Xylem Aquavar Instruction Manual Download Page 164

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9.4 Wire sizing charts

VFD input wire sizing

Maximum allowable conductor length (45°C Ambient, 5% drop)
Line

power

supply

Controller ratings

Conductor size for 75°C rated wire (lengths in bold require 90°C rated wire)

Freque

ncy

conver

ter

rating

Input

current

Wires/

phases

1/0

2/0

3/0

4/0

250

300

350

400

500

3x460

V AC

1500 150

183

717

904

1141 1439

2000 250

291

905

1143 1439 1699 2040

2500 300

438

1204 1421 1706

3000 350

427

1158 1390

4000 450

531

992

1252 1577 1862 2236 2613 2988 3718

4500 500

580

908

1146 1444 1705 2047 2393 2736 3404

5000 550

667

997

1256 1483 1780 2080 2379 2960

6000 600

718

1167 1377 1654 1933 2210 2749

3x575

V AC

2000 200

189

695

875

1104 1393

2500 250

234

892

1125 1421 1790 2113 2537

3000 300

286

921

1163 1464 1729 2076

3500 350

339

1235 1459 1751

4000 400

390

1268 1522

4500 450

434

962

1214 1532 1930 2279 2736 3197 3656 4549

5000 500

482

866

1093 1380 1738 2052 2463 2879 3292 4096

6000 600

549

959

1211 1526 1801 2163 2528 2890 3596

VFD output wire sizing

Maximum allowable conductor length (45°C Ambient, 5% drop)
Line

power

supply

Controller ratings

Conductor size for 75°C rated wire (lengths in bold require 90°C rated wire)

Freque

ncy

conver

ter

rating

Input

current

Wires/

phases

1/0

2/0

3/0

4/0

250

300

350

400

500

3x460

V AC

1500 150

190

691

870

1099 1386

2000 200

240

870

1097

2500 250

302

872

1101 1387 1637 1966

3000 300

361

1160 1370 1644

3500 350

443

1116 1340

4500 450

540

975

1231 1551 1831 2199 2570 2939 3656

5000 500

590

893

1127 1420 1676 2012 2352 2690 3346

5500 550

678

981

1235 1459 1751 2047 2340 2912

6000 600

730

1147 1355 1626 1901 2174 2704

9 Technical Specification

162

Aquavar

Intelligent Pump Controller - 150 HP to 600 HP INSTRUCTION MANUAL

Summary of Contents for Aquavar

Page 1: ...INSTRUCTION MANUAL IM273 Rev C Aquavar Intelligent Pump Controller 150 HP to 600 HP...

Page 2: ......

Page 3: ...ncy converter controller functions 24 4 Mechanical Installation 25 4 1 Pre installation 25 4 1 1 Installation site checklist 25 4 1 2 Frequency converter and motor pre installation check list 25 4 1 3...

Page 4: ...dure 85 6 2 Pre startup inspections 85 6 3 Apply power 86 6 4 Discharge time 86 6 5 Frequency converter programming 87 6 5 1 Programming the controller 87 6 5 2 Setup and commissioning 92 6 5 3 Pump p...

Page 5: ...9 4 Wire sizing charts 162 9 5 Parameter list 164 10 Product warranty 166 Table of Contents Aquavar Intelligent Pump Controller 150 HP to 600 HP INSTRUCTION MANUAL 3...

Page 6: ...re authorized to install commission and maintain equipment systems and circuits in accordance with pertinent laws and regulations Also the personnel must be familiar with the instructions and safety m...

Page 7: ...rical risks if instructions are not followed in a proper manner NOTICE A potential situation which if not avoided could result in undesirable conditions A practice not related to personal injury 1 3 U...

Page 8: ...Check the explosion risk before you weld or use electric hand tools Precautions during work Observe these safety precautions when you work with the product or are in connection with the product Never...

Page 9: ...wered High voltage can be present even when the frequency converter is not powered High voltage can be present even when the warning LED indicator lights are off Failure to wait the specified time aft...

