 551 26 CPC20241 24 2 7 5 R2 227 776 52 CPC20311 30 8 10 R2 285 373 52 CPC20461 46 2 15 R3 420 1434 79 CPC20591 59 4 20 R3 536 1829 79 230 3 CPC20751 74 8 25 R4 671 2290 165 CPC20881 88 0 30 R4 786 2685 165 CPC21141 114 0 40 R4 1014 3463 165 CPC21431 143 0 50 R6 1268 4431 238 CPC21781 178 0 60 R6 1575 5379 238 CPC22211 221 0 75 R 1952 6666 238 CPC22481 248 0 100 R6 2189 7474 238 140 TECHNICAL DATA Dimensions and Weights Frames R1 R6 The dimensions and mass for the AQUAVAR depend on the frame size and enclosure type If unsure of frame size first find the Type code o
65. 7 Installation Flow Chart The installation of the AQUAVAR adjustable speed pump controller follows the outline below The steps must be carried out in the order shown At the right of each step are references to the detailed information needed for the correct installation of the unit Task PREPARE for installation v UNPACK the drive Vv PREPARE the Mounting Location v REMOVE the front cover v MOUNT the drive y INSTALL wiring y CHECK installation y REINSTALL the cover y APPLY power START UP See Preparing for Installation on page 15 Unpack the Drive on page 21 Prepare the Mounting Location on page 21 Remove Front Cover on page 21 Mount the Unit on page 22 Install the Wiring on page 23 Check Installation on page 32 Reinstall Cover on page 33 Apply Power on page 33 Start Up on page 33 INTRODUCTION AQUAVAR CPC Product Numbering Voltage Phase NEMA 1 Base Model Full koad Amps Frame Size Normal Duty Normal Duty Horsepower CPC20071 7 5 R1 1 CPC20171 8 5 R1 2 CPC20241 12 R2 3 CPC20311 15 5 R2 5 CPC20461 23 R3 7 5 230 1 CPC20591 29 5 R3 10 CPC20881 44 0 R4 15 CPC21141 57 0 R4 20 CPC21431 71 5 R
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67. EMOTE before enabling LOCAL LOCK Minimum Speed Options When the Aquavar CPC reaches the minimum speed that is set in parameter 14 02 it can be programmed to stay at that minimum speed indefinitely or to shut down after a time delay This reaction applies to conditions where Aquavar is trying to regulate to a setpoint when it faults due to a secondary protect condition or there is little or no process demand If the parameter 14 03 CONFIG SPEED MIN is set to MINIMUM FREQ the drive will stay at minimum speed indefinitely until the system demand increases it is shutdown manually or a fault occurs forcing it to shutdown If it is operating at minimum speed due to a Secondary Protect fault it will stay at minimum speed until the fault is reset If a Pump Protect condition exists and CONFIG SPEED MIN is set to MINIMUM FREQ Aquavar will try to reset the fault while at minimum speed if parameter 12 02 AUTO RESTART is set to ONT and parameter 24 06 ERROR RESET is set for the desired number of attempts If the fault has not cleared after the selected number of resets has been attempted the pump will be shut down If parameter 24 06 ERROR RESET 0 the pump will be shut down upon a Pump Protect fault If parameter 14 03 CONFIG SPEED MIN is set to ZERO 0 DEFAULT the drive will stop the pump for Pump Protect and Secondary Protect faults The reaction to stop the pump when at minimum speed can be delayed for up to 1800 seconds by programmin
68. I1 Minimum Defines the minimum value for 4 20 4 20 analog input Al1 mA mA 0 10 VDC A 0VDC signal will activate a Sensor Failure fault function unless 24 01 and 24 02 are disabled 4 20mA Default 4 mA is selected as the minimum value Tuned Value Select tuned value after the tune function has been completed This will select the tuned value for the minimum value of AT 61 PARAMETER LISTINGS Group Reference 16 Select 1604 AI 1 Minimum continued Relay Outputs Relay RO1 Output Group 18 Range Description This parameter sets the minimum value of the signal to be applied to Al1 When tune is selected and enter is pressed the tuned value for Al1 is set to the actual Al1 value when the tune function was activated This function is useful for zeroing out any system hysteresis Description Selects the AV status to be indicated through relay output 1 RO1 The relay energizes when the status meets the setting Relay warnings are reset automatically faults must be manually reset Not Sel The output is not used Run The output indicates the drive is running Ready Default The output indicates that power is supplied to the drive and it is awaiting a start command VFD Fault The drive has faulted Low Water The secondary protection warning or fault function has be
69. IMING DELAY Value Range 0 6000 Seconds 0 Default Note s The priming delay time is added to the pump protection delay time NOTE Do not set beyond normal priming time for specific pumps or damage may occur Refer to pump manufacturer for maximum allowed priming times before shutdown 106 FEATURES Pump Protect Ctrl This feature is designed to protect the pump from lack of available NPSH loss of or low suction pump run out This pump protection feature is exclusive to the Aquavar and measures the discharge pressure of the pump via the transducer and compares it with the minimum allowed system pressure as entered into parameter 2403 PROTECTION LIMIT If this parameter is set then a time delay will need to be set in number of seconds allowed to run at or below this limit before shutting down on a fault Parameter Name Value Range Note s 24 02 PUMP Disabled Default Provides no warning warning or PROTECT WARN warning and then shut off CTRL WARN amp CTRL 24 03 PROTECTION 0 6553 5 Actual value units LIMIT 24 04 PROTECTION 0 200 seconds Provides a time delay for 24 03 DELAY NOTE It is recommended to set this pump protection according to suggested minimum allowed system requirements i e pump run out limits Regulation Mode The regulation mode can either be NORMAL or INVERSE The default and more common selection is NORMAL where the Aquavar softwar
70. INSTRUCTION MANUAL IM167 4 A AQUAVAR CPC Centrifugal Pump Control INSTALLATION AND OPERATION MANUAL GOULDS a xylem brand ZAA ZA ZN CLAN tA in Jose OF dino ewe 1ndul zamog aseud aseyd ON ad DC if S ei S ei GEIER LA In 200 9410 GY s zIS awel4 uo e cieus Di a LAA LA In yndu amod aseud ZM ZA ZN AO 0 nd no 1 mod seud ONG VUm ONS Jd GU zis Suel ye SMAIOS Zeg AOWAI SIOM B Jeu Bujeoj 104 RS iNINMHVAA QY z S owes ye Ly s zIS Swed UO EIWZ pue LW 18 Smas snow Stoen Buneo j 104 i NINYYM Buiu JO Jq pue LM LN gen ysnw amod jndul aseud albus y pur LN s ziS wesg Jenuew uononnsul eu u Suono uuoo 1 MOd 89S S EUILUL9 SUD BY O1 Seil punos pue JOJOW amod 1o uuoo y sain dins synpuos uBnoiu Bum 10 0W pue amod mdut aynoy Z xoq 0 suni JINDUOD p uuop JOMOg Bulli xoq pue BAImnpuo2 esu Z xoq puej6 npuo ay ul p ijddns you sduue o 1inpuo2 eM UIU e1su Ajuo Aeddeoa Bun M Su IIe1Sul eys onsejd p su y uo BenB ue pendosdde y u 1 21 S Bulusem e yoeny 2 I SJQUIOD INO je ua 461 Ajaundes 0 SHOQ JO SM S sn pue YVAVNOV y UOIISOY 13409 y aAOWAI 0 do L yp e u nd doy aur re Mais ander y u soo Z p uoene J Ke dsip Igued onuoo y aBAOWAY
71. ION Frames R1 R6 Reinstall Cover IP 21 UL Type 1 1 Align the cover and slide it on 2 Tighten the captive screw 3 Reinstall the control panel IP 54 UL Type 12 1 Align the cover and slide it on 2 Tighten the captive screws around the edge of the cover 3 Slide the hood down over the top of the cover 4 Install the two screws that attach the hood 5 Reinstall the control panel NOTE The control panel window must be closed to comply with IP 54 UL type 12 6 Optional Add a lock not supplied to secure the control panel window Apply Power Always reinstall the front cover before turning power on IP2009 WARNING The AQUAVAR will start up automatically at power up if the external run command is on 1 Apply input power When power is applied to the AQUAVAR the green LED comes on NOTE Before increasing motor speed check that the motor is running in the desired direction Start Up The AQUAVAR has default parameter settings that are sufficient for many situations However review the following situations Perform the associated procedures as appropriate Proceed to Start Up section of this manual 33 INSTALLATION Frames R7 R8 AQUAVAR Drive Manuals GENERAL MANUALS AQUAVAR User s Manual IOM 1 150 HP Safety e Diagnostics e Installation e Maintenance e Start Up e Technical Data AQUAVAR User s Manual IOM 200 550 HP Safety e D
72. IT key Using the up arrow enter your factory password number Default is 66 Press the save key Use up arrow to group 1001 PARAMETER LOCK then i press the EDIT key Next use the up arrow to select OPEN then press the SAVE key This group should appear as OPEN if it does not you have entered the pass code incorrectly or it has changed Contact your local Goulds Water Technology representative for the master code Once your group 1001 is showing OPEN you can access the entire pump and drive parameters in the Aquavar After the SAVE key is pressed in the above group press the EXIT key then the down arrow to highlight the group 11 START UP DATA then Press the SEL key once Using the arrows highlight 1102 APPLIC MACRO then press the EDIT key Using the UP arrow highlight MULTICONTROL option then press the SAVE key REM MAIN MENU 1 PARAMETERS REM PAR GROUPS 10 02 PUMP SIGNALS 03 FB ACTUAL SIGNALS 10 LOCKS PASSWORDS 11 START UP DATA 12 START STOP EXIT SEL REM PARAMETERS 1001 PARAMETER LOCK 1002 PASS hy 1003 LOCAL LOCK 1004 PARAM SAVE REM PARAMETERS 1001 Get GE LOCK PEN 1002 PASS CODE 1003 LOCAL LOCK 1004 PARAM SAVE EXIT EDIT REM PAR GROUPS 11 02 PUMP SIGNALS 03 FB ACTUAL SIGNALS d d ORDS PROGRAMMING MultiPump Constant Pressu
73. Intermediate circuit DC voltage is not sufficient Check for and correct e Missing phase in the input power supply e Blown fuse check input wiring e Undervoltage on mains 7 All LOSS Analog input 1 loss Analog input value is less than AT MIN 1604 Check for and correct e Source and connection for analog input e Parameter settings for AI1 MIN 1604 8 Al2 LOSS Analog input 2 loss Analog input value is less than SENSOR MIN 1506 Check for and correct e Source and connection for analog input e Parameter settings for SENSOR MIN 1506 and 1503 TRANSDUCER MIN 9 MOT OVERTEMP 116 Motor is too hot based on either the drive s estimate or on temperature feedback device e Check for overloaded motor e Adjust the parameters used for the estimate 1104 1109 e Check the temperature sensors and Group 11 parameters e Check motor wiring and connections Possible MOTOR phase loss FAULTS ALARMS Fault Code 10 Fault Name In Panel PANEL LOSS Description and Recommended Corrective Action Panel communication is lost and either e Drive is in local control mode the control panel displays LOC or e Drive is in remote control mode REM and is parameterized to accept start stop direction or reference from the control panel To correct check e Communication lines and connections for control panel e Parameter 2401 KEYPAD FAILURE e Parameters in Group 10 Command Inputs and Group 11 Refer
74. Isolation Input transformers are sometimes used to provide impedance to isolate drives from line connected power factor correction capacitors PWM drive inputs do not require power factor correction capacitors as drive power factors are generally greater than 92 and cannot be significantly improved with power factor correction capacitors which only correct for fundamental However drives should be isolated from power factor correction capacitors by about 3 to 6 additional impedance with respect to the drives Line reactors can perform this function much more cost effectively than isolation transformers ABB drives have either an internal 3 line reactor or an equivalent 3 to 5 bus reactor 5 RFI EMI Mitigation Neither input isolation transformers nor line or bus reactors provide good high frequency filtering although an isolation transformer with a static shield will provide some RFI mitigation If RFI EMI mitigation is required an RFI EMI filter mounted inside the drive should be used together with all the proper wiring and grounding techniques Some RFI EMI filters may operate only on a power source with a grounded neutral Establishing a local neutral ground may require the use of an input isolation transformer INTRODUCTION Study these installation instructions carefully before proceeding Failure to observe the warnings and instructions may cause a malfunction or personal hazard AN WARNING Before you begin read Safety on page
75. LEDs This table describes LEDs of the drive Where OMIO Board Control Panel Mounting Platform OITF Board Control Panel Cleaning LED When the LED is lit Red blinking Drive in fault state Green The power supply on the board is OK Red Drive in fault state Green The main 24 V power supply for the control panel and the OMIO board is OK V204 green 5 V voltage of the board is OK V309 red Prevention of unexpected start is ON V310 green IGBT control signal transmission to the gate driver control boards is enabled Use a soft damp cloth to clean the control panel Avoid harsh cleaners which could scratch the display window Battery A battery is only used in Assistant Control Panels that have the clock function available and enabled The battery keeps the clock operating in memory during power interruptions The expected life for the battery is greater than ten years To remove the battery use a coin to rotate the battery holder on the back of the control panel Replace the battery with type CR2032 129 TECHNICAL DATA Sizing The current ratings are the same regardless of the supply voltage within one voltage range To achieve the rated motor power given in the table the rated current of the drive must be higher than or equal to the rated motor current Note 1 The maximum allowed motor shaft power is limited to 1 5 Times Rated HP If the limit is exceeded motor torq
76. M9Vf 309 JAd JAd IHN IVNIWYJL JING 30N383333 NOILISOd 301293NNO2 31VW3J 941M UIDIP OMY 02 oocivic 1 f noma v d WIG D I piarys ei 194seXjod poztuiwnjyj ggzzo y yg ug OMY 81 YOLINGNOD Z 290 ONJ SIHL LV OI LOINNOD LON OQ dluls 150 APPENDIX Spare Parts List Part Number Description 64732048 Control Panel Keypad Connector CPCCPA Control Panel Keypad OCATO1 Control Panel Extension Cable 8 ft CPCB01 Control Board OMIO fits all sizes OFAN KIT R1 Fan Kit R1 Frame Size Aquavar CPC OFAN KIT R2 Fan Kit R2 Frame Size Aquavar CPC OFAN KIT R3 Fan Kit R3 Frame Size Aquavar CPC OFAN KIT R4 Fan Kit R4 Frame Size Aquavar CPC OFAN KIT R5 Fan Kit R5 Frame Size Aquavar CPC OFAN KIT R6 Fan Kit R Frame Size Aquavar CPC 64391615 Fan Kit R7 Frame Size Aquavar CPC 64391658 Fan Kit R8 Frame Size Aquavar CPC 151 GOULDS WATER TECHNOLOGY LIMITED WARRANTY This warranty applies to all Aquavar CPC controllers manufactured by Xylem Inc Any part or parts found to be defective within the warranty period shall be replaced at no charge to the dealer during the warranty period The warranty period shall exist for a period of twenty four 24 months from date of installation or thirty 30 months from date of manufacture whichever period is shorter A dealer who believes that a warranty claim exists must contact the authorized Goulds
77. METER LISTINGS Group Spd Lim 14 Strt Lvl 1407 Priming Delay Group Transducer 15 Var Transducer Unit Range 0 6000 s Range Description When the drive is starting from 0 RPM this parameter delays pump protection faults 2404 and 2407 for the setting time The default setting is 0 Once the priming delay time is complete the protection delay parameter 2406 becomes functional During the priming delay the pump runs at the maximum speed setting parameter 1401 since it cannot achieve the set point Description Selects the units default is pressure for the primary process transmitter feedback located at Al2 In speed control macro default unit is RPM GPM Psig Default Ft F Deg CDeg Single Synch Defaults Multi Pump ronous Control Single Pump Synch ronous Multi Control Constant Slave Constant Slave Speed Control Speed Control 1502 Transducer Max 0 6553 5 For single pump and multipump macros this parameter defines the full scale feedback 20 mA setting of the primary process transmitter at Al2 This parameter also correlates to the maximum value of Reference set points 1 and 2 For the Speed Control macro this parameter scales the maximum 20 mA or keypad speed setting Note when units are i
78. MING AlddNs YIMOd TANVd TOYLNOD YO JDYNOS ALVYWdsAS Ad DV OZL D3 GAY4MOd 38 LSNIN dOO1 1OULNOD LEO ZOU LOY SLNdLNO ses uma hapas saa ss l ANTON VIA dIAINd 3AV1S G33dS LNVLSNOD ADYNOS YAMOd OL SANYININOD NI SANSSI YVAVNOV dOO1 1OY LNOD LON cee dO1S LUVLS T aeou zz y weou 9z gt de0u sz NIS LYWLS m 9204 vz e OL LAS x wzou lez lo dINV Z XVIN DYA OSZ SL dNOUD NI SDadS LNdLNO ATI GaNDISSv 39 NYD 34098 1 ON 8101 SLNdLNO AVIY alow Lz 2D WLOU DN DLO gt WLOU 2N 31I03_ YALYVLS 0 Ka 31V1S ATI YVAVNOV OO TVNIIA31 LN l l l l l l l l l l l l i L Q dINNd JAV1S DLOUY 6L JLON l l l l l l J4NVd 1OY LNOD GaliddNs YIWOLSND l HvAvnoW INVYDVIC dINAd JAVITS Ddd YVAVNOV 94 PROGRAMMING MultiPump Slave Pump Control Overview The Aquavar CPC has the ability to use up to three dry relay contacts for constant speed SLAVE or lag pump control This is useful if the operator requires a wide range of flow rates in certain situations i e emergency flow and does not require all variable speed controlled pumps When the required demand increases beyond capacity of the variable speed controlled lead pump then the FULL SPEED lag pump will turn on Each relay will be wired
79. Mu QOS unullu W roy v OqQA 0 JOMA OSZ uInuulxelW acoA ve V Oq Z Buiuuni s dund peal anezaq ajqewwes6 old Z indyno Aejay VW OL AZL Mu QOS WNW UIA xoda acl iz sindino Aejay v OQA oE OVA OSZ WINWIXe VLOU O Plays VEETIS Jeonp suely QAP O1 JaMod uni zynejaq ajqewwel6 oid yndyno Aejay gt Gineep yu O Trip eg ii A01 O LIV indu Bojeuy Dumac sodune L a10N uuun o2 1x u u yeyo S G LX 91 32e q JO y ym 4g90npsue41 y wouy ann 1ndino Bo eue p uuop S OL LX PULA 0 UMOJG JO Pad 129NpsueI ayy JO aim Ajddns samod ay p uuop r LoL X euler 0 Jaonpsuely y JO SIM u Jjos BY D uuoO IIM u 1S y L ISIM pue Bulyyeeys ajqeo Jaonpsued ayy due Z Inpuo2 y S yBnosuy ajqeo J onpsue41 ay a1m0 LU Joonpsuedl y Bui MA FEATURES Quick Reference Guide Analog Output 102 Auto Restart 102 Energy Savings Information 103 Fieldbus Control 103 Keypad Control Panel 104 Language 104 Locking 104 Low Water Protection 108 Manual Override 104 Minimum Speed Options 105 Priming Delay 106 Pump Protect Control 107 Ramp Hysteresis 113 Ramp Settings 113 Regulation Mode 107 Relay Outputs 107 Restart Value 106 Secondary Protection 108 Setpoints Dual 109 System Curve Compensation 110 Test Run 111 Tuning 111 Win
80. ND NOTES gt gt There are two types of safety instructions throughout this manual e Notes draw attention to a particular condition or fact or give information on a subject e Warnings caution you about conditions which can result in serious injury or death and or damage to the equipment They also tell you how to avoid the danger The warning symbols are used as follows DANGEROUS VOLTAGE WARNING warns of high voltage which can cause physical injury and or dam age to the equipment GENERAL WARNING warns about conditions other than those caused by electricity which can result in physical injury and or damage to the equipment TYPICAL DRIVE LABEL SW ACS550 U1 046A 2 ACS550 U1 046A 2 SW V 2 06B V 2 06B meee UMMM MTA IA S N2053901277 S N2053901277 Input 3 PH48 63 1 PH48 63 Hz Medean USA of foreign parts Voltage U1 208 240 Vac 208 240 Vac E Current 11n 46 2A 46 2 A G R L C US e Short Circuit 100 kAIC 100 kAIC 159339 Se Se Output 3PHO 500Hz 3 PH 0 500 Hz Voltage U2 0 U1 Vac 0 U1 Vac Mfg Date 31 October 2005 Orig Firmware V 2 06B Current 12n 46 2A 22A GE 3084 WN Power Pn 15 HP 7 5 HP S N2053901277 Power Phd ACS550 U1 046A 2 POWER DISTRIBUTION SYSTEMS The type of transformer and the connection configuration feeding a drive plays an important role in its performance and safety The following is a brief description of some of the more common configurations and a