Page 10: ...ed upon Recycling guidelines Always follow local laws and regulations regarding recycling Waste and emissions guidelines Do not dispose of equipment containing electrical components together with dome...

Page 11: ...NING Assembled units and their components are heavy Failure to properly lift and support this equipment can result in serious physical injury and or equipment damage Lift equipment only at the specifi...

Page 12: ...ry location free from heat dirt and vibrations NOTICE Protect the product against humidity heat sources and mechanical damage NOTICE Do not place heavy weights on the packed product 2 Transportation a...

Page 13: ...mote commands from external controls Monitors the system and motor status Issues warnings or alarms for fault conditions Starts and stops the motor Optimizes energy efficiency Operation and monitoring...

Page 14: ...ETR warning NOTICE The ETR function is initialized at 1 16 x rated motor current and rated motor frequency The ETR function provides class 20 motor overload protection in accordance with the NEC Motor...

Page 15: ...to the input to which the thermistor is connected Refer to the examples below for wiring details The thermistor cut out value is 3k Integrate a thermistor PTC sensor in the motor for winding protecti...

Page 16: ...p Set 1 90 Motor Thermal Protection to Thermistor Trip 2 Set 1 93 Thermistor Source to Digital Input 19 4 Figure 4 ON OFF with a digital input and the 10 V as a power supply Using an analog input and...

Page 17: ...y Voltage V Cut out Values Threshold Cut out Values Digital 24 6 6k 10 8k Digital 10 800k 2 7k Analog 10 3 0k 3 0k With the Torque limit feature the motor is protected from being overloaded independen...

Page 18: ...74 2 9 A 981 38 6 1166 45 9 310 12 2 163 6 4 420 16 5 417 16 4 380 15 0 177 0 7 0 354 0 13 9 1209 45 4 849 33 4 160 6 3 120 4 7 304 12 0 160 6 3 25 1 0 1154 45 4 B C 225 8 9 225 8 9 Figure 6 D1 enclo...

Page 19: ...8 18 4 Figure 8 Exterior dimensions for D1h with NEMA 3R Kit 9K715 586 23 0 189 7 4 1122 44 2 1074 42 3 763 30 0 468 18 4 425 16 7 431 17 0 430 16 9 280 11 0 Figure 9 Exterior dimensions for D2h with...

Page 20: ...1 5 9 408 16 1 1280 50 4 161 6 3 375 14 8 417 16 4 1327 52 2 298 11 7 977 38 5 160 6 3 120 4 7 304 12 0 185 7 3 369 14 5 25 1 0 160 6 3 1282 50 5 225 0 8 9 225 0 8 9 Figure 11 D4 enclosure cabinet mou...

Page 21: ...3 8 MTG bolt 11 0 4 64 2 5 24 0 9 20 0 8 9 0 3 Min 225 8 9 airspace outlet Figure 13 D5 Enclosure 1754 69 1 209 8 2 1282 50 5 1931 76 386 15 2 156 6 2 23 0 9 161 6 3 25 11 420 16 5 411 16 2 280 11 374...

Page 22: ...Cable base 56 2 2 25 1 0 25 1 0 F F Figure 15 E1 Enclosure floor or cabinet mount 64 2 5 1320 52 0 585 23 0 156 6 2 269 10 6 498 19 5 1547 60 9 1502 59 1 539 21 2 139 5 5 304 12 0 184 7 3 184 7 3 184...

Page 23: ...4 138 Frame Size D1 D2 D3 D4 Enclosure protection IP 21 54 00 NEMA Type 1 Type 12 Chassis Normal overload rated power 110 overload torque 150 250 HP 110 160 kW at 400 V 380 480 V 150 200 HP 132 160 kW...

Page 24: ...450 600 HP 450 560 kW at 690 V 525 690 V NOTE The typical power loss is at nominal load conditions and expected to be within 15 tolerance relates to variety in voltage and cable conditions The losses...

Page 25: ...nector 6 Serial bus terminal switch 7 Analog switches A53 A54 8 Relay 1 01 02 03 9 Re ay 2 04 05 06 10 Lifting ring 11 Mounting slot 12 Cable clamp PE 13 Ground 14 Motor output terminals 96 U 97 V 98...

Page 26: ...the power factor reflected back to the line Reduce harmonics on the AC input 5 Capacitor bank Stores the DC power Provides ride through protection for short power losses 6 Inverter Converts the DC in...

Page 27: ...ly closed Ensure all cable glands and unused holes for glands are properly sealed Ensure that the unit cover is properly closed Do not leave the frequency converter uncovered For outdoor enclosures en...

Page 28: ...sary bending allowance As the IP00 enclosure is open to the bottom cables must be fixed to the back panel of the enclosure where the frequency converter is mounted for example by using cable clamps NO...

Page 29: ...r air cooling must be provided Generally 225 mm 9 in is required Improper mounting can result in over heating and reduced performance Derating for temperatures starting between 45 C 113 F and 50 C 122...

Page 30: ...f the cables Terminal locations D enclosures 3X M8x20 Stud with nut Section A A mains terminals Mains terminal Section B B motor terminals Motor terminal 272 10 7 0 0 0 0 0 0 200 7 9 88 3 5 Ground 0 0...

Page 31: ...otor terminals and brake terminals Motor terminal 0 0 0 Brake terminals Brake regen terminals 284 11 2 0 0 0 0 0 0 0 0 0 B A B A 319 12 6 200 7 9 236 8 9 293 11 5 376 14 8 33 1 3 91 3 6 149 5 8 211 8...

Page 32: ...r terminals 4 Earth Ground terminals Terminal locations E enclosures Consider the following terminal positions when designing the cable access Terminal locations E1 0 0 0 0 0 0 600 23 6 525 20 7 412 1...

Page 33: ...0 0 453 17 8 B A R 81 9 19 Nm 14 FTa A A A Figure 31 IP21 NEMA Type 1 and IP54 NEMA Type 12 Enclosure Power Connection Position Detail B 4 Mechanical Installation Aquavar Intelligent Pump Controller 1...

Page 34: ...Switch Table 4 Dimensions for disconnect terminal Enclosure size Unit type Dimensions mm in E1 IP54 IP21 UL and NEMA 1 NEMA12 450 600 HP 575 V 396 15 6 267 10 5 332 13 1 397 15 6 528 20 8 N A 500 600...

Page 35: ...L3 93 W T3 98 FASTENER TORQUE M8 9 6 Nm 7 FT LB FASTENER TORQUE M8 9 6 Nm 7 FT LB Figure 33 IP00 Enclosure Power Connection Positions 0 0 0 47 1 9 83 3 3 131 5 2 167 6 6 0 0 0 147 5 8 A A A A 019Nm 14...

Page 36: ...he disconnect 104 4 1 35 1 4 10 0 4 0 0 0 0 0 0 40 1 6 78 3 1 0 0 0 26 1 0 26 1 0 Figure 36 Terminal in Detail Power connections can be made to positions A or B Table 5 Dimensions for Disconnect Termi...

Page 37: ...m of the frequency converter 1 Mains side 2 Motor side 4 1 9 NEMA 3R cover kit The NEMA 3R cover kit is designed for D1h and D2h enclosure sizes for the following applications This kit adds a cover to...

Page 38: ...plated eyebolts that came with the unit and replace with the stainless steel eyebolts provided in the bag NOTICE UL NEMA 3R RATING Eyebolts are not required to meet UL NEMA 3R rating 4 1 11 Install t...

Page 39: ...moving Gland Plate 3 2 1 Figure 41 Installing NEMA 3R Gland Plate 1 Gasket 2 Screw with captive washer 3 Gland plate 4 Mechanical Installation Aquavar Intelligent Pump Controller 150 HP to 600 HP INST...