81. NOM CURR EXIT ED REM PARAMETERS PROGRAMMING Single Pump Programming Pressure transducer 7 10 11 Use the down arrow until group parameter 1105 MOTOR NOM CURRENT is highlighted then press EDIT Using the arrows enter your motor s maximum allowed amp draw at full speed or Service Factor Amps NOTE Enter motors service factor from nameplate or motor manual Once you have entered the amps press the SAVE key Use down arrow until you highlight group parameter 1107 MOTOR NOM RPM then press the EDIT key Use arrows to enter the RPM from the motor nameplate default is 3550 RPM Press the SAVE key to store setting Use down arrow until you highlight group parameter 1108 MOTOR NOM POW then press the EDIT key Use arrows to enter the motors Horsepower rating from nameplate then press the SAVE key Once you have saved parameter 1108 use the down arrow until you highlight group parameter 1201 START STOP then press EDIT Default is KEYPAD This parameter determines how the operator will control the Aquavar via the keypad or via MODBUS communication If no changes are required press the CANCEL key then EXIT and go to the next step From group 12 press the down arrow until group 14 SPD LIM STRT LVL is highlighted then press EDIT Use down arrows to highlight group 1402 MINIMUM FREQ then press EDIT Using the arrow keys select the appropriate minimum speed in
82. O MOTOR AIR BLADDER TANK 3 PHASE MOTOR GATE VALVE BALL VALVE PRESSURE GAUGE SUCTION D AQUAVAR CPC FUSIBLE DISCONNECT Gi CENTRIFUGAL PUMP CHECK VALVE NON SLAM TYPE PRESSURE TRANSDUCER CABLE ASSEMBLY NOTES A Use of load filter reactor should be used between the Aquavar and motor if motor leads exceed 60 wire feet B If single phase power is supplied on 200 240 volt three phase units use U1 and WI as input terminals from single phase supply and de rate unit by 50 of three phase rating C Tank size should be 10 20 total volume of flow in system Pre charge tank 10 15 PSI below system pressure 73 PROGRAMMING Single Pump Programming Pressure transducer Programming Step s 1 Access the main menu on the keypad Press the MENU key once and the display will show PARAMETERS WIZARDS CHANGED PAR Using the arrow keys highlight the parameters option then press the ENTER key 2 Once the parameters option has been chosen the 74 parameter groups will be displayed Each group will be numbered see parameter groups list on page 50 for detailed information Use the arrow keys to highlight the parameter group 10 LOCKS PASSWORDS then press the SEL key Use the arrow keys to highlight group 1002 PASSCODE then press the EDIT key Enter your factory password number Default is 66 Press the save key Use up arrow to group 1001 PARAMETER LOCK
83. OCK When in the ON position the set point cannot be changed from the control panel This prevents unwanted changes to Aquavar settings To change the drive parameters including 10 03 LOCAL LOCK the parameter lock must be opened To open the parameter lock go to parameter 10 02 PASS CODE and scroll to the number 66 and press ENTER Parameter 10 01 PARAMETER LOCK will read OPEN NOTE If power to the drive is lost power failure disconnect etc parameter 10 01 PARAMETER LOCK will automatically reset to LOCKED 104 FEATURES Parameter Name Value Range Note s 10 01 PARAMETER LOCKED Default This parameter displays the status of the OPEN parameter lock and can be used to lock the parameters when necessary To OPEN the parameter lock use parameter 10 02 10 02 PASS CODE Not Displayed Using the arrow keys scroll to the number 66 and press enter This will open the parameter lock Note The number entry will disappear once ENTER has been pressed 10 03 LOCAL LOCK OFF Default This parameter disables local control of ON the drive Start Stop setpoint changes 10 06 SET POINT OFF Default This lock prevents the set point from LOCK ON being changed on the control panel Must enter password first WARNING It is not possible to stop the drive through the keypad with LOCAL LOCK set to ON e Use LOCAL LOCK only with a remote external stop start method e Keypad must be set in R
84. OME CHING ALARMS ahne ir E E E E dion O E AE TE E 120 Section 10 MAINTENANCE Frame Sizes R1 R6 Maintenance Intervals esoe tetienebeiur Seege a e E E E E SE E AEE EE a kleine 122 lees recm ienee baa eegen Ee ots E A A 122 Main Fari Replacementynisiy siioni E EE 122 Internal Eoclosure Fan Re placeMent s acceecisoccesechvsequenseteasesdeseasstedecgoburdescdsenedctealasendansauebsovanvesadevesensoleuaneetaes 123 CAPACI NS eosar geg baka Eed GEES ee enee E ested iaveededaavione 124 Controli Paneler a dentate Ae Eed E 124 Section 10 MAINTENANCE Frame Sizes R7 R8 LAV OU Sates esoe added ee gl 125 e Ue as EE 126 Replacing the Fame u a Deeg Sege 126 CAPACITORS eegent svtucevea sane borereacaesesueschnvsartovessgeeades dee Eden dee 128 RE 129 Control Panelini iaioa ine EE EIE eet dee ee deene 129 Section 11 TECHNICAL DATA SE HR Le EE 130 Cable Sizing Ratings 208 240 Volt Drives oo csccesssssssessssseeeeesseseseseeseeeseecsesscecaessnesacarscseeesscacaesesanseaeeceeesereneeees 131 Cable Sizing Ratings 380 480 Volt Drives ceeceessesesesessseesseeseseseseesescsesceesseecaesenesaeaeseeeeesscaeaeeesanseaeeeeeeseeeaeeees 132 Fuse Sizing Ratings 208 240 Volt Drives 0 cecesessssesseeseseseesesesescseeessesesesesesacscsesececseaeaeeecaracetsesesaeseneeseecaceeetenees 133 Fuse Sizing Ratings 380 480 Volt Drives ty veer u a uu aasawa eb etes eee EE 134 Cable Terminals frames R1 R6 and frames R R8 nn nn 135 Input Power Mans COnne coN
85. PE GND 3 Phase 3 Phase Power Input Power Output to Motor U1 V1 W1 U2 V2 W2 A WARNING For floating networks remove screws at F1 and F2 25 INSTALLATION Frames R1 R6 Single Phase Wiring Connection Diagram Diagram shows the R3 frame Other frames have similar layouts J1 DIP Switches for Analog Inputs J1 TAI in Voltage Position u E3 Al2 in Current Position x Panel Connector X1 Analog Inputs and Outputs and 10 V Ref Voltage Output Power LED Green J j Fault LED Red GELI s X1 Digital Inputs and 24 V Aux Voltage Output a 3 o Paar i i X1 Relay Outputs Ze Single Phase i ISS L l i E i Input Power J Optional Module 1 should use T JE Ir Communications Power i f RS485 Terminals l U1 W1 i i i Optional Module 2 and the D otuked PE ground EB y Single Phase eat 3 Phase Power Input FW j Power Output to Motor U1 w1 in ce eee ees oe I U2 V2 W2 Frame Sizes R5 R6 differ See EM3 next page EM1 SS GND PE AN WARNING For floating networks remove screws at EM1 and EM2 WARNING For single phase wiring derate the 3 phase nominal HP and amps 50 26 INSTALLATION Frames R1 R6 Wiring IP 21 UL Type 1 Enclosure with Conduit 1 Open the appropriate knockouts in the conduit gland box 2 Install thin wall conduit clamps not supplied 3 I
86. PM x 3 pumps 501 GPM A smaller sized pump is more capable of providing the low flow rates rather than a larger pump that may oscillate more at the low flows One of the immediate benefits is to have all the same pumps for parts and spares No smaller jockey pumps Each pump is evenly distributing the required flow and pressure Remember to allow system friction losses at maximum flow Tank Sizing Similar to the single pump constant pressure system the multi pump system should have a diaphragm or bladder type tank for system cushion The tank should be rated for the maximum system pressure and be sized for 10 25 of the single pump capacity This is total tank volume not drawdown If you have a triplex system of 167 GPM per pump capacity then your tank size should be a minimum of 17 Gallon capacity Go to the next higher tank volume if you have a suction lift or flooded suction The tank provides small drawdown capacities on drive start up and provides a cushion for the entire system at normal operation and will provide compressibility at shut down The tank pressure will greatly improve system operation A larger tank is acceptable and sometimes required just do not exceed 50 volume of the flow for one pump this may cause system problems Programming The following steps are for multi pump constant pressure systems with up to four 4 Aquavar CPC Each Aquavar CPC will have to be programmed according to this parameter guide The pa
87. S OQA te yndino afeuon ueI Ixnv GW uPnou pub sisseuo2 o euj lu p 1o uuoo uouuuuoo y imoui jndjno Bo euv 00S gt peol VW 0 0 pesn TON ATC e qeuw ey weiBoid 3ndino Bojeuy 00S gt peol yw oZ 0 uano pasn JON zynejeq ajqew weiboid indino Boyeuy GW yonoiyy pub sisseyo o eu Jeu p p uuo uow Wo0 N2119 ndu Bojeuy VW Och QO z Abt aNo9y LOV yndu AJ 5npsue4u is1ndul e1i6iq oeinooe 10 uonnjos y z JouUeYD 1ndu 6ojeuy Cpasn JON Z Heine i 9j uuonu lod jndul Bo eue 104 nd no 6eyon u 1 J 1 YU QL A 01 CLL LX O 84M A duunr MAN yBnosuy pub s ssey gt o jjeu Jeu p p uuo uow WO2 HINDJIID Indu Bo euv Gii 6001 IM yw 0Z 0 NO UU IV AOL ANDY EE OA ZLE IM AOL 0 4dO UNLE oeinooe LO uonn os s aouesejes ouenbau 2a nej q sJeonpsued puz I8uueuo 1ndu Hojeuy punoiB sisseyd o jeu 19 U p lo uuoo pPjalys Jaonpsued JO EULA Bui lonuoo lt O z Q lt l di Lewmedut jeubig p y 10 umolg Aiddng JeMmoq Jeonp Sue O Bojeuy M S 13409 xoq puej6 ynpuo gt y el1su 9 VW OL ACL MW 00S unwluIN v OQA OE HO D o OVA OSZ UINWIXe pasn 30u ajnejeq ajqewuwes6 oad nd no Aejay WHOL AZL
88. T 2207 Pump Address 1 2 3 or 4 SYSTEM TUNING Group 13 Ramps allow for tuning of the system response Ramps 1 and 2 provide control of start and stop ramps and can be used to produce smooth operation throughout pumping level Ramps 3 and 4 work within the regulation window to provide a final adjustment of system operation when needed reference pages 112 114 NOTE Level control application performance is dependant on sump size maximum flow rate and pump selection An oversized pump may produce on off type system operation similar to a level switch This condition might not be fully correctable with ramp control 86 PROGRAMMING MultiPump Constant Pressure Control Overview The Aquavar CPC has the ability to connect and control up to four centrifugal pumps to form a Multi Pump lead lag and alternating pumping system This will allow the operator to maintain a constant pressure through a larger system flow range and provides equal wear for the pumps and motors The Aquavar units will be hard wired together via the RS485 terminals 29 30 31 and provide communication to maintain a constant pressure to the system Once the lead pump cannot maintain a certain pressure and allows a slight pressure drop the next lag pump will turn on and vary the speed according to the flow demand This sequencing can be programmed according to the specific system requirements and is field adjustable If a pump or controller fails the
89. T 2 55 33 286 1 30 11 26 LIFTING LUG 4 pcs DET B SEE SHEET 2 MAIN SWITCH 734 16 74 598 4 23 56 3AFE 64626264 30 04 02 41 INSTALLATION Frames R7 R8 Detail R7 Dimensions are listed in millimeters and inches 42 H DEE D E N VW ec us um S aS og 3 em go os Do ga S oA Ps Da BN Ra So Bose Si eeng EE E S Al KEEN DET B 25 0 0 00 INSTALLATION Frames R7 R8 Extension Module R8 Dimensions are listed in millimeters and inches BOTTOM PLATE HOLE 014 55 787 30 98 BAFE 64626388 30 04 02 43 INSTALLATION Frames R7 R8 Detail R8 Dimensions are listed in millimeters and inches Eee e die Il sssi FL u wll m IE 44 START UP Wizards The Wizard configures the drive This process sets parameters that define how the drive op erates and communicates Depending on the control and communication requirements the start up process may require any or all of the following e The Start up Wizard steps you through the default configuration The Start up Wizard can be activated at the first power up or can be accessed at any time using the main menu e Application macros can be selected to define common alternate system configurations us ing the default settings See Single or Multipump Setup
90. The only significant layout difference is in the power and ground terminals for frame sizes R5 and R The following diagrams show e Terminal layout for frame size R3 which in general applies to all frame sizes except as noted above e Power and ground terminal layout for frame sizes R5 and R Diagram shows the R3 frame Other frames have similar layouts J1 DIP Switches for Analog Inputs J1 Alt in Voltage Position S p ATT in Current Position X1 Analog Inputs and Outputs and 10 V Ref Voltage Output Panel Connector Power LED Green Fault LED Red X1 Digital Inputs and 24 V Aux Voltage Output X1 Relay Outputs J2 J5 DIP Switches Optional Module 1 for RS485 Termination X1 Communications RS485 J2 J5 J2 J5 G L JL I off position on position Optional Module 2 3 Phase 3 Phase Power Input 9 Power Output to Motor U1 V1 W1 AARDAS U2 V2 W2 Frame Sizes R5 R6 differ See next page EM1 X0003 AN WARNING For floating networks remove screws at EM1 and EM3 24 INSTALLATION Frames R1 R6 Three Phase Wiring Connection Diagrams continued Frame Size R5 GND F2 Frame Size R6 3 Phase 3 Phase Power Inp t Power Output to Motor Ul V1 W1 U2 V2 W2 F1 Connection 1 A Ja my DUU Grp HSC HEEL 04S 1 D E vu W1 R R UDC U2 v2 w2 KTD arare A e e x0013
91. U1 WI and Ground connections and derate the drive by 50 from the three phase rating Example 230 volt three phase 10 HP Aquavar becomes a 5 HP 230 volt single phase rated drive 80 PROGRAMMING Single Pump Submersible Pump Constant Pressure Each component of the electrical Aquavar system should have the same grounding point or reference Programming Step s Standard view of the display in REM remote mode You will see the reference pressure REF PRESSURE actual pressure ACT PRESSURE and motor frequency in HZ Access the main menu on the keypad Press the MENU key once and the display will show PARAMETERS WIZARDS CHANGED PAR Using the arrow keys highlight the parameters option then press the ENTER key N Once the parameters option has been chosen the parameter groups will be displayed Each group will be numbered see parameter groups list on page 51 for detailed information Use the arrow keys to highlight the parameter group 10 LOCKS PASSWORDS then press the SEL key W I Use the arrow keys to highlight group 1002 PASSCODE then press the EDIT key Using the up arrow enter your factory password number Default is 66 Press the save key 4 Use up arrow to group 1001 PARAMETER LOCK then press the EDIT key Next use the up arrow to select OPEN then press the SAVE key This group should appear as OPEN if it does not you have entered the pa
92. able sequence speed 2203 Constant Slave The master unit starts up to three fixed speed slave units when needed See RO1 RO2 and RO3 settings parameters 1801 1804 and 1807 Speed Control AV follows a speed reference only Pump protect fault function is inactive 1101 Language Selects the display language English English English English English English AM American English Default Espa ol Spanish full translation Francais French full translation 1102 Application Selects the application macro V V Y V V Macro Single Pump One AV regulating to a set point Default Synchronous Lag pumps start as needed and all pumps regulate to the set point atthe same speed Note itis recommended that all pumps be identical Multicontrol Lag pumps start as needed The 1103 Application No Restore Yes Resets parameters to default settings 55 PARAMETER LISTINGS Group 11 Start Up Data Range Description Single Pump Synch ronous Control Multi Defaults Constant Slave Speed Control Group 12 Start Stop Description Defines the connections and source of the start stop commands Comment DI Enable 0 Disable 1 Enable DI2 Low Water 0 Fault 1 OK DI3 Estop 0 Estop 1 OK After Estop restart from keyp
93. above Lag Te Lc L Al Wa j 127 MAINTENANCE Frame Sizes R1 R6 Capacitors The drive intermediate circuit employs several electrolytic capacitors Their life span is at least 90 000 hours depending on the operating time of the drive loading and ambient temperature Capacitor life can be prolonged by lowering the ambient temperature It is not possible to predict a capacitor failure Capacitor failure is usually followed by damage to the unit and an input cable fuse failure or a fault trip Contact your Goulds Water Technology authorized Aquavar CPC distributor or the factory Replacing the Capacitor Pack R7 Replace the capacitor pack as described in section Replacing the Fan R7 on page 126 Replacing the Capacitor Pack R8 1 Remove the upper front cover and the side plate equipped with control panel mounting slot 2 Disconnect the discharging resistor wire 3 Undo the fastening screws 4 Lift the capacitor pack out 5 Install the capacitor pack in reverse order to the above d p IL Wi Ki D ry bi S aime im i d Lei ell aie d Il ik xs EESER A ke er n SKI D St SI HH d SS x ahd D A D Sch ah mol br p P d U wl ef R TO kK E E WH Yw Ed E R a Kat paz x MAINTENANCE Frame Sizes R7 R8
94. ad required Keypad Start Stop from keypad After a fault reset the drive will restart only if auto restart 1202 is set to on If auto restart is off the drive must be started from the keypad Fieldbus Start via fieldbus control word Keypad Synch ronous Control Multi Motor Nom 11 345V Defines the motor voltage Voltage 230 690V Equal to the value on the 460 460 460 460 460 motor nameplate 575 575 575 575 575 1105 Motor Nom 0 2 land Defines the motor current 1 0 1 0 1 0 1 0 1 0 Current 2 0 bond Equal to the value on the D Ka E KL E motor nameplate 1106 Motor Nom Freq 10 0 500Hz Defines the motor nominal 60 60 60 60 60 frequency Equal to the value on the motor nameplate 1107 Motor Nom RPM 50 18000 Defines the motor nominal 3550 3550 3550 3550 3550 RPM speed Equal to the value on the motor nameplate 1108 Motor Nominal 0 2 2 0 P y Defines the motor power hp 1 0 Pha 1 0 Pha 1 0 Pha 1 0 Pha 1 0 Pha Power Equal to the value on the nameplate Constant Slave Speed Control 1202 Auto Restart Selects whether the AV will automatically restart after a power failure or fault reset Not selected Selected The AV will automatic ally restart if conditions permit On On On On On 1203 TestRun Selects when the drive will perform atestrun NotSel default Not selected
95. age from any input line to ground be always less than 110 of the nominal power line to line voltage The use of optional RFI EMC filters may require that the voltage from any input line to ground be less than 110 of the nominal power line to neutral voltage Drive input isolation or dry type transformers may be required for the following 1 Step up or down An input transformer may be required to step the local input power line voltage up or down to the level of the drive input rating 2 Ground Isolation An input isolation transformer with a direct or a high impedance wye neutral secondary ground connection may be required to establish a local power source with a ground relationship different from the utility power source A If ground isolation is required to prevent a ground fault in one section from shutting down equipment in another section B To bring local line voltages within the line to ground limits 110 balance stated in the opening paragraph C Some ground fault protection schemes and peripheral components require a grounded neutral power source D A symmetrical wye neutral grounded power source along with proper ground wiring techniques according to NEC good ac grounding from motor to drive and from drive to earth ground provides the best means to control the ground currents that the drive switching frequency and dv dt rate insert into the motor frame and shaft 3 Phase shifting delta wye or zig zag isolation t
96. age in the DC link is too high Check for and correct e Missing mains phase e Blown fuse e Input wiring connections 23 RESERVED Not used 24 OVERSPEED Motor speed is greater than 120 of the larger in magnitude of 1402 MINIMUM SPEED or 1401 MAXIMUM SPEED Check for and correct e Parameter settings for 1401 and 1402 e Adequacy of motor braking torque e Applicability of torque control 25 RESERVED Not used 26 DRIVE ID Internal fault Configuration Block Drive ID is not valid Contact your local factory representative 117 FAULTS ALARMS Fault Fault Name sss I Description and Recommended Corrective Action Code In Panel 27 CONFIG FILE Internal configuration file has an error Contact your local factory representative Cycle power e Check Group 9902 Drive Size Type 28 SERIAL 1 ERR Fieldbus communication has timed out Check for and correct e Fault setup 2409 COMM FAULT FUNC and 2410 COMM FAULT TIME e Communication settings Group 31 or 32 as appropriate e Poor connections and or noise on line 29 EFB CON FILE Error in reading the configuration file for the fieldbus adapter 30 FORCE TRIP Fault trip forced by the fieldbus See the fieldbus User s Manual 31 EFB 1 Fault code reserved for the EFB protocol application 32 EFB 2 The meaning is protocol dependent 33 EFB 3 34 MOTOR PHASE Fault in the motor circuit
97. als a fault when the AQUAVAR is powered down INSTALLATION Frames R1 R6 You can wire the digital input terminals in either a PNP or NPN configuration PNP Connection Source NPN Connection Sink Communications Terminals 28 32 are for RS485 or modbus communications Use shielded cables For lengths of cable beyond 100 feet use screen connections Do not directly ground the RS485 network at any point Ground all devices on the network using their corresponding earthing terminals As always the grounding wires should not form any closed loops and all the devices should be earthed to a common ground Terminate the RS485 network using 120 Q resistors at both ends of the network Use the DIP switch to connect or disconnect the termination resistors See following diagram and table Terminated Terminated Station Station Station Station eoo00 p0000 e0000 ooo0oo00 _ X1 Identification Hardware Description 28 Screen RS485 Multidrop Application RS485 Interface 29 B Other Modbus Devices J2 J5 J2 J5 RS485 lt CR 28 Multipump 30 A AA A 4 Connections 431 AGND ON ON 32 Screen off position on position Bus Termination 1 For functional descriptions see Standard Serial Communication addendum 31
98. ceeeeeseseneeecsnseneseeesseseaeecnesacaeaeeacesseeeeeeeearaees 73 Single Pump Submersible Pump Constant Pressure ceescesssssseeseseseeseeeseseeceessescaeseseeseecaesceesaceeaeeseecsceeeeeeareees 78 MultiPump Constant Pressure Control uuu u u Eder 87 MultiPump Slave Pump Control 328 NEESS 94 Section 8 FEATURES Analog Out e 102 Auto Restart Energy Saving Information Group Z i 102 TABLE OF CONTENTS e lg 103 language let DEE 104 Minim m Speed OPTIONS ut AEN ee EES du esucbsegessbidtaevadvelarenetectoteuaneaners 105 Priming Delay Pump Protect Ctrl Regulation Mode naa sssssssssaa 106 107 Relay Outputs Restart Options Low Water Suction ProtechHon as asssssss 107 108 Keypad Faill res csvczeseaesvectcangidacodantvestdcolbaaseueseqieutioleanssaudsducvssnassexstedaudavageauonddeed ayana sledasesaedatpste seven ai Enaisi ede eate 109 Set Points Dual with example u E u D eegene 109 SYSTEM Curve COMP SMSATOM suse eege see ere Serge Eed e SEENEN dovecieushans 110 Test Run Tuning System TE 111 Window Setting Reeg Window sisarccsccd iasieuaessdiecl siecbeenguentiedgotereyeacscedessnsecansneutdeadyeedbudeydenbiis EE Raa i EEEa 112 Raimi HYSTERESIS eeii sb EE EER EEE E eE EE avid EE REE REE 113 Adj sting Ramp Rate y a n A ERRE EEEE EENEN EE EE EE enen 113 Section 9 FAULTS ALARMS KETTEN 115 Seriean MR AEE AE eee nero PETE A EE EN CLT AA 116 Fault Resetting unan e eea E aaa kaha EEEE RER EEE e 119 C
99. ct the two fiber optic cables Make note of the terminal colors for use when reconnecting SO Carefully remove the cables disconnected in the above steps Pull the cables down inside the pedestal and bundle them so that they will not get damaged or caught in the trolley when the drive mod ule is wheeled out 39 INSTALLATION Frames R7 R8 10 Remove screws fastening the drive module trolley to the pedestal WARNING These screws are an important step during re assembly the screws are required for grounding the drive 11 R8 The front of the trolley includes support braces that fold out Lift each brace slightly and fold it out 12 Remove screws that fasten the drive module to the extension module CAUTION The drive module is now separated and could tip over Use care when moving the drive module 13 Pull on the handle to wheel the drive module out Drive Maintenance See the AQUAVAR User s Manual for drive maintenance procedures page 34 Re Assembly Re attach the modules in reverse order to the above 40 R7 Trolley INSTALLATION Frames R7 R8 Technical Data Dimensional Drawings See the AQUAVAR User s Manual for drive module dimensions Extension Module R7 Dimensions are listed in millimeters and inches 598 9 23 58 523 20 59 323 12 72 29 1 14 0 00 BOTTOM PLATE HOLE 14 6 pcs DET A SEE SHEE
100. ction If Connecting the Wye secondary neutral to ground through a resistor is an acceptable method of grounding Under a short circuit secondary condition any of the output phases to ground will not exceed the normal line to line voltage This is within the rating of the MOV input protection devices on the drive The resistor is often used to detect ground current by monitoring the associated voltage drop Since high frequency ground current can flow through this resistor care should be taken to properly connect the drive motor leads using the recommended cables and methods In some cases multiple drives on one transformer can produce a cumulative ground current that can trigger the ground fault interrupt circuit Open Delta consult factory lt This type of configuration is common on 230 volt systems From time to time it may be encountered where only single phase power is available and three phase power is required The technique uses two single phase transformers to derive a third phase When used to power a drive this configuration must be derated to about 70 of the single phase rating of one transformer This system provides poor regulation and it is possible that only the two line connected phases will provide power In this case the drive must be derated to 50 of its rating Ex A 20 HP 230 volt drive now becomes a 10 HP 230 volt drive Single Phase Connection For small drive with a diode rectifier front end it i
101. d using the 50 derate factor Consult factory Sometimes drive input isolation transformers are specified to deal with one or more of the following issues 1 Short Circuit Protection Input transformers are sometimes used to provide impedance to reduce the available short circuit current to levels that the input clearing devices such as fuses or circuit breakers are rated to handle Line reactors can perform this impedance function much more cost effectively 2 Transient Protection Input transformers are sometimes used to provide transient surge impedance All the Aquavar CPC drives have capacitors and MOV s Metal Oxide Varistor transient protectors providing 120 to 360 joules line to line and line to ground transient protection Isolation transformers are not required for this protection within those energy levels Additional distribution transformer primary transient surge arrestors may be required if the potential transient energy reflected to the drive exceed those levels MOV s are rated to handle high levels of one shot transient energy MOV s are not meant to handle continuously recurring transients A problem of continuously recurring transients should be corrected before connecting a drive 3 Harmonic Mitigation Input transformers are sometimes used to provide impedance to reduce the harmonic currents generated in the drive Line reactors can perform this function much more cost effectively 4 Power Factor Capacitor
102. ding Select the appropriate range then press SAVE If no changes are necessary press CANCEL REM PARAMETERS 1101 LANGUAGE 1102 APPLIC MACRO 1104 MOTOR NOM VOLT 1105 MOTOR NOM CURR 4 MOT 1105 MOTOR NOM CURR 3 5 EXIT TEDIT REM PARAMETERS 1104 MOTOR NOM VOLT 1105 MOTOR NOM CURR 1106 MOTOR NOM FRE OTOR NOM RP EXIT EDIT PARAMETERS MOTOR NOM CURR 6 MOTOR NOM FREQ REM PARAMETERS 1501 TRANSDUCER UNIT 1502 Me EE MAX 300 0 1503 TRANSDUCER MIN 1504 SENSOR 91 PROGRAMMING MultiPump Constant Pressure Control 12 Use the down arrow to highlight 1503 TRANSDUCER MIN 0 0 then press EDIT Default should be 0 psi Press CANCEL to advance to the next step If this group needs to be changed based on another type of transducer value press SAVE to store 1 Ww 14 15 16 17 92 Use the down arrow to highlight 1506 SENSOR MIN then press EDIT Use the up arrow until the TUNE value is displayed press the SAVE key This provides the transducer a tuned value of 0 ZERO psi NOTE Make sure that your transducer is wired to the Aquavar but free from any pressure in the system The transducer must be exposed to 0 psi when this step is performed Press the SAVE key to tune your transducer Once you have saved the parameter 1506 press the EXIT key Use down arrow until you highlight pa
103. discussion of their virtues and shortcomings Always ask what type of power system the site has before sizing the drive Delta Wye with grounded Wye neutral SES This configuration is one of if not the most common It provides rebalancing of unbalanced voltage with a 30 degree phase shift Depending on the output connections from the drive to motor the grounded neutral may be a path for common mode current caused by the drive output Delta Delta with grounded leg lt Another common configuration providing voltage rebalancing with no phase shift between input and output Again depending on the output connections from the drive to motor the grounded neutral may be a path for common mode current caused by the drive output Ungrounded secondary spy IEG Grounding of the transformer secondary is essential to the safety of personnel as well as the safe operation of the drive Leaving the secondary floating can permit dangerously high voltages between the chassis of the drive and the internal power structure components In many cases this voltage could exceed the rating of the input MOV protection devices of the drive causing a catastrophic failure In all cases the input power to the drive should be referenced to ground If the transformer can not be grounded then an isolation transformer must be installed with the secondary of the transformer grounded POWER DISTRIBUTION SYSTEMS Resistance grounding and ground fault prote
104. dow Regulation 112 TABLE OF CONTENTS Section 1 SAFETY Userof Warnings and Notes 2 u ccaseacessassnz cuceceasdenteotscsbatdenenasigesdesdeaezsantvisentsadeasseouterqeovendetesardyeacabgaatenaacena cbes 7 Section 2 POWER DISTRIBUTION SYSTEMS Delta Wye with grounded Wye neutral 9 Delta Delta with grounded leg 9 NG NOU CSG EE 9 Resistance grounding and ground fault protection nn n sasana 10 Open D ltl u uk os gat stesso us hatin Sosa seas Leed Egger dies eege dee 10 Single Phase REISE AE EE EE 10 Section 3 INTRODUCTION Input Power and Line Transformer Requirements eceeeeeseseseseeeeeeseeesesceeceseseeeeesscseneeessnscaeeceeeseseaeeeeeseaeieeeteeees 11 Issues for Drive Input Isolation Transformers 11 Installation Flow Chart uu a asuanata Sains baha aaa akunata 13 Aquavar CPC Product Numbering a nn n EE EEN EEEE E EENES ESEESE S ESEE tete ree rent 14 Preparing for Installation Drive Identification a n na 15 Section 4 INSTALLATION Frames R1 R6 SUP Ply COMME TEE 19 Thermal Overload and Short Circuit Protectio Mesirna ei 19 Ground Fault Prot ecti rk a anaq EES 19 Emergency Olt Dieu Tee steiere A mus Su s Du SD nan un am ua 19 Selecting the Power Cables ic side uuu ee Ge Eeer dd 20 Mertert EE 20 Additional US Requirements yc csiccctecasseisissstesieieheeteseckeveckeossiel een lassi suni a aeai a e e aaia 20 laf elle he NEIE EN Wiring Connection Diagrams
105. e Cable fittings shown are typical examples PE Connection Motor Output U2 V2 W2 Input U1 V1 W1 Switch Fuse OMIO Board Control Wiring Terminals and Option Module Mounts y PDM 146378 8 37 INSTALLATION Frames R7 R8 e The following diagram shows the power and control connection points in the enclosure module supplied with the R8 drive module R8 Frame Size Gland Conduit Plate Cable fittings shown are typical examples PE Connection Motor Output U2 V2 W2 E Input U1 V1 W1 kap S Switch Fuse AL IR Geelen SA se Pas las ER OMIO Board Control Wiring Terminals and Option Module Mounts e Re mount the high voltage shield TN WARNING Always replace all high voltage shields before applying power e See the AQUAVAR User s Manual for detailed instructions on control connections installation check list and drive start up process 38 INSTALLATION Frames R7 R8 Maintenance This section describes the procedure for separating the drive and extension modules which is required to provide service access to the drive module Safety WARNING Read Safety on the first pages of this manual before performing any maintenance on the equipment Ignoring the safety instructions can cause injury or death Note There are parts carrying
106. e A E lt Top View E1 i pE H1 X2 d c A NEMA 1 Enclosure H1 W2 Depth Weight E1 E2 Frame mm in mm in mm in kg Ib mm in mm in R7 1503 59 17 609 23 98 495 19 49 195 430 92 3 62 250 9 84 R8 2130 83 86 800 31 5 585 23 03 375 827 92 3 62 250 9 84 Drawing is not for engineering purposes Degrees of Protection Available enclosures IP 21 UL Type 1 Enclosure The site must be free of airborne dust corrosive gases or liquids and conductive contaminants such as condensation carbon dust and metallic par ticles Indoor use only IP 54 UL Type 12 Enclosure This enclosure provides protection from airborne dust and light sprays or splashing water from all directions Indoor use only e UL Type 3R Enclosures are intended for outdoor use to provide a degree of protection from falling rain Undamaged by the formation of ice on the enclosure May be cooled by forced air and louvers for vents This rating is met by placing the drive into a NEMA 3R Enclosure Compared to the IP 21 UL Type 1 Enclosure the IP 54 UL Type 12 Enclosure has e The same internal plastic shell as the IP 21 Enclosure e A different outer plastic cover e An additional internal fan to impr
107. e Check for overloaded motor pump 2011 UNDERLOAD Motor load is lower than expected This alarm warns that a Motor Underload fault trip may be near Check e Motor and drive ratings match motor is NOT undersized for the drive 2012 MOTOR STALL Motor is operating in the stall region This alarm warns that a Motor Stall fault trip may be near Check motor connections 2013 AUTORESET This alarm warns that the drive is about to perform an automatic fault reset note 1 which may start the motor e To control automatic reset use parameter Group 12 AUTOMATIC RESET 2015 ALARM 2015 Pump protection has been triggered via parameter 2403 protection limit PUMP and 2404 protection delay This protection is enabled when the pump PROTECT reaches maximum frequency and cannot maintain system set point for the specific delay time Check for air entrainment plugged impeller blocked suction lack of NPSHa pump run out 2016 LOW WATER Check DI2 contact or suction switch continuity 2017 NOT USED 2023 E STOP Check jumper connection between Terminal 10 and 15 DI3 FAULT 121 MAINTENANCE Frame Sizes R1 R6 WARNING Read Safety on page 7 before performing any maintenance on the equipment Ignoring the safety instructions can cause injury or death Maintenance Intervals If installed in an appropriate environment the drive requires very little maintenance This table lists the routine maintenance intervals recommended by G
108. e Follow local codes for cable size conduit grounding and motors e Keep these four classes of wiring separated input power wiring motor wiring control communications wiring Always use separate conduit for motor control wires e Refer to the specifications recommendations in Cable Sizing Rating on page 131 Cable Terminals on page 135 Input Power Mains Connection on page 136 and Motor Connection on page 136 e Multiple motor wire should always be run in separate conduit Shielded and grounded Control Cables General Recommendations Use shielded cables temperature rated at 60 C 140 F or above e Control cables must be multi core cables with a braided copper wire screen w Seana ii a Shielded Single Shielded Example JAMAK by Draka NK Cables Example NOMAK by Draka NK Cables e The screen must be twisted together into a bundle not longer than five times its width and connected to terminal X1 1 for digital and analog I O cables or to either X1 28 or X1 32 for RS485 cables 17 INTRODUCTION Route control cables to minimize radiation to the cable e Route as far away as possible from the input power and motor cables at least 20 cm 8 in e Where control cables must cross power cables make sure they are at an angle as near 90 as possible e Stay at least 20 cm 8 in from the sides of the drive Use care in mixing signal types on the sam
109. e anticipates an increase in system pressure and will decrease speed of the pump based on a rising system pressure If the regulation mode is set to INVERSE the process condition is expected to increase with a decrease in pump speed Parameter Name Value Range Note s 21 01 REGULATION NORMAL Default Inverse is normally used for control of MODE INVERSE suction side systems EXAMPLE If an Aquavar unit is trying to control the level in a suction side tank or sump the regulation mode would be set to INVERSE As the level in the sump increased Aquavar would respond by increasing pump speed to maintain a constant level Relay Outputs The AQUAVAR CPC has three relay outputs that are configurable for different operating and fault conditions Relays will revert to original states once warnings or faults are reset or cleared Comment s Maximum Contact Voltage 30 VDC 250 VAC Maximum Continuous Current 2 ARMS Refer to the terminal layout diagram for RELAY OUTPUT specifications Maximum Contact current power 6A 30 VDC 1500 VA 250 VAC 107 FEATURES Parameter Name Value Range Note s 18 01 RELAY RO NOT USED Default for RO1 OUTPUT 18 04 RELAY R02 RUNNING Default for RO2 OUTPUT 18 07 RELAY R03 READY Default for RO3 OUTPUT VFD FAULT SECND PRTECTA Secondary Protect A activation PUMP PROTECT Pump protection activation START SLAVE Used with multi pump macro only STAND BY
110. e cable e Do not mix analog and digital input signals on the same cable e Run relay controlled signals as twisted pairs especially if voltage gt 48 V Relay controlled signals using less than 48 V can be run in the same cables as digital input signals NOTE Never mix 24 VDC and AC power signals in the same cable Analog Cables Recommendations for analog signal runs e Use double shielded twisted pair cable Use one individually shielded pair for each signal e Do not use a common return for different analog signals Digital Cables Recommendations for digital signal runs e A double shielded cable is the best alternative but single shielded twisted multi pair cable is also usable Control Panel Cable If the control panel is connected to the drive with a cable use only Category 5 Patch ethernet cable INSTALLATION Frames R1 R6 Supply Connection Disconnecting Device Mains Install a hand operated input disconnecting device between the AC power source MCC and the drive The disconnecting device must be of a type that can be locked to the open position for installation and maintenance work Follow all local NEC codes Fuses See Technical Data Fuse Sizing Rating on pages 133 and 134 Thermal Overload and Short circuit Protection The drive protects itself and the input and motor cables against thermal overload when the cables are dimensioned according to the nominal current of the drive No additional therma