Page 40: ...ed since the cover has slotted screw openings 4 1 12 1 Calculating Nominal Current when Using a NEMA 3R Cover The nominal current of a frequency converter with the NEMA 3R cover is 88 of its current r...

Page 41: ...80 90 1 2 3 4 5 6 7 8 9 A B Figure 43 60 AVM High Overload HO 150 50 C 52 C 100 50 70 80 90 1 2 3 4 5 9 A B 60 45 C 6 7 8 Figure 44 60 AVM Normal Overload HO 110 50 C 52 C 110 50 100 70 80 90 1 2 3 4...

Page 42: ...lowing requirements Electronic control equipment is connected to hazardous mains voltage Extreme care should be taken to protect against electrical hazards when applying power to the unit Run motor ca...

Page 43: ...ion A fault current in the frequency converter at the output power terminals might contain a DC component which can charge the filter capacitors and cause a transient earth current The earth leakage c...

Page 44: ...igure 47 Basic electrical connection Terminal 37 is the input to be used for Safe Stop For instructions on safe stop installation refer to the section Safe Stop Installation in the adjustable frequenc...

Page 45: ...e connections are situated as shown below Dimensioning of cable cross section must be done in accordance with the current rating and local regulations See the specifications section for details For pr...

Page 46: ...iven length of cable Keep the motor cable as short as possible to reduce the noise level and leakage currents Switching frequency When adjustable frequency drives are used together with sine wave filt...

Page 47: ...frame size D1 Figure 52 Compact IP 21 NEMA 1 and IP 54 NEMA 12 with disconnect fuse and RFI filter frame size D2 1 AUX Relay 2 Temperature switch 5 Electrical Installation Aquavar Intelligent Pump Co...

Page 48: ...tables for part number 7 AUX Fan 8 Fan fuse see fuse tables for part number 9 Line power ground 10 Motor Figure 53 Compact IP 00 chassis frame size D3 5 Electrical Installation 46 Aquavar Intelligent...

Page 49: ...3 Line 4 Load sharing 5 Brake 6 SMPS Fuse see fuse tables for part number 7 AUX Fan 8 Fan fuse see fuse tables for part number 9 Line power ground 10 Motor Figure 55 Position of ground terminals IP00...

Page 50: ...A type 1 and IP54 NEMA type 12 D2 and D4 shown as examples D1 and D3 are equivalent Figure 57 Compact IP 21 NEMA 1 and IP 54 NEMA 12 frame size E1 5 Electrical Installation 48 Aquavar Intelligent Pump...

Page 51: ...3 Line 4 Load sharing 5 Brake 6 SMPS Fuse see fuse tables for part number 7 AUX Fan 8 Fan fuse see fuse tables for part number 9 Line power ground 10 Motor Figure 59 Position of ground terminals IP00...

Page 52: ...ring is run in the same conduit as the motor wiring these pulses can couple electrical noise back onto the building power grid Control wiring should always be isolated from the high voltage power wiri...

Page 53: ...le protective grounding or grounding can be used as extra protection provided that local safety regulations are complied with In the case of a ground fault a DC component may develop in the fault curr...

Page 54: ...motor Connect the 3 phase motor wiring to terminals 96 U 97 V and 98 W Ground the cable in accordance with grounding instructions provided Torque terminals in accordance with the information provided...

Page 55: ...nameplate to ensure that the AC line voltage of the adjustable frequency drive matches the power supply of your plant Ensure that the power supply can supply the necessary current to the adjustable fr...

Page 56: ...ine voltage connection for the cooling fans The fans are factory equipped to be supplied from a common AC line jumpers between 100 102 and 101 103 If an external supply is needed the jumpers are remov...

Page 57: ...ave filter Nominal AC Line Voltage Motor Insulation UN 420 V Standard ULL 1300 V 420 V UN 500 V Reinforced ULL 1600 V 500 V UN 600 V Reinforced ULL 1800 V 600 V UN 690 V Reinforced ULL 2000 V Motor be...