111. e conduits must be coupled together bridge the joint with a ground conductor bonded to the conduit on each side of the joint Bond the conduits also to the drive enclosure Use separate conduits for input power motor brake resistors and control wiring Do not run motor wiring from more than one drive in the same conduit Armored cable shielded power cable The motor cables can be run in the same cable tray as other 460 V power wiring Control and signal cables must not be run in the same tray as power cables Six conductor 3 phases and 3 ground type MC continuous corrugated aluminum armor cable with symmetrical grounds is available from the following suppliers tradenames in parenthesis e Anixter Wire amp Cable Philsheath e BICC General Corp Philsheath e Rockbestos Co Gardex e Oaknite CLX Shielded power cables are available from Belden LAPPKABEL OLEFLEX and Pirelli Installing the Drive WARNING Before installing the AQUAVAR ensure the input power supply to the drive is off Unpack the Drive 1 Unpack the drive 2 Check for any damage and notify the shipper immediately if damaged components are found 3 Check the contents against the order and the shipping label to verify that all parts have been received Prepare the Mounting Location The AQUAVAR should only be mounted where all of the requirements defined Preparing for Installation on page 15 are met 1 Mark the position of the mounti
112. e drive 0306 Fault Word 2 Fault word 2 ofthe drive 0307 Fault Word 3 _ Fault word 3 ofthe drive 0308 Alarm Word 1 Alarm word 1 of the drive 0309 Alarm Word 2 Alarm word 2 of the drive 53 PARAMETER LISTINGS Defaults Synch Multi Constant Speed Status Words Range Description g P ronous Control Slave Control Group 03 AV Alarm Word Aquavar Alarm word AV Fault Word _ Aquavar Fault word Comm RO Word _ Comm Value 1 _ 0311 0312 0313 Comm Value 2 Group Locks S Synch Multi Constant Speed 10 Passwords nange dch de ronous Control Slave Control Locked Locked Locked Locked Locked Parameter Lock Selects the state of the parameter lock The lock prevents parameters from being changed Open The lock is open Parameter values can be changed Locked Parameter values cannot be Default changed from the keypad The lock can be opened by entering the valid password in parameter 10 02 When the keypad is locked the AV keypad function ality is limited to starting stopping and changing the reference set point 1002 Pass Code 0 300000 Password setting 66 opens the 0 0 0 lock and returns the value to zero on the display The pass word relocks when power is disconnected To relock the keypad reset parameter 1001 to Locked 1003 Local Lock Disable
113. e parameters for trigger points on the cooling fan motor revolutions run time used power in Megawatts Provides actual time run on each component Group 99 INFORMATION Provides firmware version drive rating for the Aquavar 51 PARAMETER LISTINGS Group 01 VFD Signals Range Description Single Synch Pump ronous Control Slave Defaults Multi Constant Speed Control 0101 Motor 0 0 500 0Hz Calculated VFD output Frequency frequency Hz 0102 Motor Current U ZU Measured Motor Current A 0103 Motor Power Motor Power kW 0104 DC Bus Voltage Measured intermediate circuit voltage V 0105 MotorVoltage 0 2 0 V4 Calculated motor voltage V 0106 Drive Temp 0 150 C VFD Temp Deg C 0107 VFD On Time 0 9999h Elapsed time counter runs when the drive is powered Hrs since last reset Re settable by parameter 2605 0108 0 9999h Motor run time counter Hrs since last reset The counter runs when the inverter modulates Re settable by parameter 2605 0109 KWh Counter 0 9999kWh_ kWh counter kWh since last reset Re settable by parameter 2605 0110 DI6 1 Status 000000 Status of digital inputs 111111 Example 0000001 DI1 is on DI2 DI off 0111 AI1 0 100 Value of analog input 1 0112 Al2 Trnsder Fdbk 0 100 Value of analog input 2 0113 RO3 1 Status 000 111 Status of relay out
114. e pump protection warning or fault function has been activated Start Slave Used in multipump macro to start slave pump only Stand by Drive is in sleep mode due to no system demand Single Synch Pump ronous Control Defaults Multi Constant Speed Slave Control 1808 RO3 ON Delay 0 3600 s Defines the operation delay for relay output RO3 1809 RO3 OFF Delay Group Analog 19 Outputs 0 3600 s Defines the release delay for relay output RO3 Description Single Synch Pump ronous Control Multi Constant Speed Slave Control AO 1 Content Sel Connects a AV signal to analog output 1 AO1 Used Used Used Used Not Sel default Not in use Frequency Output frequency 20 mA motor nominal frequency 1106 Current Output current 20 mA motor nominal current 1105 Torque Motor torque 20 mA 100 of motor nominal rating Power Motor Power 20 mA 100 of motor power rating Proc Var Actual value of process variable Actual Al2 20 mA Reference 1 Max 1603 Energy Saving Calculated energy savings option 1 or 2 over a conven tional fixed speed system 20 mA Savings scale 2603 1902 AO1 Content Various Selects the minimum value of the Min characterisitc being monitored 1903 AO1 Content Various Selects the maximum value of the 4 4 4
115. eezing temperatures high altitude dust vibration lack of air flow PROGRAMMING SINGLE PUMP LEVEL CONTROL Submersible Transducer Setup PARAMETER SETTINGS QUICK LIST 1002 Pass Code 66 1001 Parameter Lock OPEN 1102 Application Macro SINGLE PUMP 1104 Motor Nom Volt 1105 Motor Nom Current 1106 Motor Nom Freq 1107 Motor Nom RPM 1108 Motor Nom Pow 2101 Regulation Mode INVERSE 1501 Transducer Unit FT SYSTEM TUNING Group 13 Ramps allow for tuning of the system response Ramps 1 and 2 provide control of start and stop ramps and can be used to produce smooth operation throughout pumping level Ramps 3 and 4 work within the regulation window to provide a final adjustment of system operation when needed reference pages 107 111 NOTE Level control application performance is dependant on sump size maximum flow rate and pump selection An oversized pump may produce on off type system operation similar to a level switch This condition might not be fully correctable with ramp control 85 PROGRAMMING MULTI PUMP LEVEL CONTROL Submersible Transducer Setup PARAMETER SETTINGS QUICK LIST 1002 Pass Code 66 1001 Parameter Lock OPEN 1102 Application Macro MULTIPUMP 1104 Motor Nom Volt 1105 Motor Nom Current 1106 Motor Nom Freq 1107 Motor Nom RPM 1108 Motor Nom Pow 2101 Regulation Mode INVERSE 1501 Transducer Unit F
116. el Temperature default 20 seconds 113 FEATURES Ramp 2 Fast Deceleration This ramp is the fast run down time used when the pump is shutting down If the setting R2 setting is too fast the pump may oscillate or hunt while it tries to attain the set point If it is too slow the actual process value may rise well above the set point NOTE AQUAVAR UNITS ABOVE 10 HP RAMP 1 AND RAMP 2 SHOULD BE SET FOR AT LEAST 8 10 SECONDS NOTE Air in the pump system may cause a condition that looks like oscillation or hunting Make sure all the air is purged from the system before trying to change the Ramp 2 setting Parameter Name Value Range Note s 13 02 RAMP 2 0 1800s Pressure default 5 sec FAST DECEL Level Temperature default 20 seconds Ramp 3 Slow Acceleration This ramp is the slow run up time used when the pump is operating within its setpoint window If the R3 setting is too slow pressure or flow may be slow to respond to the set point as demand varies A setting too fast may lead to oscillation Parameter Name Value Range Note s 13 03 RAMP 3 0 1800s Pressure default 60 seconds SLOW ACCEL Flow magnetic flow meter default 50 sec Level Temperature default 200 seconds Ramp 4 Slow Deceleration This ramp is the slow run down time used when the pump is operating within its set point window If the R4 setting is too slow it will lead to oscillation A setting too fast may delay the
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118. en activated DI4 is low for the protection delay setting 2404 Closed normal Open Secondary Protect fault function is active Pump Protect The pump protection waming or fault function has been activated Start Slave Used in multipump macro to start slave pump only Stand by Drive is in sleep mode due to no system demand mA Single Synch Pump ronous Control mA Synch ronous Defaults Multi mA Multi Control Constant Slave mA Constant Slave Slave Speed Control mA Speed Control 1802 RO1 ON Delay 0 3600 s Defines the operation delay for relay output RO1 1803 RO1 OFF Delay 0 3600 s Defines the release delay for relay output RO1 62 PARAMETER LISTINGS Group 18 Relay Outputs 1804 Relay RO2 Output Range Description Selects the AV status to be indicated through relay output 2 RO2 The relay energizes when the status meets the setting Relay warnings are reset automatically faults must be manually reset Not Sel The output is not used Run Default The output indicates the drive is running VFD Fault The drive has faulted Low Water The secondary protection warning or fault function has been activated DI4 is low for the protection delay setting 2404 Closed normal Open Secondary Protect fault function is active
119. ence Select if drive operation is REM ID RUN FAIL The motor ID run was not completed successfully Check for and correct e Motor connections wiring MOTOR STALL Motor or process stall Motor is operating in the stall region Check for and correct e Excessive load e Insufficient motor power e Blocked pump 13 14 RESERVED PUMP PROTECT Not used Pressure has fallen below value in Group 2403 15 16 LOW WATER EARTH FAULT DI12 has been activated Check for proper suction supply The load on the input power system is out of balance e Check for correct faults in the motor or motor cable e Verify that motor cable does not exceed maximum specified length UNDERLOAD Motor load is lower than expected Check for and correct e Disconnected load e Drive oversized THERM FAIL Internal fault The thermistor measuring the internal temperature of the drive is open or shorted Contact your local factory representative OPEX LINK Internal fault A communication related problem has been detected on the fiber optic link between the OITF and OINT boards Contact your local factory representative 20 OPEX PWR Internal fault Low voltage condition detected on OINT power supply Contact your local factory representative 21 CURR MEAS Internal fault Current measurement is out of range Contact your local factory representative e Replace drive 22 SUPPLY PHASE Ripple volt
120. erating modes that are available through the main menu e A fault mode that is triggered by faults The fault mode includes a diagnostic assistant mode REM C MAIN MENU PARAMETERS WIZARDS CHANGED PAR ENTER Access to Main Menu Modes To reach the main menu 1 Press EXIT as necessary to step back through the menus or lists associated with a particular mode Continue until you are back to the Output Mode 2 Press MENU from the Output Mode At this point the middle of the display is a listing of the other modes and the top right text says Main Menu 3 Press UP DOWN to scroll to the desired mode 4 Press ENTER to enter the mode that is highlighted The following sections describe each of the other modes Parameters Mode Use the Parameters Mode to view and edit parameter values 1 Select PARAMETERS in the main menu REM C MAIN MENU PARAMETERS WIZARDS CHANGED PAR EXIT ENTER _ f REM C PAR GROUPS 01 2 Press UP DOWN to highlight the appropriate parameter Gi SARI R DATA group then press SEL SSES DALA 10 START STOP DIR 11 REFERENCE SELECT EXIT SEL EM PARAMETERS 101 LANGUAGE 3 Press UP DOWN to highlight the appropriate parameter l in a group 102 APPLIC MACRO SINGLE PUMP NOTE The current parameter value appears below the 1104 MOTOR NOM VOLT hiehlieh 1105 MOTOR NOM CURR ighlighted parameter EXIT EDIT
121. ess 1 and Aquavar address 4 would have their DIP SWITCHES in the ON position see diagram If you have a DUPLEX system then Aquavar address 1 and Aquavar address 2 would have the switches in the ON position Always follow your local codes or National codes and have a certified electrician perform the necessary wiring NOTE Fieldbus cannot be used with RS485 multipump Modbus Devicenet Profibus Single pump only Terminated Terminated Station Station Station Station 00000 ooo0oo0o0 oo000 Looss A A X1 Identification Hardware Description e 28 Screen RS485 Multidrop Application RS485 Interf Multipump p App nterface Connections 29 B Other Modbus Devices J2 35 J2 J5 for each 30 A al A ON ON h mi lt AGND GE 32 Screen off position on position Bus Termination 1 For functional descriptions see Standard Serial Communication addendum 88 PROGRAMMING MultiPump Constant Pressure Control Pump Sizing It is recommend to use the same size pump for a multi pump configuration This is to ensure even distribution of flow rates especially when small flow demands are put on the system If the operator requires a flow range of 10 500 GPM for the system it would be recommended to select a TRIPLEX system with each pump capable of a maximum of 167 GPM at the required TDH 167 G
122. eter 2605 returns to disabled Disabled Reset Range Description Activates the optional external DCS and selects the interface Referto the ABB IOM chapter on fieldbus control Can be used only with Single Pump Constant Slave or Speed Control modes Single Pump abled Single Pump Synch ronous Control abled Synch ronous Defaults Multi abled Multi Control Constant Slave abled Constant Slave Speed Control abled Speed Control Not Selected Default No fieldbus communication Aquavar Std Modbus Drive uses Modbus protocol on the standard RS485 port Protocol settinos are in group 32 Ext Fba Aquavar Range The drive communicates with a fieldbus adapter module in option slot 2 of the drive Note when Ext Fba is selected Param eter Groups 31 is unlocked This protocol is used for communication between the drives in the Synchronous and Multicontrol macros Description This parameter configures the module type automatically by the fieldbus adapter No action is required by the user unless changes to default settings are desired Refer to the fieldbus manual Single Pump Synch ronous Multi Control Constant Slave Speed Control 3102 FBA Parameters 3133 Meaning and values of these parameters depend on the fieldbus option connected to
123. ets the mini mum value of the signal to be applied to sensor input When tune is selected and enter is pressed the tuned value for sensor input is set to the actual sensor input value when the tune function was activated This function is useful for zeroing out any system hysteresis 60 PARAMETER LISTINGS Defaults Group Reference mane Single Synch Multi Constant Speed R D 16 Select us Ee Pump ronous Control Slave Control SP1 SP2 Select Defines the source from which the drive reads the signal that selects the setpoint Reference 1 Reference 1 set point 1 is Default being used only Did Digital Input 4 selects set point 1 or set point 2 Open Set Point 1 Closed Set Point 2 Fieldbus The set point is sent via Fieldbus control word 1602 Set Point 1 Select Selects the signal source for Keypad Keypad Keypad Keypad Reference set point 1 Keypad The set point is selected from Default the keypad Analog Input The set point is selected by an Speed Control analog input Al Fieldbus The set point is selected via Fieldbus control word 1603 Set Point 2 Select Selects the signal source for Keypad Keypad Keypad Keypad Reference1 set point 2 Keypad The set point is selected from Default the keypad Al1 The set point is selected by an analog input A11 Fieldbus The set point is selected via Fieldbus control word 1604 A
124. f they meet fuse requirements 134 TECHNICAL DATA Cable Terminals Frames R1 R6 Mains and motor cable maximum sizes per phase accepted at the cable terminals and the tightening torques are listed below U1 V1 W1 Earthing PE Fama Ua V2 W2 Ground mm AWG Nm lb ft mm AWG Nm lb ft R1 6 8 141101 4 10 114 10 R2 10 6 1 4 9 10 8 14 10 R3 25 3 18 16 6 18 13 R4 50 0 20115 35 2 2 0 15 R5 70 27 0 15 114 70 20 15 114 d 185 Se 40 295 95 40 8 59 Control Wire Maximum Wire Size Torque mm AWG Nm Ib ft Cable Terminals Frames R7 R8 Mains and motor cable maximum sizes per phase accepted at the cable terminals and the tightening torques are listed below Frame Size R8 Number of holes per phase U1 V1 W1 U2 V2 W2 Cable Diameter Torque M12__ 50 75 35 55 M12 50 75 35 55 Tightening Earthing PE Torque Tightening son l NOTE Maximum AWG size for R7 Frame is 2 x 5010MCM Maximum AWG size for R8 Frame is 3 x 500MCM 135 TECHNICAL DATA Input Power Mains Connection Input Power Mains Connection Specifications Voltage U 400 41 5 440 460 480 VAC 3 phase 10 15 for CPC4XXXX Prospective Short Circuit Current IEC 629 208 220 230 240 VAC
125. fting lifting R p au Se space space a d 600 24 300 12 R8 b 600 24 300 12 lifting lifting c i aa ie space space Space for the installer not included Space for the fan and capacitor replacement not included Mounting orientations a and b Make holes in the wall recommended 1 Lift the unit against the wall into the mounting place 2 Mark the locations for the two fixing points in the wall 3 Mark the bottom edges of the unit to the floor 138 TECHNICAL DATA Air Flow 380 480 Volt Drives The following table lists heat loss and air flow data for 380 480 Volt drives GWT AQUAVAR CPC NEMA1 Full NORMAL Frame S Air Voltage Phase Base Load DUTY Size Flow Model Amps HORSEPOWER Watts BTU HR CFM CPC40061 CPC40081 8 8 5 R1 127 433 26 CPC40121 11 9 7 5 R1 172 587 26 CPC40151 15 4 10 R2 232 792 52 CPC40231 23 15 R2 337 1150 52 CPC40311 31 20 R3 457 1560 79 CPC40381 38 25 R3 562 1918 79 CPC40451 45 30 R3 667 2276 165 CPC40591 59 40 R4 907 3096 165 CPC40721 72 50 R4 1120 3820 165 CPC40771 77 60 R4 1295 4420 168 460 3 CPC40971 97 75 R4 1440 4915 168 CPC41251 125 100 R5 1940 6621 239 CPC41571 157 125 R6 2310 7884 239 CPC41801 180 150 R 2810 9590 239 CPC42451 245 200 R7 3850 13144 319 CPC43161 316 250 R7 6850 23386 319 CPC43681 368 300 R8 6850 23386 721 CPC44141 414 350 R8 7850 26800 721 CPC44861 486 400 R8 7850 26800 721 CPC45261 52
126. g for a new transducer NOTE Goulds Water Technology provides a 0 300 psi transducer as standard Select the appropriate range then press SAVE If no changes are necessary press CANCEL 14 Use the down arrow to highlight 1503 TRANSDUCER MIN 0 0 then press EDIT Default should be 0 psi Press CANCEL to advance to the next step If this group needs to be changed based on another type of transducer valve press SAVE to store 15 Use the down arrow to highlight 1506 SENSOR MIN then press EDIT Use the up arrow until the TUNE value is displayed press the SAVE key This provides the transducer a tune value of 0 ZERO psi NOTE Make sure that your transducer is wired to the Aquavar but free from any pressure in the system The transducer must be exposed to 0 psi when this step is performed Press the SAVE key to tune your transducer REM PARAMETERS 1401 MAXIMUM FREQ 1402 MINIMUM FREQ 1403 CONFIG SPEED MIN 1404 STP ER SPD REM PARAMETERS 1410 UNDERVOLT CTRL 1411 PRIMING DELAY 1501 TRANSDUCER UNIT 1502 ae ar MAX REM PAR GROUPS 15 e XDUCER VARIABLES 16 18 RELAY OUTPUTS 19 ANALOGI oa 21 REGULA EXIT REM PARAMETERS 1504 SENSOR 1505 K DP FLOW METER 1506 SENSOR MIN 4mA EXIT REM C PAR EDIT 1506 SENSOR MIN TUNED VALUE 83 PROGRAMMING Single Pump Submersible Pump Constant Pressure 16 Final step
127. g parameter 14 04 Stp Delay Min Spd For example if the MINIMUM FREQ is set for 35 HZ and the Stp Delay Min Spd is set for 5 seconds the pump will ramp down to 35HZ and remain at that speed for 5 seconds then turn off This is dependent upon the demand decreasing in the system Leaks will keep the pump running at slow speeds Also check for properly seated check valves and bladder tank pressure WARNING It is not possible to manually set speed or frequency below the MINIMUM SPEED setting in parameter 14 02 105 FEATURES Minimum Speed Options continued Parameter Name Value Range Note s 14 03 CONFIG SPD MINSPD Selecting SPD MINSPD will result in the drive SPEED MIN SPD 0 default staying at minimum speed until it is manually shut off process demand increases a secondary protection fault is cleared or a pump protection fault forces it to shutdown If SPD 0 is selected the drive will stop 14 04 STP DELAY 0 1800 sec This parameter enables the drive to remain at MIN SPD 0 default minimum speed for a period up to 1800 seconds before shutting down 14 05 RESTART 0 0 150 If the drive is shutdown by CONFIG SPEED MIN VALUE 0 default 14 03 due to no system demand pressure control and level control modes only the drive will sleep until the process actual value drops below a set restart value 14 05 for longer than the restart delay 14 06 If operating in inverse mode 21 01 the drive
128. gt Ku U cc RO3A Maximum 250 VAC 30 VDC 2 A RO3B Minimum 500 mW 12 V 10 mA NOTE Normally Closed NC RO1A RO2A RO3A Common Connection CC RO1C RO2ZC RO3C Normally Open NO RO1B RO2B RO3B SLAVE Pump Sizing Piping It is recommended that each slave pump be sized the same and with the same performance curve All necessary check valves ball valves or gate valves should be installed in the system to limit or choke each SLAVE pump discharge in order to maintain proper head conditions and to prevent pressure oscillations or system hunting Follow all recommended Hydraulic Institute standards for piping size and pipe layout 96 PROGRAMMING MultiPump Slave Pump Control Programming Steps Default settings for each relay are set for NOT USED Therefore the operator will have to access the programming and go to GROUP 18 RELAY OUTPUTS and set each relay to START SLAVE SEE BELOW FOR DETAILED PROGRAMMING STEPS Each relay is labeled RO1 RO2 RO3 and can be programmed to respond based on a drop in system pressure and delay time in seconds Therefore you can control the relay when the system pressure starts to drop and you allow a certain time delay in seconds to respond When the demand stops each LAG pump will stop after a time delay and operation will return solely to the Aquavar controlled pump REM C MAIN MENU PARAMETERS 1 Access the main menu on the
129. he wires Connect the power motor and ground wires to Strip and connect the individual control wires to Remove and discard the clamping plate conduit will be installed The cable seals are cone shaped rubber seals on the bottom of the drive IP5003 connectors not supplied IP5006 the drive terminals See Power Connections on page 29 IP5007 N Route the control wiring through the conduit Strip the control cable sheathing and twist the 10 11 copper screen into a pigtail 13 Connect the ground screen pigtail for digital and analog I O cables X1 1 the drive terminals See Control Connections on pages 29 and 30 Install the conduit gland box cover 1 screw Install and wire transducer as stated in previous steps on pages 27 and 28 IP5008 INSTALLATION Frames R1 R6 Power Connections WARNING Ensure the motor is compatible for use with the AQUAVAR The AQUAVAR must be installed by a competent person in accordance with the considerations defined in Preparing for Installation on page 15 If in doubt contact your local AQUAVAR sales or service office Always consult the NEC for information e Refer to the following table to complete the power connections If appropriate also perform the instructions for the braking and floating networks Terminal Description Note F Input Power Mains Connection a U1 V1 Wi 3 phase power su
130. hen input power is connected After disconnecting the supply wait at least 5 minutes to let the intermediate circuit capacitors discharge before removing the cover WARNING Even when power is removed from the input terminals of the AQUAVAR there may be dan gerous voltage from external sources on the terminals of the relay outputs R01 R03 WARNING When the control terminals of two or more drive units are connected in parallel the auxiliary voltage for these control connections must be taken from a single source which can either be one of the units or an external supply WARNING The AQUAVAR CPC wall mount version is nota field repairable unit Never attempt to repair a malfunctioning unit contact the factory or your local Authorized Service Center for replacement WARNING The AQUAVAR will start up automatically after an input voltage interruption if the external run command is on WARNING The heat sink may reach a high temperature in excess of 200 F Severe burns are possible WARNING If the drive will be used in a floating network remove screws at EM1 and EM3 Frame size R1 R4 or F1 and F2 Frame size R5 or R See diagrams on pages 24 and 25 respectively NOTE For more technical information contact the factory or your local AQUAVAR representative WARNING Always consult your local state municipal or NEC codes for proper wiring electrical installa tion of inverter drives and AC motors USE OF WARNINGS A
131. hrough a menu or list displayed in the middle of the LCD Display Decrements a value if a parameter e Increments a value if a parameter is selected is selected e Decrements the reference if the upper right corner is highlighted in reverse video Increments the reference if the upper right corner is highlighted in reverse video Help Displays context sensitive information when the button is pressed The information displayed describes the item currently highlighted in the middle area of the display LOC REM Changes between local and remote control of the AQUAVAR STOP Stops the drive START Starts the drive 45 START UP Output mode Use the output mode to read information on the drive s status and to operate the drive To reach the Output Mode press EXIT until the LCD display shows status information as de scribed below Status Information Top The top line of the LCD display shows the basic status information of the drive e LOC indicates that the drive control is local that is from the control panel REM indicates that the drive control is remote which is required to operate the pump and automatically control pressure This mode is also used for fieldbus control e g Trans ducer or PLC control e D indicates the drive status as follows Control Panel Display Significance Rotating arrow blinking Drive is running Stationary
132. iagnostics e Installation e Maintenance e Start Up e Technical Data OPTION MANUALS Fieldbus Adapters I O Extension Modules etc manuals delivered with optional equipment Relay Output Extension Module typical title e Installation e Diagnostics e Start Up e Technical Data 34 INSTALLATION Frames R7 R8 Introduction AQUAVAR CPC drives include an extension module that is not covered in the AQUAVAR User s Manual The exten sion module is attached to the drive module at the factory which includes fusible disconnect This supplement provides the additional extension mod ule information required for AQUAVAR drives e Additional installation steps and considerations e Steps for separating the drive from the extension mod ule for drive service access Extension A Module e Dimensions for the extension module WARNING Only qualified electricians are allowed to carry out the work described in this chapter Follow requirements in Safety on the first pages of this manual Ignoring the safety instructions can cause injury or death Planning When planning for cable conduit routing refer to the AQUAVAR User s Manual but note that for the AQUAVAR all connections are routed through the top of the extension module Moving the Unit 1 Move the transport package by pallet truck to the installation site 2 Unpack the transport package 3 To position the unit use a lif
133. ight 1503 TRANSDUCER MIN REM e PAR GROUPS 15 0 0 then press EDIT Default should be 0 psi Press CANCEL to advance to the next step If this group needs to be changed based on another type of transducer value press 19 ANALOG OUTPUTS SAVE to store 21 REGULATE REFERENCE SEL 18 RELAY OUTPUTS 14 Use the down arrow to highlight 1506 SENSOR MIN REM PARAMETERS then press EDIT Use the up arrow until the TUNE value is i504 SENSOR displayed press the SAVE key This provides the transducer 1505 K DDP FLOW METER a tune value of 0 ZERO psi NOTE Make sure that your 1506 SENSOR MIN transducer is wired to the Aquavar but free from any 4mA pressure in the system The transducer must be exposed to 0 psi only when this step is performed Press the SAVE key to tune your transducer REM PAR EDIT _ IREM C PAR EDIT 1506 SENSOR MIN TUNED VALUE 1506 SENSOR MIN Status 15 Final step is to enter your required pressure in LED the system After above programming has been completed press the EXIT key three 3 times until you arrive back to the first control display screen Then press the UP or DOWN arrow to select the required system pressure Once pressure has sor been selected press the green START key on the KEY 1 keypad UP SOFT KEY 2 DOWN HELP START START LOC REM STOP 76
134. ight group parameter 1108 Use down arrow until group parameter 1104 MOTOR NOM VOLTAGE is highlighted then press EDIT Use the arrows to enter your motors nameplate voltage then press the SAVE 1104 MOTOR NOM VOLT key REM PARAMETERS 230V 1105 MOTOR NOM CURR EXIT EDIT EM PARAMETERS JO LANGUAGE 1 1 NOM CURRENT is highlighted then press EDIT Using the arrows enter your motor s maximum allowed amp draw at full speed or Service Factor Amps NOTE Enter motor service factor from nameplate or motor manual Once you have entered the amps press the SAVE key 02 APPLIC MACRO 04 MOTOR NOM VOLT 05 MOTOR Ce CURR MOTOR NOM RPM then press the EDIT key Use arrows to enter the RPM from the motor nameplate default is 3550 RPM Press the SAVE key to store setting REM C PARAMETERS 1105 MOTOR NOM CURR 1106 MOTOR NOM FREQ 1107 MOTOR NOM RPM 1108 EA Gr POW MOTOR NOM POW then press the EDIT key Use arrows to enter the motors Horsepower rating from nameplate then press the SAVE key EXIT EDIT Once you have saved parameter 1108 use the down REM C PARAMETERS arrow until you highlight group parameter 1201 START 1111 MOTOR ID RUN STOP then press EDIT Default is KEYPAD This parameter determines how the operator will control the Aquavar via 1202 AUTO RESTART the keypad or via MODBUS communication If no changes 1203 TEST RUN are
135. indicated by a flashing red LED e Turn the power off for 5 minutes Red LED To reset the drive for faults indicated by a red LED on not flashing correct the problem and do one of the following e From the control panel Press RESET e Turn the power off for 5 minutes NOTE In some cases a fault reset soft key will appear on the display Press this button to reset then press the start key e When the fault has been removed the motor can be started Fault History For reference the last three fault codes are stored in Group 01 VFD Signals Specifically pa rameters 0116 0118 The Aquavar CPC stores additional fault data which helps the operator identify operating conditions at the time of fault Parameters 0119 0126 To clear the fault history go to PAR GROUPS 01 VFD SIGNALS Press the SEL key Down arrow to 0116 LAST FAULT then press the EDIT key Next press the UP and DOWN arrow at the same time until NO RECORD shows on the display This clears all the faults in the history 119 FAULTS ALARMS Correcting Alarms The recommended corrective action for alarms is e Determine if the Alarm requires any corrective action action is not always required e Use Alarm Listing below to find and address the root cause of the problem e Press the reset key when available or turn the power off for at least 5 minutes Alarm Listing The following table lists the alarms by code number and describes each
136. ings 208 240 Volt Drives Branch circuit protection must be provided by the end user electrical contractor or distribu tor sized per local state or local National Electrical Codes Recommendations for fused circuit protection are in the following tables GWT AQUAVAR CPC NEMA 1 Full NORMAL Frame Input Voltage Phase Base Load DUTY Current Model Amps HORSEPOWER DE amps Fuse Type JJN CPC20171 8 5 R1 17 3 20 CPC20241 12 3 R2 24 5 30 CPC20311 15 5 5 R2 31 6 40 CPC20461 23 7 5 R3 46 9 60 CPC20591 29 5 10 R3 60 2 70 230 1 CPC20881 44 0 15 R4 89 8 110 CPC21141 57 0 20 R4 116 3 150 CPC21431 71 5 25 R 145 9 175 CPC21781 89 0 30 R 181 6 225 CPC22211 110 5 40 R 225 4 300 CPC22481 124 0 50 R 252 9 300 CPC20121 11 8 3 R1 12 0 15 CPC20171 16 7 5 R1 17 0 25 CPC20241 24 2 7 5 R2 24 7 30 CPC20311 30 8 10 R2 31 4 40 CPC20461 46 2 15 R3 47 1 60 CPC20591 59 4 20 R3 60 6 70 230 3 CPC20751 74 8 25 R4 76 3 90 CPC20881 88 0 30 R4 89 8 110 CPC21141 114 0 40 R4 116 3 150 CPC21431 143 0 50 R6 145 9 175 CPC21781 178 0 60 R6 181 6 225 CPC22211 221 0 75 R6 225 4 300 CPC22481 248 0 100 R6 252 9 300 3 UL Class T fuses are recommended for short circuit protection Very fast acting Bussmann T tron type JJN and JJS are shown in the Aquavar CPC tables Other manufaturers are acceptable if they meet fuse requirements Bussmann is a registe
137. ion Single Synch Pump ronous Disabled Multi Control Disabled Disabled Constant Speed Slave Control Spd Lim Strt Lvl 1401 Maximum Range Minimum Frequency Speed Frequency 60 Hz Description Defines the allowable maxi mum speed Default setting is parameter 1106 Motor Nom Freq May want to show RPM or HZ Single Pump 60 Synch ronous 60 Ramp 1 FastAccel 0 1800 sec Defines the fast acceleration time 5 5 5 1302 Ramp 2FastDecel 0 1800 sec Defines the fast deceleration time 5 5 5 5 5 1303 Ramp 3 Slow Accel 0 1800 sec Defines the slow acceleration time 60 60 60 60 60 1304 Ramp4SlowDecel 0 1800 sec Defines the slow deceleration time 60 60 60 60 60 1305 Ramp Hysteresis 0 100 Per cent of window set aside 80 80 80 80 80 for hysteresis error 1306 Reg Window 0 100 Window around the set point which the control algorithm 8 8 8 8 8 operates Multi Control 60 Constant Slave 60 Speed Control 60 57 PARAMETER LISTINGS Group Spd Lim 14 Strt Lvl Range Description Single Synch Pump ronous Control Slave Control Defaults Multi Constant Speed 1402 Minimum 0 Max Frequency Speed Frequency Defines the minimum speed range Default setting is 10 of parameter 1106 Motor Nom Freq May want to show RPM
138. ion Analog Inputs and Outputs Digital Inputs Control Connection Specifications See table heading Hardware Description on page 29 Digital input impedance 1 5 kQ Maximum voltage for digital inputs is 30 V Relays Digital Outputs e Maximum contact voltage 30 V DC 250 V AC e Maximum contact current power A 30 V DC 1500 VA 250 V AC e Maximum continuous current 2 Arms cos g 1 1 Arms cos 0 4 e Minimum load 500 mW 12 V 10 mA e Contact material Silver nickel AgN e Isolation between relay digital outputs test voltage 2 5 kV rms 1 minute Cable Specifications See Control Cables on page 17 Efficiency Frames R1 R8 Approximately 98 at nominal power level Cooling Frames R1 R6 Cooling Specifications Method Internal fan flow direction from bottom to top Requirement Free space around the unit e 200 mm 8 in above and below the unit e 25 mm 1 in along each side of the unit 137 TECHNICAL DATA Cooling Frames R7 R8 Installation Procedure Choose the mounting orientation a b c or d a b Symbols Baza air inlet surface c Lifted from above x wallfixing point recommended ma control panel mounting slot Required Free Space Around the Unit for Frame Mounting Size Orientation Front Mounting Maintenance Service and Cooling Side Above li
139. is to enter your required pressure in Status 17 84 the system After above programming has been ki completed press the EXIT key three 3 times until you arrive back to the first control display screen Then press the UP or DOWN arrow to select the required system pressure Once pressure has been UP selected press the green START key on the keypad sorr KEY 1 SOFT KEY 2 DOWN HELP START START LOC REM STOP Optional Step To lock out access to the control panel keypad refer to page 109 This will prevent unauthorized users from changing programming NOTE If an error or fault occurs refer to the troubleshooting faults section of this manual page 116 When troubleshooting an Aquavar system always break down into the following components 1 Aquavar programming check default settings recommended for single pump multi pump slave pump etc 2 Electrical supply motor wiring grounding check your supply voltage motor wiring transducer wiring and grounding 3 Mechanical Pump Rotation check your pump rotation rubbing or other mechanical problems Pump run out 4 Hydraulic System Piping check to ensure proper suction and discharge piping layout proper NPSHa air entrainment vortex friction loss system curve compensation etc 5 Environment protect from high temperatures direct sun fr
140. keypad Press the MENU key once and the display will show PARAMETERS WIZARDS CHANGED PAR Using the arrow keys highlight the parameters option then press the ENTER key Der DAD EXIT ENTER 1 N Once the parameters option has been chosen the parameter groups will be displayed Each group will be numbered see parameter groups list on page 50 for detailed information Use the arrow keys to highlight the parameter group 10 LOCKS PASSWORDS then press the F 10 LOCKS PASSWORDS SEL key SEL REM PAR GROUPS 10 WP Use the arrow keys to highlight group 1002 PASSCODE REM C PARAMETERS then press the EDIT key Enter your factory password number Default is 66 Press the save key 1002 PASS erie 1003 LOCAL LOCK 1004 PARAM SAVE 4 Use up arrow to group 1001 PARAMETER LOCK then REM PARAMETERS press the EDIT key Next use the up arrow to select 1001 PARAMETER LOCK OPEN then press the SAVE key This group should 1002 PASS appear as OPEN if it does not you have entered the pass 1003 LOCAL LOCK code incorrectly or it has changed Contact your local 1004 PARAM SAVE E DIT Goulds Water Technology representative for the master code Once your group 1001 is showing OPEN you can access the entire pump and drive parameters in the Aquavar 97 PROGRAMMING MultiPump Slave Pump Control 5 After the SAVE key is
141. l protection devices are needed WARNING If the drive is connected to multiple motors a separate thermal overload switch or a circuit breaker must be used for protecting each cable and motor These devices may require a separate fuse to cut off the short circuit current The drive protects the motor cable and the motor in a short circuit situation when the motor cable is dimensioned according to the nominal current of the drive Mains Cable AC line cable Short circuit Protection Always protect the input cable with fuses Standard gG US T or L very fast acting fuses will protect the input cable in short circuit situations and prevent damage to adjoining equipment in case of a short circuit inside the drive Size the fuses according to local safety regulations appropriate input voltage and the rated current of the drive For fuse ratings see Technical Data pages 133 and 134 WARNING Circuit breakers are not capable of providing sufficient protection because they are inherently slower than fuses Always use fuses with circuit breakers if you are not sure of the circuit braking capacity and mains short circuit power Ground Fault Protection The drive is equipped with an internal ground fault protective function to protect the unit against ground faults in the motor and the motor cable This is not a personal safety or a fire protection feature The ground fault protective function can be disabled with a parameter contac