Page 58: ...cable routing as shown in the picture Remember to connect the shields in a proper way to ensure optimum electrical immunity Serial communication bus connection Connections are made to the relevant op...

Page 59: ...ic noise depends on the transfer impedance ZT The shield of a cable is normally designed to reduce the transfer of electric noise however a shield with a lower transfer impedance ZT value is more effe...

Page 60: ...c noise may occur that will disturb the entire system Solve this problem by fitting an equalizing cable next to the control cable Minimum cable cross section 6 AWG or 16 mm2 Figure 67 Correct screenin...

Page 61: ...mm2 2 Equalizing cable Alternatively the connection to terminal 61 can be omitted Figure 70 Twisted pair cables without terminal 61 1 Min 6 AWG or 16 mm2 2 Equalizing cable 5 16 Control terminal type...

Page 62: ...e two Form C relay outputs that are in various locations depending upon the frequency converter configuration and size Some options available for ordering with the unit may provide additional terminal...

Page 63: ...ed digital input This input can be configured for use as a Pump Protect External Interlock Warning or Alarm Input See Pump protect to enable the Warning or Alarm associated with this input 29 5 13 63...

Page 64: ...n Integrated RC filter for cable shield ONLY for connecting the shield when experiencing EMC problems 68 8 3 RS485 interface 69 8 3 RS485 interface 5 17 Wiring to control terminals 5 17 1 Unplug termi...

Page 65: ...itch A54 is used to configure analog input 54 If the analog input 54 is used the analog input configuration switch A54 must be set properly Remove power from the controller before changing the analog...

Page 66: ...ngle pump constant pressure operating more 5 17 4 Analog input 53 The default operating mode of the frequency converter is Single Pump Constant Pressure mode In this mode a current feedback signal fro...

Page 67: ...ble gland It may be necessary to apply potential equalizing cables to maintain the same ground earth potential throughout the network Particularly in installations with long cables To prevent impedenc...

Page 68: ...category III pollution degree 2 Wiring for factory default setup This configuration utilizes the controller factory default settings for I O The factory default settings for IT are configured for a s...

Page 69: ...vent an automatic restart set the 14 20 Reset Mode to Manual Reset Note that the 14 20 Reset Mode parameter affects all other Alarms that are not listed as a Trip Lock Alarm Refer to the Warnings Alar...

Page 70: ...06 The parameter listing that follows shows how to configure the additional transducer Analog inputs can be configured using the Start Up Genie Be sure to properly set the analog input configuration s...

Page 71: ...xample for a 0 300psi transducer set to 0 psi 21 12 Ext 1 Maximum Reference Ext 1 Maximum Reference Maximum transducer feedback value For example for a 300 psi DP transducer set to 300 psi 6 24 Termin...

Page 72: ...nal potentiometer Figure 80 Connections for speed control over current signal from PLC or BMS Figure 81 Connections for speed control with PLC or BMS 5 Electrical Installation 70 Aquavar Intelligent P...

Page 73: ...Voltage 0 V and 6 21 Terminal 54 High Voltage 10 V Set 6 24 Terminal 54 Low Ref Feedb Value to value corresponding to the command speed at the low voltage and 6 25 Terminal 54 High Ref Feedb Value to...

Page 74: ...a duplex control system having 2 controllers and 2 variable speed pumps In this configuration pumps can be staged and destaged as needed and the lead pump can be alternated When both pumps are on the...

Page 75: ...mand to the drive Control cables must be braided screened shielded and the screen must be connected by means of a cable clamp at the controller and at the BMS PLC Refer to Using Screened Control Cable...

Page 76: ...he digital inputs Set to Controlword only to use only the serial bus 8 50 Coasting Select Determines the control location of the coasting stop function Set to Digital input to use a digital input only...

Page 77: ...recommended to control this function via digital inputs 5 19 Local control panel The controller is equipped with a local control panel LCP The LCP combines the status screen and keypad found on the fr...