142. mmetrical shielded motor cable must be used figure below A four conductor system used up to 30 kW motors cannot be used Compared to a four conductor system the use of symmetrical shielded cable reduces electromagnetic emission of the whole drive system as well as motor bearing currents and wear of bearings The motor cable and its PE pigtail twisted screen should be kept as short as possible in order to reduce electromagnetic emission as well as capacitive current Insulation Jacket Copper Wire Screen Helix of Copper Tape Inner Insulation Motor Cable Shield To effectively suppress radiated and conducted radio frequency emissions the shield conductivity must be at least 1 10 of the phase conductivity The requirements are easily met with a copper or aluminum shield The minimum requirement of the motor cable shield of the drive is shown below It consists of a concentric layer of copper wires with an open helix of copper tape The better and tighter the shield the lower the emission level and the bearing currents Cable Core Additional US Requirements Type MC continuous corrugated aluminum armor cable with symmetrical grounds or shielded power cable must be used for the motor cables if metallic conduit is not used For the North American market 600 VAC cable is accepted for up to 500 VAC For drives rated over 100 amperes the power cables must be rated for 70 C 158 F 20 INSTALLATION Frames R1 R6 Conduit Wher
143. n Fan The life span of the cooling fan of the drive is about 50 000 R7 and 60 000 R8 hours The actual life span depends on the running time of the fan ambient temperature and dust con centration See the appropriate Aquavar CPC User Manual for the actual signal which indi cates the running time of the cooling fan Replacement fans are available from Goulds Water Technology Do not use other than factory specified spare parts Replacing the Fan R7 1 Remove the upper front cover and disconnect the control panel cables 2 Disconnect the discharging resistor wire MAINTENANCE Frame Sizes R7 R8 SO CO NOW WO PS Gu Remove the DC capacitor pack by undoing the black fixing screws Disconnect the fan supply wires detachable terminal Disconnect the fan capacitor wires Undo the black fixing screws of the fan cassette Press the snap on holders to release the side cover Lift from the handle and pull the fan cassette out Install the fan in reverse order to the above and replace the fan capacitor Replacing the Fan R8 NO OB WN gt Remove the upper front cover Remove the OMIO board Disconnect the fan capacitor and power supply wires Replace the starting capacitor Undo the black fastening screws of the plastic side cover of the fan and lift the cover off Undo the black fastening screws of the fan Lift the fan out of the cabinet Install the fan in reverse order to the
144. n Ft M In or Cm Al2 Max is always based on a specific gravity 1 regardless of setting for parameter 1506 Actual pressure signals in Ft M In or Cm are corrected for specific gravity by the firmware Signal can be quadratic or linear 300 300 300 300 60 59 PARAMETER LISTINGS Defaults Single Synch Multi Constant Speed Pump ronous Control Slave Control Group Transducer 15 Var 1503 TransducerMin 0 6553 5 For single pump and multipump 0 0 0 0 0 macros this parameter defines the value normally zero of the 4 mA setting for the primary process transmitter at Al2 This parameter also correlates to the minimum value of Reference set points 1 and 2 For the Speed Control macro this parameter scales the value normally zero of the 4 mA or keypad speed setting Note when units are in Ft M In or Cm Al2 Min is always based on a specific gravity 1 regardless of setting for parameter 1506 Actual pressure signals in Ft M In or Cm are corrected for specific gravity by the firmware Signal can be quadratic or linear 1506 Sensor Min Defines the value for analog 4mA 4mA 4mA 4mA 4mA Not in Software sensor input 4 mA Default 4 mA is selected as the minimum value Range Description Tuned Value Select tuned value after the tune function has been completed This will select the tuned value for the minimum value of sensor input Tune This parameter s
145. n the drive labels Then look up that type code in the Technical Data on page 142 to determine the frame size A complete set of di mensional drawings for AQUAVAR drives is located in the Technical Data section Units with UL Type 1 Enclosures Outside Dimensions X0031 UL Type 1 Dimensions for each Frame Size Ref R1 R2 R3 R4 R5 R6 mm in mm in mm in mm in mm in mm In W 125 49 125 49 203 8 0 203 8 0 265 10 4 300 11 8 H 330 13 0 430 16 9 490 19 3 596 23 4 602 23 7 700 27 6 H2 315 12 4 415 16 3 478 18 8 583 23 0 578 22 8 698 27 5 H3 369 14 5 469 18 5 583 23 0 689 27 1 739 29 1 880 34 6 D 212 8 3 222 87 231 9 1 262 10 3 286 11 3 400 15 8 NOTE Enclosures are standard NEMA 1 indoor use only 141 TECHNICAL DATA Frames R1 R6 Mounting Dimensions See Detail A H1 E C See Detail B b d Detail A Detail B X0032 UL Type 1 Dimensions for each Frame Size R1 R2 R3 R4 R5 R Ss mm in mm in mm in mm in mm in mm in W1 98 0 3 9 98 0 3 9 160 6 3 160 63 238 9 4 263 10 4 W2 98 0 3 9 98 0 3 9 H1 318 12 5 418 16 4 473 18 6 578 22 8 588 23 2 675 26 6 a 5 5 0 2 5 5 RE 65 10 25 65 0 25 65 0 25 9 0 0 35 b 10
146. ng holes Refer to page 138 for mounting hole location 2 Drill the holes NOTE Frame sizes R3 and R4 have four holes along the top Use only two If possible use the two outside holes to allow room to remove the fan for maintenance Remove Front Cover IP 21 UL Type 1 1 Remove the control panel if attached 2 Loosen the captive screw at the top 3 Pull near the top to remove the cover INSTALLATION Frames R1 R6 IP 54 UL Type 12 1 If hood is present Remove screws 2 holding hood in i SSS place 2 2 If hood is present Slide hood up and off of the cover 3 Loosen the captive screws around the edge of the cover 4 Remove the cover Mount the Drive IP 21 UL Type 1 1 Position the AOUAVAR onto the mounting screws or bolts and securely tighten in all four corners NOTE Lift the AOUAVAR by its metal chassis 2 Non English speaking locations Add a warning sticker in the appropriate language over the existing warning on the top of the module IP 54 UL Type 12 2 For the IP54 UL Type 12 enclosures rubber plugs are required in the holes provided for access to the drive mounting slots e As required for access remove the rubber plugs Push plugs out from the back of the drive 1 3 Position the AQUAVAR onto the mounting screws or bolts and securely tighten in all four corners NOTE Lift the AQUAVAR by its metal chassis N
147. nstall conduit gland box 4 Connect conduit runs to box Always follow appropriate NEC or local electrical codes for inverter drives motor wiring 5 Route input power and motor wiring through conduits Preferably metal grounded type 6 Strip wires 7 Connect power motor and ground wires to the drive terminals See Power Connections on page 29 8 Route the control cable transducer cable through the conduit 9 Strip the control cable sheathing and twist the copper screen into a pigtail 10 Connect the transducer screen pigtail for digital and analog I O cables at X1 1 IP2004 11 Strip and connect the individual control wires to the drive terminals See Control Connections on page 29 Including transducer 12 Install the conduit gland box cover 1 screw 13 Wire transducer leads to analog 2 terminal s 24V Al2 and GND 14 Wire positive lead of transducer to terminal 10 24VDC Color is red or brown 15 Wire analog lead negative to terminal 10 of X1 for 4 20mA signal Color is white or black 16 Take the transducer cable screen to X1 1 Terminal IP2005 27 INSTALLATION Frames R1 R6 Wiring IP 54 UL Type 12 Enclosure with Conduit 1 10 11 12 13 28 Remove and discard the cable seals where For each conduit run install water tight conduit Route the power wiring through the conduit Route the motor wiring through the conduit Strip t
148. oeren 24 Single Phase Wiring Connection Diagram ua anan ENEE i oe iieiaeie 26 Wiring IP 21 UL Type 1 Enclosure with Conduite 27 Wiring IP 54 ULType 12 Enclosure with Conduit 29 uu eege Eed ENEE Eed e 28 Power COMMECTONS su un tee Ee Eed 29 Control Wirimg a unata ana EES 30 COMMUNICATION EE 31 Installation Cheek breet a ua eelere eech ER KREE 33 Section 4 INSTALLATION Frames R7 R8 Aquavar Drive Manials Deseptpttens uu u Eeer Ee Atlan Siete Ae are 34 Introduction Planning Moving the Unit and Mounting n nasa 35 Connecting Power and Control Cables eesessseseessseseseeeseseeeseseseescseseseeeeseaeaesesanscaesesesacecaesceesaceeseeeesaceeeeesaneees 36 RZ Frame EEN 37 R8 Frame lee ee ee e 38 MalNtema ine cueita si oseve lunvanobinedvunsedseanveatsves lovass Ee E Eden 39 Technical Data Extension Mod pleRt 2 se ceayand u eeh 41 DS tail u Saam asahan eegene enee e eene 42 Technical Data Extension Module R8 u ana hanasqakaqaaquapasashakaqa abvaneuentondenneatasndenaesl lt d 43 KUHN A4 Section 5 START UP Wizards and Assistant Control Panel Displav a aaaaaassssasssssassssasnssaasasassssasasaasaa ass asaasasssssssass 45 Controls EE 45 Stam Up Wizard derer erdeelt Ee Ans e dee 48 Section 6 PARAMETER LISTINGS Aquavar GPC Parameter Listu u auqa daiezees teudeleics EEEE E ans usdusdeeaetensatentty seen tonesagvarneoss 50 Section 7 PROGRAMMING Single Pump Programming Pressure TransCucer eccscssessseseseeseeeseses
149. of energy in USD Synch ronous Multi Control 2502 Trial Time 1 0 600 0s Sets the time limit used for 30s 30s 30s 30s 30s counting and limiting the number of resets 2503 Delay Time 0 0 120 0s Sets the delay between fault Os Os Os Os Os detection and attempted drive restart 2504 AR Overcurrent Auto reset after overcurrent Enabled Enabled Enabled Enabled Enabled Disable fault 2505 AR Overvoltage Auto reset of overvoltage Enabled Enabled Enabled Enabled Enabled Disable fault 2506 AR Undervoltage Auto reset for undervoltage Enabled Enabled Enabled Enabled Enabled Disable of drive 2507 ARAI lt Min Auto reset after transducer Enabled Enabled Enabled Enabled Enabled Constant Slave Speed Control 2602 Baseline Power 0 1000hp Baseline HP for a conventional fixed speed system 2603 Savings Scale 0 65535 This parameter scales the 10000 10000 10000 10000 10000 analog output when energy savings is selected 2604 Energy Save Savings Savings Savings Savings Savings Methd Savings Op 1 Op1 Op1 Op 1 Op 1 Op 1 Savings Op 2 69 PARAMETER LISTINGS Group Energy 26 Savings 2605 Energy Save Reset Group 30 Option Modules Comm Protocol Select Fieldbus Setup Group 31 Range Description Resets energy savings counter After resetting param
150. ot require adjustment The most common exceptions are with process instruments with slow response times e g insertion type flowmeter or in temperature level control applications where variables such as tank size is unknown HVAC Systems with flow meters may require adjustment as well When the Aquavar system is adjusting speed to meet the set point demand it does so using a fast rate and a slow rate As shown in the figure below the 2 point control algorithm uses four ramp rates fast acceleration fast deceleration slow acceleration and slow deceleration Aquavar characterizes these rates in terms of seconds to meet the set point hysteresis window maximum value described later NOTE In speed control mode there is only fast acceleration and fast deceleration R1 R2 An insertion type flowmeter uses a magnetic flux Coriolis effect to measure fluid flow This should not be confused with magnet flow meters or differential pressure flow meters 111 FEATURES Set Point 1utod 18S MOPUIN l lt sisasays gt R1 Ramp 1 Fast Acceleration R2 Ramp 2 Fast Deceleration R3 Ramp 3 Slow Acceleration Ramp 4 Slow Deceleration Set Point Scale e g Pressure PSIG Flow GPM etc Time Window Setting Reg Window Aquavar controls the set point within a defined window This window called the Regulation Window Parameter 13 06 REG WINDOW is automatically set based upon the operating
151. oulds Water Technology Maintenance Interval Instruction Heatsink Temperature Depends on the dustiness of the See Heatsink on page 122 Check and Cleaning environment every 6 12 months Main Cooling Every five years See Main Fan Replacement Fan Replacement on pages 122 123 126 and 127 Internal Enclosure Every three years See Internal Enclosure Fan Cooling Fan Replacement Replacement on page 123 IP 54 UL Type 12 units Capacitor Change Every ten years See Capacitors on page 124 Frame size R5 and R Replace Battery in Advanced Every ten years See Battery on page 124 Control Panel Heatsink The heatsink fins accumulate dust from the cooling air Since a dusty heatsink is less efficient at cooling the drive overtemperature faults become more likely In a normal environment not dusty clean check the heatsink annually in a dusty environment check more often Clean the heatsink as follows when necessary 1 Remove power from drive 2 Remove the cooling fan see section Main Fan Replacement below 3 Blow clean compressed air not humid from bottom to top and simultaneously use a vacuum cleaner at the air outlet to trap the dust Note If there is a risk of the dust entering adjoining equipment perform the cleaning in another room 4 Replace the cooling fan 5 Restore power Main Fan Replacement The drive s main cooling fan has a life span of about
152. ove cooling e Larger dimensions e The same rating does not require a derating e Plastic gasketed cover for keypad 144 TECHNICAL DATA Ambient Conditions The following table lists the AQUAVAR environmental requirements Ambient Environment Requirements Installation Site e 0 1000 m 0 3 300 ft e 1000 2000 m 3 300 6 600 ft Storage and Transportation in the protective package Altitude if Py and l derated 1 every 100 m above 1000 m 300 ft above 3 300 ft Ambient e 15 40 C 5 104 F 40 70 C 40 158 F Temperature2 e Max 50 C 122 F if Py and l derated to 90 Relative humidity lt 95 non condensing e No conductive dust allowed e The ACS550 should be installed in clean air according to Storage e No conductive dust allowed e Chemical gases Class 1C2 Contamination enclosure classification e Solid particles Class 1S2 levels e Cooling air must be clean free Transportation IEC 721 3 3 from corrosive materials and free e No conductive dust allowed from electrically conductive dust e Chemical gases Class 2C2 e Chemical gases Class 3C2 e Solid particles Class 2S2 e Solid particles Class 3S2 e Mechanical conditions Class 3M4 In accordance with ISTA 1A and 1B Sinusoidal IEC 60721 3 3 specifications Vibration e 2 9 Hz 3 0 mm 0 12 in e 9 200 Hz 10 m s 33 ft s Shock Not allowed Maximum 100 m s 330 ft s2 IEC 68 2 29 11ms
153. ove the sync 8 8 limit 2206 used to turn off lag pump 2 or slave 2 RO2 Twice the Sync Window is the speed step at which lag pump 3 or slave 3 ROS is turned off Used for synchronous and slave modes only 2207 1 Bump Address 1 4 Defines the pump address for 1 1 1 multipump systems 2208 Setp2 Source OFF 1 4 Defines which pump has the Off Off Off analog input connected for second set point Off Off Group Fault 24 Functions Single Synch Multi Constant Speed fange Ze Pump ronous Control Slave Control Selects how the AV will react to a keypad communication break Keypad Failure Disabled Protection is inactive Fault The drive trips on fault and the motor coasts to a stop A fault message is generated Panel Loss 2402 Pump Protect Fault Actual process value is lower Dis Dis Dis Dis Dis Ctrl than protection limit 2403 for abled abled abled abled abled protection delay 2404 and AV is at max speed for the protection delay Disabled Protection is disabled Default Warning The AV generates a warning only Pump Protect no other action is taken Warn and The AV generates a warning Control Pump Protect and controls according to the setting of Contig Speed Min 1405 67 PARAMETER LISTINGS Group Fault 24 Functions 2403 Protection Limit Range 0 6553
154. p 2 Pump 3 or Pump 4 When Pump 1 cannot maintain the required system pressure and the speed reaches 60 Hz then that will trigger the lag pump to come on and help maintain the set pressure In order for the lag pump to turn on the lead pump must be at full speed Maximum Frequency and programmed system pressure drop must be met VALUE DECREASE Each Aquavar controlled pump will vary its speed according to the demand on the entire system In a Duplex System you could have Pump 1 running at full speed 60 Hz and Pump 2 running at 50 Hz in order to maintain the system pressure at the flow demand Each pump will operate in a sequential mode when called 87 PROGRAMMING MultiPump Constant Pressure Control Wiring Connection RS485 Each Aquavar unit must be connected via terminals 29 30 and 31 Using a three wire shielded cable between each Aquavar terminal Suggested wire specifications would be 3 or 4 wire 22AWG one pair shielded TYPE CM or CL3 75 degree C UL Remember to keep the color coded wires the same to each terminal connection and inspect for loose or bad connections m wo co Go When using all the same Aquavar CPC units you must provide a BUS TERMINATION for the last drives in the multi pump system The RS485 has two yellow DIP SWITCHES that must be in the OFF position when that Aquavar CPC unit is the last or first in the system Therefore if you have 4 pumps in multi pump configuration Aquavar addr
155. pply input DEE PE Protective Ground Follow local rules for cable size U2 V2 W2 Power output to motor Moree Sennen On page 136 NOTE The AQUAVAR 208 240V series can be used with a single phase supply if output current is derated by 50 For single phase supply voltage connect power at U1 and W1 Refer to page 26 Floating Networks For floating networks also known as IT ungrounded or high impedance networks e Disconnect the internal RFI filter by removing both the EM1 and EM3 screws frame sizes R1 R4 see page 24 or F1 and F2 screws frame sizes R5 R6 see page 25 e Where EMC requirements exist check for excessive emission propagated to neighboring low voltage networks In some cases the natural suppression in transformers and cables is sufficient If in doubt use a supply transformer with static screening between the primary and secondary windings e Do NOT install an external filter Using an RFI filter grounds the input power through the filter capacitors which could be dangerous and could damage the unit Control Connections To complete the control connections use e Following tables e Single Multipump e Complete Parameter Descriptions e Cable recommendations in Control Cables 29 INSTALLATION All Frames 30
156. pump 18 REM PAR GROUPS 18 e SPD LIM STRT LEVL 15 Geer VARIABLES R CE SELECT REM PARAMETERS 1801 RELAY OUTPUT 1 NOT SEL 1802 RO1 ON DELAY 1803 RO1 OFF DELAY 1804 RELAY OUTPUT 2 REM C PARAMETERS 1801 RELAY OUTPUT 1 1802 RO1 ON DELAY 10 0s 1803 R01 OFF DELAY 1804 RELAY OUTPUT 2 EXIT EDIT REM PARAMETERS 1801 RELAY OUTPUT 1 1802 R01 ON DELAY 1803 R01 OFF DELAY 50s 1804 RELAY OUTPUT 2 If you do not require other SLAVE relays then proceed to the next step MULTIPUMP CONTROL If more relays are required repeat steps above for RELAY 2 and RELAY 3 parameters 1804 1805 1806 1807 1808 19 Once you have saved your last relay output press the EXIT key once Use the down arrow until you highlight parameter group 22 MULTIPUMP CTRL then press SEL key 20 After above step highlight parameter 2201 VALUE DECREASE then press EDIT Use arrows to program the required pressure drop allowed by the Aquavar pump before the first slave pump turns on Press the SAVE key NOTE Keep this pressure low enough from the Aquavar pressure setting and adjust your relay ON TIME DELAY to PREVENT PUMP CYCLING REM PAR GROUPS 22 16 REFERENCE SELECT 18 RELAY OUTPUTS 19 ANALOG OUTPUTS 2201 VALUE DECREASE 2202 VALUE INCREASE 2203 ENABLE SEQUENCE 2204 SWITCH LEAD LAG 100 PROGRAMMING MultiPump Slave Pump Con
157. puts Example 001 RO1 is energized RO2 amp RO3 are de energized 0114 AO1 mA Value of analog output 1 mA 0115 AO2 mA 0 20 mA Value of analog output 2 mA 0116 Last Fault Fault Codes Last fault code of the drive 0117 Previous Fault 1 Fault Codes Previous fault code of the drive 0118 Previous Fault2 Fault Codes Oldest fault code of the drive 0119 FaultTime 1 0120 Fault Time 2 0121 Speed at Flt RPM Speed at the time of the latest fault 0122 Freq at Fit Hz Frequency at the time of the latest fault 0123 Voltage at Fit V DC bus voltage at the time of the latest fault NOTE Group 01 is read only Used for monitoring 52 PARAMETER LISTINGS Group 01 VED Signals Current at Flt Range Description Motor current at the time of the latest fault Single Synch Pump ronous Defaults Multi Control Constant Speed Slave Control 0125 Status at Flt The drive status word atthe time of the latest fault 0126 DI 6 1 At Fault 000 111 The drive digital input status at the time of the latest fault 0127 Drive On Time Hi Days Drive on time in days Drive On Time Lo Pump Signals Set Point Hrs Min Sec Range 0 max scale Drive on time in hrs min secs Description Controller set point unit determined by parameter 1501 Single Pump
158. quavar controlled pump press the EXIT key two 2 or three 3 times until you arrive back to the first control display screen SEE DIAGRAM Then press the UP or DOWN UP arrow to select the required system pressure for SOFT your Aquavar controlled pump Once pressure has KEY 2 been selected press the green START key on the DOWN keypad LOC REM STOP panel keypad refer to page 104 This will prevent unauthorized users from changing programming NOTE If an error or fault occurs refer to the troubleshooting faults section of this manual When troubleshooting an Aquavar system always break down into the following components 1 Aquavar programming check default settings recommended for single pump multi pump slave pump etc N Electrical supply motor wiring grounding check your supply voltage motor wiring transducer wiring and grounding O Mechanical Pump Rotation check your pump rotation rubbing or other mechanical problems Pump run out 4 Hydraulic System Piping check to ensure proper suction and discharge piping layout proper NPSHa air entrainment vortex friction loss system curve compensation etc Wu Environment protect from high temperatures direct sun freezing temperatures high altitude dust vibration lack of air flow 93 MultiPump Slave Pump Control PROGRAM
159. rameter Group 22 MULTIPUMP CTRL Then press the SEL key After above step you should have parameter 2201 VALUE DECREASE highlighted Press the EDIT once Uses the up or down arrow to select the allowable pressure drop before the next lag pump comes on Example If the first pump reaches maximum frequency and the pressure drop allowed before the lag pump turns on is 3 psi you would set this parameter for 3 0 psi Once a pressure is set in 2201 then press the SAVE key Use the down arrow to highlight parameter 2202 VALUE INCREASE then press EDIT Use the UP or DOWN arrow to set your system pressure curve compensation If you do not require friction loss compensation at maximum frequency then enter 0 psi Then press the SAVE key NOTE System friction loss or overcoming head loss can be compensated by setting this parameter for each pump This value increase is additive for each lag pump Once parameter 2202 has been saved use the DOWN arrow to highlight parameter 2203 ENABLE SEQUENCE then press the EDIT key Using the up or down arrows select the frequency in HZ that will turn the next lag pump on when the lead pump has reached this frequency Normal setting is 59 HZ which allows the lag pump to start REM PARAMETERS 1504 SENSOR 1505 K DP FLOW METER 1506 SENSOR MIN 4mA REM PAR GROUPS 22 16 REFERENCE SELECT 18 RELAY OUTPUTS 19 ANALOG OUTPUTS 21 REGULATE 22 MULTIPUMP CTRL
160. rameters will not transfer over to each unit There are two options for downloading the parameters into each Aquavar A Manually entering each parameter into the Aquava control panel display with the following steps gous B Using the first Aquavar control panel you can download the software to each additional Aquavar via the control panel Take the programmed control panel from Aquavar 1 then insert and replace each additional control panel for Aquavar 2 3 4 This will automatically download saved parameters into the other Aquavar units See diagram to the left AQUAVAR 89 PROGRAMMING MultiPump Constant Pressure Control Programming Step s Standard view of the display in REM remote mode You will see the reference pressure REF PRESSURE actual pressure ACT PRESSURE and motor frequency in HZ N Ww on 90 Access the main menu on the keypad Press the MENU key once and the display will show PARAMETERS WIZARDS CHANGED PAR Using the arrow keys highlight the parameters option then press the ENTER key Once the parameters option has been chosen the parameter groups will be displayed Each group will be numbered see parameter groups list on page 51 for detailed information Use the arrow keys to highlight the parameter group 10 LOCKS PASSWORDS then press the SEL key Use the arrow keys to highlight group 1002 PASSCODE then press the ED
161. ransformers are used to feed 12 or 18 pulse drive inputs to provide harmonic mitigation If an isolation transformer is used for 6 pulse input the best choice is ONE three phase six winding transformer A delta primary is best for third harmonic cancellation A wye secondary avoids circulating current problems and provides the very desirable option of grounding the secondary neutral for minimum voltage stress and ripple to ground The transformer should have a KVA rating at least 1 1 times the maximum connected HP A K Factor of 6 is sufficient if transformer impedance is greater than 2 A K Factor of 5 is sufficient 11 INTRODUCTION if transformer impedance is greater than 3 The transformer manufacturer may provide derating for non K Factor rated transformers to operate at the drive produced K Factor levels Other transformer configurations are acceptable Three single phase transformers can be used if they are identical for phase to phase symmetry and balance A wye connected primary neutral should never be grounded Great care should be taken with delta primary delta secondary configurations Any lack of phase to phase symmetry could result in circulating currents and unacceptable transformer heating WARNING Never use phase converters with drives as nuisance tripping and possible damage may occur Size the drive for single phase input using 50 derate factor WARNING Use of Open Delta 230 volt power systems should be size
162. re Control 10 1 N CO Use down arrow until group parameter 1104 MOTOR NOM VOLTAGE is highlighted then press EDIT Use the arrows to enter your motors nameplate voltage then press the SAVE key Use the down arrow until group parameter 1105 MOTOR NOM CURRENT is highlighted then press EDIT Using the arrows enter your motor s maximum allowed amp draw at full speed or Service Factor Amps NOTE Enter motors service factor from nameplate or motor manual Once you have entered the amps press the SAVE key Use down arrow until you highlight group parameter 1107 MOTOR NOM RPM then press the EDIT key Use arrows to enter the RPM from the motor nameplate default is 3550 RPM Press the SAVE key to store setting Use down arrow until you highlight group parameter 1108 MOTOR NOM POW then press the EDIT key Use arrows to enter the motors Horsepower rating from nameplate then press the SAVE key After saving your motor horsepower press the EXIT key Use the down arrow until you highlight the Group 15 XDUCER VARIABLES then press SEL Press the down arrow until parameter 1502 TRANSDUCER MAX is highlighted then press EDIT Default pressure transducer setting is 300 psi Adjust this based on your maximum rating for a new transducer NOTE Goulds Water Technology provides a 0 300 psi transducer as standard Always check the maximum range of your transducer before procee
163. red trademark of Cooper Industries Inc 133 TECHNICAL DATA Fuse Sizing Ratings 380 480 Volt Drives The following table provides Aquavar CPC rating information and recommended fuse sizing for the input short circuit protection Branch circuit protection must be provided by the end user contractor or distributor Sized according to local or applicable NEC codes GWT AQUAVAR CPC NEMA 1 Full NORMAL Frame Input Voltage Phase Base Load DUTY Current Model Amps HORSEPOWER DES Amps Fuse Type JJN CPC40061 6 9 3 R1 7 0 10 CPC40081 8 8 5 R1 9 0 15 CPC40121 11 9 7 5 R1 12 1 15 CPC40151 15 4 10 R2 15 7 20 CPC40231 23 15 R2 23 5 30 CPC40311 31 20 R3 31 6 40 CPC40381 38 25 R3 38 8 45 CPC40451 45 30 R3 44 9 60 CPC40591 59 40 R4 60 2 70 CPC40721 72 50 R4 73 4 90 CPC40771 77 60 R4 78 5 90 460 3 CPC40971 97 75 R4 98 0 125 CPC41251 125 100 R5 126 5 150 CPC41571 157 125 R6 160 1 200 CPC41801 180 150 R6 183 6 225 CPC42451 245 200 R7 250 0 300 CPC43161 316 250 R7 322 3 400 CPC43681 368 300 R8 375 4 450 CPC44141 414 350 R8 422 3 500 CPC44861 486 400 R8 495 8 600 CPC45261 526 450 R8 536 5 800 CPC46021 602 500 R8 614 0 800 CPC46451 645 550 R8 658 0 800 3 UL Class T fuses are recommended for short circuit protection Very fast acting Bussmann T tron type JJN and JJS are shown in the Aquavar CPC tables Other manufaturers are acceptable i
164. s are in group 32 EXT FBA The drive communicates with a fieldbus adapter module in option slot 2 of the drive NOTE When EXT FBA is selected parameter group 31 is unlocked Any parameter changes that are made using a Fieldbus control system must be saved to the drive Parameter Name Value Range Note s 10 04 PARAMETER DONE Default Parameters that are manually entered through SAVE SAVE the keypad are automatically saved only parameters entered through a Fieldbus connection must be saved To save select SAVE and press the ENTER key Language The Aquavar CPC system fully supports 3 languages English AM French and Spanish English AM refers to American English and is the default language Units of power are in HP Parameter Name Value Range Note s 11 01 LANGUAGE ENGLISH AM ENGLISH AM is the default setting ESPANOL FRANCAIS Locking The AQUAVAR CPC has three levels of control panel keypad locking LOCAL LOCK PARAMETER LOCK and SET POINT LOCK e PARAMETER LOCK In parameter lock parameters may be viewed however they cannot be changed Starting Stopping set point changes and drive fault resets may still be performed using the keypad A valid password must be entered in parameter group 10 02 e LOCAL LOCK In local lock starting and stopping and setpoint changes are prevented Resetting of drive faults is still possible and ON and OFF control SET POINT L
165. s contain lead both of which will be classified as hazardous waste within the EU They must be removed and handled according to local regulations For further information on environmental aspects and more detailed recycling instructions please contact your local recycler Applicable Standards The drive complies with the following standards The compliance with the European Low Volt age Directive is verified according to standards EN 50178 and EN 60204 1 EN 50178 1997 Applicable Standards Electronic equipment for use in power installations EN 60204 1 1997 EN 60529 1991 IEC 529 IEC 60664 1 1992 Safety of machinery Electrical equipment of machines Part 1 General requirements Provisions for compliance The final assembler of the machine is responsible for installing e An emergency stop device e A supply disconnecting device Degrees of protection provided by enclosures IP code EN 61800 3 1996 Amendment A11 2000 UL508C EMC product standard including specific test methods UL Standard for Safety Power Conversion Equipment second edition 146 TECHNICAL DATA UL Markings The AQUAVAR is suitable for use on a circuit capable of delivering not more than 65 000 RMS symmetrical amperes 480 V maximum The AQUAVAR has an electronic motor protection feature that complies with the requirements of UL 508C When this feature is selected and properly adjusted additional o
166. s local control on the Oft Oft Oft keypad WARNING Before activating ensure that the control panel is not needed for stopping the drive Off Default Local control allowed On Local control disabled 1004 Parameter Save Saves the parameter valuesto Done Done Done Done Done the permanent memory Done Default Parameters entered via the keypad are automatically saved Parameters are not automatically saved when altered through the fieldbus connection 54 PARAMETER LISTINGS Group 10 1004 Locks Range Passwords g Parameter Save continued Description Used for manually saving parameters that have been altered through the fieldbus connection Single Synch Pump ronous Control Multi Defaults Constant Speed Control Slave 1005 New Pass Code 0 300000 Sets new pass code for parameter lock Returns to 0 after saving 1006 Group 11 Set Point Lock Disables set point changes from the keypad Off Default Local control allowed On Start Up Range Data ng Local control allowed Description Off Single Synch Pump ronous Control Off Multi Off Constant Speed Slave Control last lag pump to start regulates to the set point the remaining pumps operate at an en
167. s possible to run a three phase output with a single phase input Only part of the three phase input bridge is used Ripple current becomes 120 Hz rather than 360 This places a greater demand on the DC filter components capacitor bank and DC choke The result is that the drive must be derated to 50 current Single phase will not work with an SCR front end drive INTRODUCTION Input Power and Line Transformer Requirements The Aquavar CPC requires that the input line voltage and transformer power that meet certain phase and balance requirements If you or your installing electrical contractor is in doubt of the requirements the following provide guidelines for the Aquavar CPC When in doubt contact the local power utility or the factory Drive input isolation transformers are not generally required for the Aquavar CPC The Aquavar CPC utilizes as standard 3 line impedance therefore unless additional filtering is needed an input line reactor is not required NOTE 60 THROUGH 550 HP UNITS PROVIDE AN ACTUAL 3 IMPEDANCE LINE REACTOR BUILT INTO THE DRIVE CABINET The internal power circuit of the drive is floating with respect to earth ground except for transient protection MOV s and EMI capacitors therefore earth ground potential reference is established only by the user s power line grounding configuration The drive can operate with many different power grounding schemes The drive requires only that the steady state RMS volt
168. s the SAVE key to tune your transducer REM PAR GROUPS 15 15 XDUCER VARIABLES 16 18 RELAY OUTPUTS REM PARAMETERS 1501 TRANSDUCER UNIT 1502 TRANSDUCER MAX 300 0 1503 TRANSDUCER MIN 1504 SENSOR REM PARAMETERS 1501 TRANSDUCER UNIT 1503 TRANSUUCER MIN REM PARAMETERS 1504 SENSOR 1505 K DP FLOW METER 1506 SENSOR MIN REM PAR EDIT 1506 SENSOR MIN REM PAR EDIT 1506 SENSOR MIN TUNED VALUE 99 PROGRAMMING MultiPump Slave Pump Control 14 Once you have saved the parameter 1506 press the EXIT key Use down arrow until you highlight parameter group 18 RELAY OUTPUTS Then press the SEL key 15 After above step you should have parameter 1801 RELAY OUTPUT 1 highlighted Press the EDIT once Uses the up arrow to highlight START SLV then press SAVE 16 Use the down arrow to highlight parameter 1802 RO 1 ON DELAY then press EDIT Use the UP arrow to set your time delay to TURN ON RELAY 1 in seconds Then press the SAVE key NOTE You may have to adjust this time delay based on your system 17 Once parameter 1802 has been saved use the DOWN arrow to highlight parameter 1803 RO 1 OFF DELAY then press the EDIT key Use the UP arrow to select the OFF DELAY for relay 1 in seconds Press the SAVE key This will allow a timed delay when relay 1 turns off the first slave
169. shut off the pump when not required Parameter 26 04 SAVINGS OPTION 2 allows the savings of using Aquavar to be tracked during automatic shutdown The OPTION 2 will calculate according to a fixed speed unit that is designed to run continuously 24 hrs a day 7 days a week NOTE This is an estimated comparative data used for ideal situations Goulds Water Technology cannot guarantee savings will be exactly as stated Many system variables may increase or decrease estimated savings Fieldbus Control The Aquavar CPC may be integrated into BMS Building Management Systems or existing Distributive Control Systems DCS via optional Fieldbus control modules The use of Fieldbus control modules allows selected Aquavar parameters and operating signals to be accessed and modified Fieldbus control modules are available in numerous communication protocols including DeviceNet Modbus Profibus Modbus is the DEFAULT protocol for the Aquavar CPC With the control module installed See INSTALLATION manual set parameter 30 01 FIELDBUS to YES This will open up parameter groups 90 D SET REC ADDR and 92 D SET TR ADDR These parameter groups define the addresses and data sets that are exchanged between Aquavar and the DCS 103 FEATURES Parameter Name Value Range Note s 30 01 COMM NOT SELECTED No fieldbus communication PROTOCOL Default SELECT STD MODBUS Drive uses MODBUS protocol on the standard RS485 port Protocol setting
170. sible type 1 Motor cable length from the Aquavar to the motor is more than 50 wire feet 2 Drive uses IGBT type of switching which is industry standard and is used by the Aquavar If all of the conditions are present above then it is recommended to wire aLOAD REACTOR between the Aquavar output U2 V2 W2 and the motor Keep the load reactor as close to the output of the Aquavar for best results NOTE See suggested layout drawing and always refer to your specific motor manufacturers recommendation for VFD s Grounding NOTE Always follow local codes for wiring and grounding or refer to the National Electrical Codes Submersible installations are susceptible to stray voltage or grounding problems It is recommended to ground the transducer shield to the chassis of the Aquavar cabinet and to check with a meter for any stray voltage from the three phase motor Each component of the electrical Aquavar system should have the same grounding point or reference Always follow the submersible motor manufacturer s recommended installation procedures NOTES V Motors used must be three phase equal to input voltage V Standard enclosure is rated for NEMA 1 INDOOR USE ONLY Consult Factory Price pages for outdoor rated enclosures kv Aquavar CPC not for use on RESIDENTIAL WELL PUMP applications Consult with factory for appropriate variable speed controller like the BF15 V Input voltage for the Aquavar can be single phase Use the
171. sizes and flow rates on simple systems As flow increases velocity increases causing friction loss through piping and various fixtures Normally this would provide a loss in flow or overall pressure to the system With the Aquavar you can compensate for this friction loss The diagram below illustrates a typical system curve in relation to pump speed Head N 100 Pressure DEN System Curve Ki 7 ene 7 3 com Xx 8 cur 7 N xe ar gN oc o 70 22 Ree oo a gt en E a a Set _ Z Im m u GonstantPressure Line ressure N 0 Flow In this case the system pressure set point is shown at shutoff 0 flow and the increase in setpoint pressure is shown for increasing flow EXAMPLE If the set point is 150 Ft 65 PSIG 1 0 SG and the system resistance increase 10 Ft at the maximum flow rate or roughly 7 of the set point parameter 21 08 would be set as 7 110 FEATURES Parameter Name Value Range Note s 21 02 PRESS INCR 0 60 HZ This is the frequency at which system curve SPEED 20 HZ Default compensation begins At speeds below this no compensation for increased resistance is made 21 03 PRESS INCR 0 100 This is the amount that Aquavar will have 0 0 0 Default increased the set point at maximum speed Test Run The TEST RUN capability allows the Aquavar system to run periodically if it has been inactive The most common circumstance for which Test