Page 78: ...local control The second word in the status line shows the Reference Site Remote The speed reference is given from external signals serial communication or internal preset references Local The contro...

Page 79: ...mote reference is active which holds the present speed Freeze output was selected as a function for a digital input parameter group 5 1 Digital Inputs The corresponding terminal is active Speed contro...

Page 80: ...uick stop function was activated via serial communication Ramping The motor is accelerating decelerating using the active Ramp Up Down The reference a limit value or a standstill is not yet reached Re...

Page 81: ...g the Status key toggles between different status screens There are three different status screens five readouts default four line readouts or Smart Logic Control Use the Status key for selecting the...

Page 82: ...mode by pressing either Info Back or Cancel OK OK is used for choosing a parameter marked by the cursor and for enabling the change of a parameter Arrows The four navigation arrows are used to navigat...

Page 83: ...ed via 0 42 Auto on Key on LCP Reset The Reset key is used for resetting the controller after an alarm trip The key can be enabled or disabled via parameter 0 43 Reset Key on LCP Status lights If cert...

Page 84: ...CP press OK to select 7 The progress bar will show the status of the process 8 Press Status to return to the main status screen 9 Press Auto On or Hand On to resume previous operating mode Factory Res...

Page 85: ...Adaptation AMA Performing an AMA will ensure optimum performance The AMA measures the values from the motor model equivalent diagram 1 Connect terminal 37 to terminal 12 if terminal 37 is available 2...

Page 86: ...f the alarm will assist you in troubleshooting If you contact Xylem for service make sure to mention the number and alarm description NOTE Unsuccessful AMA is often caused by incorrectly registered mo...

Page 87: ...f frequency converter and motor 6 2 Pre startup inspections Item to Inspect Description Checked Auxiliary equipment Look for auxiliary equipment switches disconnects or input fuses circuit breakers th...

Page 88: ...sult in death serious injury equipment or property damage POTENTIAL HAZARD IN THE EVENT OF INTERNAL FAILURE Risk of personal injury when the frequency converter is not properly closed Before applying...

Page 89: ...using the up and down arrows Press OK to enter the sub menu or selected parameter group Once in the sub menu or parameter group use the up and down arrows to highlight the desired parameter Press OK t...

Page 90: ...escription Q1 My Personal Menu Contains parameters commonly used to configure pump applications Q2 Quick Setup Contains parameters commonly used to configure the controller Q3 Function Setups Provides...

Page 91: ...general purpose digital input is designated for the Pump Protect Function 5 12 Terminal 27 Digital Input No operation This general purpose digital input is designated for the Pump Protect Function 22...

Page 92: ...and 2 functions This array parameter allows configuration of both relays See Programming the controller for details on how to navigate the array parameter screen 0 Relay 1 1 Relay 2 5 41 On Delay Rel...

Page 93: ...de by the user The Genie allows the user to configure the Motor Application type inputs outputs pump protection features flow compensation and communications The application types include Single Pump...

Page 94: ...n arrow to save the parameter the Genie may be slow to respond as these settings and calculations are performed Press Cancel to exit parameter editing without saving or to change a saved parameter or...

Page 95: ...ay index The array index is shown on the left side of the parameter value Use the up and down arrows to select the desired index Press OK to set the array index and enable editing of the parameter at...

Page 96: ...which can automatically adjust the system setpoint to offset the affect of friction loss in the system Pump Protection This setup configures Sleep Mode Flow Check No Water Loss of Prime and Pump Prot...

Page 97: ...ters first to avoid overwriting any settings made in the Start Up Genie Application setup The next menu set is the Application Setup which will allow selection and configuration of the application typ...

Page 98: ...this mode for constant pressure flow or level applications that use 1 controller operating a single pump The Application Type allows selection of the type of control Select either Constant Pressure F...