172. ss code incorrectly or it has changed Contact your local Goulds Water Technology representative for the master code Once your group 1001 is showing OPEN you can access the entire pump and drive parameters in the Aquavar Wu After the SAVE key is pressed in the above group press the EXIT key then the down arrow to highlight the group 11 START UP DATA then Press the SEL key once Using the arrows highlight 1102 APPLIC MACRO then press the EDIT key Default is set for SINGLE PUMP Change this group whether your system is Single Pump Multi Pump Slave Pump etc To exit press CANCEL to save this parameter press the SAVE key once REM C 0 0 40 2 PSI sp 0 0 PSI ac 0 0 HZ DIR MENU REM MAIN MENU PARAMETERS WIZARDS 1 CHANGED PAR REM C PAR GROUPS 10 01 VFD SIGNALS 02 PUMP SIGNALS 03 FB ACTUAL SIGNALS 10 LOCKS PASSWORDS 11 START UP DATA EXIT REM PARAMETERS 1001 PARAMETER LOCK 1002 PASS GOPE 1003 LOCAL LOCK 1004 PARAM SAVE EXIT ED REM PARAMETERS 1001 PARAMETER LOCK OPEN 1002 PASS CODE 1003 LOCAL LOCK 1004 PARAM SAVE EXIT EDIT 81 PROGRAMMING Single Pump Submersible Pump Constant Pressure 6 10 11 82 Use the down arrow until group parameter 1105 MOTOR Use down arrow until you highlight group parameter 1107 Use down arrow until you highl
173. t connected as shown Mounting Fastening the Unit See the Dimensional Drawings on page 41 for the exact locations of the mounting points 1 Use at least four screws two at the front two at the back to attach the unit base plate to the floor 2 Use at least two screws to attach the back of the enclosure to a wall There are two holes available at the top of each the extension module and the drive module 35 INSTALLATION Frames R7 R8 Connecting Power and Control Cables Additional considerations that apply with the enclosure extension The power cable connection diagram that applies for the AQUAVAR is OO ExtensionModule IT aouawap Extension Module Drive Module I I Switch fuse Disconnect I I I I Control Wiring L1 L2 L3 PE Supply e Temporarily remove the upper high voltage shield clear plastic to gain access to the power connections in the extension module To avoid metal shavings inside the cabinet temporarily remove the gland conduit plate at the top of the extension module Then drill holes and mount conduit or cable fittings as needed e Route all power and control wiring through the top of the extension module 36 INSTALLATION Frames R7 R8 e The following diagram shows the power and control connection points in the enclosure module supplied with the R7 drive module R7 Frame Size Gland Conduit Plat
174. t factory for more information The EMC filter of the drive includes capacitors connected between the main circuit and the frame These capacitors and long motor cables increase the ground leakage current and may cause fault current circuit breakers to function Emergency Off Devices For safety reasons install the emergency off devices at each operator control station and at other operating stations where emergency off may be needed Pressing the stop key on the control panel of the drive does not generate an emergency off of the motor or separate the drive from dangerous potential 19 INSTALLATION Frames R1 R6 Selecting the Power Cables copper only General Rules Dimension the mains input power and motor cables according to local regulations e Do not use aluminum wires e The cable must be able to carry the drive load current See Technical Data for the rated currents e The cable must be rated for at least 70 C 158 F maximum permissible temperature of conductor in continuous use For US follow local codes for cable size or refer to NEC table 310 16 e The inductance and impedance of the PE conductor cable grounding wire must be rated according to permissible touch voltage appearing under fault conditions so that the fault point voltage will not rise excessively when an ground fault occurs e 600 VAC cable is accepted for up to 500 VAC concerning the entire AQUAVAR CPC range For frame sizes R7 and R8 sy
175. tart after a MIN transducer or analog signal loss 102 FEATURES Energy Savings Information Group 26 Aquavar can calculate the energy savings as compared to a constant speed pump application To enable this function to perform properly local energy costs and comparative application information must be entered Enter the local energy cost in local currency per kWh into parameter 26 01 KWhr and then enter the nominal power rating of a comparable fixed speed unit into parameter 26 02 baseline power To find this look at the fixed speed pump performance curve and enter the power for the rated operating point or maximum Brake Horsepower for the specific pump impeller combination Example If your power cost is 0 06 per kWh enter a value of 06 into parameter 26 01 Parameter Value Range Note s Default is zero BASELINE 0 1000 HP Default is zero POWER 26 03 SAVINGS 0 65535 Scales the analog output when energy SCALE savings is selected 26 04 ENERGY SAVINGS OP 1 Calculates energy savings with the Aquavar SAVE based ona fixed speed pump that turns METHOD ON and OFF when not required SAVINGS OP 2 Calculates energy savings with the Aquavar based ona fixed speed pump that operates 24 hrs a day Does not turn off 26 05 ENERGY DISABLED Default Allows resetting of savings to zero SAVE RESET RESET One of the benefits of using Aquavar is its ability to automatically
176. ter 2 Press the up down arrow to select WIZARDS then press SELECT 3 Enter the values for the parameters as seen in the table below and follow each entry by pressing the SAVE key 4 When complete press the EXIT key until the main screen is displayed again 5 Set the required system pressure using the up and down arrows then start the pump using the green START key Task Name Description 10 02 Pass Code Pass word setting to open the parameter lock 10 01 Parameter Lock Enables or disables the parameters from being changed 11 01 Language Selects the display language 11 04 Motor Nom Voltage Defines the motor nameplate voltage 11 05 Motor Nom Current Defines the motor nameplate current 11 06 Motor Frequency Defines the motor nameplate frequency 11 08 Nominal Motor Power Defines the motor nominal power 15 07 Sensor Min Adjusts the transducer to a zero reference point Changed Parameters Mode Use the Changed Parameters Mode to view and edit a listing of all parameters that have been changed from default values Procedure 1 Select CHANGED PAR in the Main Menu The display lists all changed parameters 2 Press ENTER 3 Press UP DOWN to select a changed parameter As each parameter is highlighted the parameter value appears 4 Press EDIT to edit the parameter value 48 START UP 5 Press UP DOWN to select a new value edit the parameter value Pressing both keys at
177. th the list of Aquavar models NOTE ALL MOTORS MUST BE THREE PHASE Minimum Frequency Submersible pump motors require a minimum speed or frequency to operate properly Because submersible motors use the water to lubricate and cool they require this minimum frequency when controlled by a Variable Speed Drive Franklin has suggested that the Minimum Frequency is set to at least 30 HZ in the Aquavar Therefore it is recommended to set the Aquavar Minimum Frequency to 30 to 35 HZ depending on static head in programming group 1402 See programming section WARNING FAILURE TO SET THE MINIMUM FREQUENCY FOR SUBMERSIBLE TURBINE INSTALLATION COULD RESULT IN DAMAGE TO THE PUMP AND OR MOTOR Tank Sizing An appropriate size diaphragm tank must be sized for smooth operation The tank will also provide a needed compressability at zero flow A tank with approximately 20 of total system volume in GPM would be recommended 79 PROGRAMMING Single Pump Submersible Pump Constant Pressure Load Reactor Filter A Load reactor or load filter is an electrical device that provides protection to the motor windings from a specific variable speed drive Motors are more susceptible to voltage spikes and switching frequencies found in IGBT type drives especially when the motor leads exceed 50 ft Therefore a load reactor is required when all of the following conditions are met for ANY type of AC induction motor above ground or submer
178. tion motor NEMA MG1 Nominal current Motor value is within this range 0 2 2 0 lna long drive heavy duty Type code label on drive entry for Output Current or Type code on drive and rating current table in Technical Data on page 131 Nominal frequency 50 70 Hz Voltage range Motor is compatible with the AQUAVAR 208 240 V for CPC2XXXX or 380 480 V for CPC4XXXX voltage range Tools Required To install the AQUAVAR you need the following e True RMS multimeter e Screwdrivers as appropriate for the mounting hardware used e Wire stripper e Tape measure Drill e Mounting hardware screws or nuts and bolts four each The type of hardware depends on the mounting surface and the frame size Frame Size Mounting Hardware R1 R4 M5 10 R5 M 1 4 in R M8 e in Suitable Environment and Enclosure Confirm that the site meets the environmental requirements To prevent damage prior to installation store and transport the drive according to the environmental requirements specified for storage and transportation See Ambient Conditions on page 145 Confirm that the enclosure is appropriate based on the site contamination level e IP 21 ULtype 1 enclosure indoor use only The site must be free of airborne dust corrosive gases or liquids and conductive contaminants such as condensation carbon dust and metallic particles INTRODUCTION
179. to operate NOTE The WARNING ONLY mode may result in damage to the pump if a low water condition occurs It is recommended to set this for WARN amp CONTROL Keypad Failure In the event of a keypad failure Aquavar has been configured to fault and shut down the controller This functionality can be disabled or configured to result in a drive fault Parameter Name 24 01 KEYPAD DISABLED default FAILURE FAULT Note s Fault message PANEL LOSS Value Range Set Points Dual The Aquavar can alternate between two fixed set points or one fixed point and a variable set point The alternating between set points may be accomplished using a digital switch or through a Fieldbus command EXAMPLE for 16 02 and 16 03 An irrigation system requires 110 psi for watering all zones then Parameter Name Value Range Note s 16 01 SP1 SP2 SETP 1 Default This parameter defines the source that SELECT DI4 toggles the Aquavar unit between FIELDBUS Set Point 1 or Set Point 2 e SET POINT 1 Default indicates that only set point 1 is being used e DI4 is a digital input where 0 Open selects Set Point 1 and 1 Closed selects Set Point 2 16 02 SET POINT 1 KEYPAD Default This selects where the value for SEL Al 1 Set Point 1or 2 is coming from FIELDBUS e KEYPAD a number e g 100 will be manually entered via the keypad Selecting ANALOG INPUT will require entry of parameters 16 03 16 04
180. transducer Normal Inverse modes Friction loss compensation Group 22 MULTIPUMP CONTROL Defines parameters for multi pump control algorithm Addresses each drive Required group for alternating each pump Group 24 FAULT FUNCTIONS Defines parameters for faults pump protection and run enable mode e g keypad failure pump protect low water error reset Group 25 AUTOMATIC RESET This group defines conditions for automatic reset An automatic reset occurs after a particular fault is detected The Aquavar holds for a delay time then automatically restarts You can limit the number of restarts in a specific period of time for a variety of faults e g overcurrent over under voltage Group 26 ENERGY SAVINGS Defines parameters used for energy savings and kW hr usage Group 27 CRITICAL SPEEDS This group defines up to three critical speeds or resonant frequencies This mechanical resonance may occur on certain loads at certain frequencies Group 30 OPTION MODULES Defines parameters used for fieldbus communication networks and optional fieldbus adapter Group 31 FIELD BUS SETUP Parameters used for actual set up for the field bus communication via the RS485 terminals Group 32 MODBUS SETUP Defines parameters used for the Modbus setup and protocol baud rate parity status functions Group 50 MOTOR CONTROL Provides adjustment of the switching frequency for the drive Group 51 MAINTENANCE TRIGGERS Defines th
181. trol 21 22 2 Ww 24 j j j j Status Final step Is to enter your required pressure In TED Once previous step has been saved use the Down Arrow REM C PARAMETERS and highlight parameter 2203 ENABLE SEQUENCE then eu VALLE EE press EDIT Using the up or down arrow enter the frequency in Hertz HZ that you wish the SLAVE pump will turn on once 2203 ENABLE SEQUENCE the lead pump reaches this speed Default is set for 59 HZ and is typical for 60HZ systems If you change this setting press the SAVE key If no changes are required then press the EXIT key 59 00 HZ 2204 SWITCH LEAD LAG Group 2205 Enter frequency for slave pump to be turned off the system After above programming has been completed press the EXIT key two 2 or three 3 times until you arrive back to the first control display screen SEE DIAGRAM Then press the UP or DOWN arrow to select the required system Up pressure for your Aquavar controlled pump Once sort pressure has been selected press the green Geh START key on the keypad DOWN LOC REM Optional Step To lock out access to the control STOP panel keypad refer to page 104 This will prevent unauthorized users from changing programming NOTE If an error or fault occurs refer to the faults alarms section of this manual page 115 When troubleshooting an Aquavar system always break down into the
182. trol Lead vs Lag The Aquavar controlled pump will always be considered the LEAD pump and start first in the system sequence The constant speed pumps will always be the SLAVE or LAG pumps in the system When the Aquavar controlled pump starts to run out or cannot meet the system demand then the first relay output will actuate based on a programmed pressure and time delay The Aquavar CPC has up to three contacts that can be used for SLAVE operation Wiring Connection The relays used for the SLAVE pump control are dry relay contacts rated fora MAXIMUM 250 VAC or 30VDC 2 Amps free from inductivity Minimum is 500 mW 12V 10mA Refer to diagram below or in APPENDIX section Each relay will be wired to a voltage starter DO NOT EXCEED 250 VOLTS AC through each relay Each relay is designed for control power only It is up to the operator to provide necessary starters overloads or fuses for each SLAVE pump motor control Always follow your local codes or National codes and have a certified electrician perform the necessary wiring RO1C Relay output 1 programmable Default Run power to drive RO1A Ir Maximum 250 VAC 30 VDC 2 A RO1B Minimum 500 mW 12 V 10 mA RO2C Relay output 2 programmable Default Ready pump is running RO2A Maximum 250 VAC 30 VDC 2 A RO2B E Minimum 500 mW 12 V 10 mA RO3C Relay output 3 programmable Default not used Sa L i 3 Q e O
183. ue and current are automatically restricted The function protects the input bridge of the drive against overload Note 2 The ratings apply in ambient temperature of 40 C 104 F Derating The load capacity current and power decreases if the installation site altitude exceeds 1000 meters 3300 ft or if the ambient temperature exceeds 40 C 104 F or if 8 kHz switching frequency parameter 5001 is used Temperature Derating In the temperature range 40 C 50 C 104 F 122 F the rated output current is de creased 1 for every 1 C 1 8 F above 40 C 104 F The output current is calculated by multiplying the current given in the rating table by the derating factor Example If the ambient temperature is 50 C 122 F the derating factor is 100 1 C x 10 C 90 or 0 90 The output current is then 0 90 x lan or 0 90 x hpa Altitude Derating The derating is 1 for every 100 m 330 feet above 3300 feet If the installation site is higher than 2000 m 6600 feet above sea level please contact the factory for assistance Single Phase Supply Derating For 208 240 Volt series drives a single phase supply can be used In that case the derating is 50 for the maximum amps and corresponding power rating of the three phase drive at 208 230 Volt input Switching Frequency Derating If the 8 kHz switching frequency parameter 5001 is used derate HP and current output to 80 13
184. us but not receiving any messages Exec Init Drive is initializing Modbus Time Out Atime out has occurred Config Error Drive has configuration error Off line Drive is receiving messages that are NOT addressed to itself On Line Drive is receiving messages that are addressed to itself Reset Drive is performing hardware reset Listen Only Drive is in listen only mode 71 PARAMETER LISTINGS Defaults Group Modbus 32 Setup 3210 EFB Parameters 3220 Single Synch Multi Constant Speed kange Pump ronous Control Slave Control Description Meaning and values of these parameters depend on the selected fieldbus protocol Group Motor 50 Control Single Synch Multi Constant Speed Pump ronous Control Slave Control 8 8 kHz kHz Range Description Switching Freq 4 8 12kHz Sets the switching frequency 8 for the drive kHz Group Maintenance 51 Triggers Single Synch Multi Constant Speed Pump ronous Control Slave Control Range Description Cooling Fan Trig 0 0 6553 5 Sets the trigger point for the kh drive s cooling fan counter 0 0 disabled 5102 Cooling FanAct 0 0 6553 5 Defines the actual value of the kh drive s cooling fan counter The parameter is reset by writing 0 0 to it 5103 RevolutionTrig 0 65535 Sets the trigger point forthe 32000 32000 32000
185. uu ENEE 136 Motor COMME CT OM LULU aasan R condense teeta dE ETT ATO TO 136 ControliGeniniectionmiug un asa A kq anti usu sinu A EE asss 137 Efficiency frames R1 R8 Cooling frames RI R i 137 Cooling frames R7 R8 Mounting Orientations a be 138 Air Flow 380 480 Volt Eessen ee eegen 139 Air Flew 208 240 Volt ET 140 Dimensions and Weights Frames RI R i 141 Units with IP 54 UL Type 12 Enclosures drusere eege dd Eden deeg 143 Weights and Dimensions Frames R7 R8 460 Mot 144 Degrees Ot PLOTS CEIOM sscssseicsssscsesceessssesnpszsesodssansnsnyeteossteadeeasnodeadesdedstnaavhatcrteunssatanpetlveseg auaoaviaushdvesesesnea Eeer 144 Ambient Con EE 145 Materials Applicable Standards uu s ua u nunus Eege EE ee cts dashes 146 UL Markings Liability Limits nasha cae soueteasand pddecvouadeeusavandsdesatavcedarsseesnevancenadengucaapnaueseanats 147 Section 12 APPENDIX Pressure Iransducer uuu dee eren tad 148 Transducer Data Specifications Drawing A00462C naa 149 Transducer Data Specifications Drawing BAOOA2EC a naa 150 Spare EE EE 151 Ell e 152 SAFETY gt PSP PEPE PEE WARNING The AQUAVAR adjustable speed AC drive should ONLY be installed by a qualified electri cian WARNING Even when the motor is stopped dangerous voltage is present at the Power Circuit termi nals U1 V1 W1 and U2 V2 W2 and depending on the frame size UDC and UDC or BRK and BRK WARNING Dangerous voltage is present w
186. verload protection is not required unless more than one motor is connected to the drive or unless additional protection is required by applicable safety regulations The drives are to be used in a controlled environment See section Ambient Conditions on page 145 for specific limits Liability Limits The manufacturer is not responsible for e Any costs resulting from a failure if the installation commissioning repair alteration or ambient conditions of the drive do not fultill the requirements specified in the documentation delivered with the unit and other relevant documentation e Units subjected to mususe negligence or accident e Units comprised of materials provided or designs stipulated by the purchaser In no event shall the manufacturer its suppliers or subcontractors be liable for special indirect incidental or consequential damages losses or penalties If you have any questions concerning your product please contact the local distributor or Goulds Water Technology The technical data information and specifications are valid at the time of printing The manufacturer reserves the right to modifications without prior notice 147 APPENDIX PRESSURE TRANSDUCER 300 PSI 4 20 mA P N PRTO300SB1P To order sensor with 30 cable use P N 9K391 Packard 3 pin Metri Pack Series 150 3 25 out Supply Snubber te l Brown added 3 16 Dia sphere of silicon grease at

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