Page 99: ...ation Constant Pressure Level Control Flow Control Transducer Max Feedback 300 unit 300 unit 300 unit Transducer Type 4 20mA 4 20mA 4 20mA Feedback 1 Source AI 53 AI 53 AI 53 PID Performance Normal Fi...

Page 100: ...nd the setpoint in which no staging or destaging of pumps will occur This range is set to avoid frequent staging and destaging of pumps and to accommodate normal fluctuations present in the system The...

Page 101: ...default configurations are described in the table below Table 25 Duplex Autoset Configuration Duplex Autoset Configuration Transducer Max Feedback 300 unit Transducer Type 4 20mA Feedback 1 Source AI...

Page 102: ...Time expires Enabling Alternation allows equalization of loading between the 2 pumps and controllers The Alternation Time is based on elapsed time not pump run time Because of this it is recommended t...

Page 103: ...ercise Time After the Pump Exercise Time the pump will continue to run if demand is present or will go to sleep if there is no demand Enabled Enabled On Alternation and no demand the new lead pump wil...

Page 104: ...w Ref Feedb Value is the speed value that corresponds with the low current 0 or 4mA for current references or low voltage 0V for voltage references that will be applied to the analog input The High Re...

Page 105: ...leration and deceleration in Test Run Mode Feedback setup The controller can utilize up to 3 feedback sources using the onboard IO 2 of these sources can be configured for the analog inputs AI 53 and...

Page 106: ...falls below 2mA for 4 20mA signals the Sensor Fault is issued The Sensor Fault will automatically restart according to 14 20 Reset Mode and 14 21 Automatic Restart Time The defaults for these paramet...

Page 107: ...r 22 81 Square linear Curve Approximation can be modified to adjust the control curve between a linear 0 and quadratic 100 Note that 100 quadratic is the ideal compensation curve The diagram below ill...

Page 108: ...t be enabled With the 22 82 Work Point Calculation enabled the controller will calculate the speed at the design point based on settings of some additional parameters correlating to the points shown o...

Page 109: ...the design flow to form point D 22 89 Flow at Design Point This setting corresponds to the system design flow Intersects with the pressure at rated speed to form point D and with the setpoint to form...

Page 110: ...Mode Use this parameter to prevent the pump from entering sleep mode too soon The Restart Difference 22 44 is the difference between the setpoint and the actual value that will cause the pump to resta...

Page 111: ...he Flow Check function is performed only when the pump is running A diagram showing the Flow Check function is shown below Motor speed is shown to illustrate the pump reaction to the Flow Check functi...

Page 112: ...below illustrates a typical pump power curve at the pump design flow and at no flow When the pump is operated at no flow the power consumption will follow the no flow power curve for that specific pum...

Page 113: ...tion will not operate properly The next screen prompts to close all discharge valves and to press Hand On to begin the No Flow Power Calibration process Doing this ensures the pump will operate at no...

Page 114: ...amount of time the No Water Loss of Prime alarm is issued If the No Water Loss of Prime function is disabled the pump will not be protected against running dry and or loss of prime NOTE In Duplex Con...

Page 115: ...22 31 will increase the scaling of the No Water Loss of Prime Limit 22 39 so that a No Water Loss of Prime condition is detected at a higher power The amount of increase above 100 is dependent on the...

Page 116: ...e drop in the system is due to the pump running dry or losing prime To avoid this set the Under Pressure Delay Time 22 51 longer than the No Water Loss of Prime Protection Delay 22 27 The Under Pressu...

Page 117: ...atic Restart Time 14 21 6 5 4 Digital input setup Any unused digital input can be configured as part of the Digital Input Setup A list of the digital inputs and their associated functions are shown be...

Page 118: ...g or Alarm Input See Pump Protect section to enable the Warning or Alarm associated with the input 27 5 12 0 No Operation 0 No Operation 0 No Operation Unused digital input for all models This input c...

Page 119: ...Common Common Common Common for digital inputs and reference for 24 V supply Table 29 Digital input functionality based for duplex mode Digital I O Duplex Control Mode Terminal Number Parameter Number...

Page 120: ...ad Inverse Terminal 29 is configured as an output This output is used to indicate which controller is the lead pump and which is the lag pump 32 5 14 Slave Select Slave Select When this input is high...

Page 121: ...ning Relay 1 function is programmed as array parameter 5 40 0 Relay 2 function is programmed as part of array parameter 5 40 1 Relay 1 On Delay is programmed as part of array parameter 5 41 0 Relay 2...

Page 122: ...70 Logic rule 0 71 Logic rule 1 72 Logic rule 2 73 Logic rule 3 74 Logic rule 4 75 Logic rule 5 80 SL digital output A 81 SL digital output B 82 SL digital output C 83 SL digital output D 84 SL digit...

Page 123: ...Torque limit 4 16 Torque Limit Motor Mode 0 20 mA 105 Torque 0 Tnom 0 Motor rated torque 0 20 mA 106 Power 0 Pnom 0 Motor rated power 0 20 mA 107 Speed 0 HighLim 0 Speed High Limit 4 13 Motor Speed L...

Page 124: ...be used to store or save a parameter configuration It is recommended to copy all parameters to the LCP after commissioning the controller or prior to making adjustments during troubleshooting Select Y...

Page 125: ...n for details Run this procedure on a cold motor for best result NOTE The AMA algorithm does not work when using PM motors To run AMA 1 Press Main Menu to access parameters 2 Scroll to parameter group...

Page 126: ...wer ON but before operating the frequency converter 1 Press Main Menu twice on the LCP 2 Use the navigation keys to scroll to parameter group 0 Operation Display and press OK Figure 91 Main menu 3 Use...

Page 127: ...rs 1 20 1 21 to 1 25 The information can be found on the motor nameplate 1 1 20 Motor Power kW or 1 21 Motor Power HP 1 22 Motor Voltage 1 23 Motor Frequency 1 24 Motor Current 1 25 Motor Nominal Spee...

Page 128: ...oltage generated by a PM motor when no drive is connected and the shaft is turned externally Back EMF is normally specified for nominal motor speed or for 1000 RPM measured between two lines If the va...

Page 129: ...tor rotation Before running the frequency converter check the motor rotation The motor will run briefly at 5 Hz or the minimum frequency set in 4 12 Motor Speed Low Limit Hz 1 Press Quick Menu 2 Scrol...

Page 130: ...ion programming to be completed Application set up examples are intended to help with this task Other aids to application set up are listed in 1 2 Additional Resources The following procedure is recom...

Page 131: ...pped that is the frequency converter suspends operation to prevent frequency converter or system damage The motor will coast to a stop The frequency converter logic will continue to operate and monito...

Page 132: ...us indicator lights Figure 98 Status indicator lights Table 31 Status indicator lights explanations Warning LED Alarm LED Warning On Off Alarm Off On Flashing Trip Lock On On Flashing Warnings Alarm m...

Page 133: ...before an alarm is issued This is possible for instance in 1 90 Motor Thermal Protection After an alarm or trip the motor continues to coast and the alarm and warning flash Once the problem has been...

Page 134: ...X X 30 Motor phase U missing X X X 4 58 Missing Motor Phase Function 31 Motor phase V missing X X X 4 58 Missing Motor Phase Function 32 Motor phase W missing X X X 4 58 Missing Motor Phase Function...

Page 135: ...4 30 Motor Feedback Loss Function 62 Output Frequency at Maximum Limit X 63 Mechanical Brake Low X 2 20 Release Brake Current 64 Voltage Limit X 65 Control Board Over temperature X X X 66 Heat sink Te...

Page 136: ...5202 92 No Flow X X 22 2 No Flow Detection 93 No Water Loss of Prime North America Dry Pump International X X 22 2 No Flow Detection 94 Under pressure X X 22 5 95 Broken Belt X X 22 6 96 Start Delayed...

Page 137: ...sensor X X 246 Pwr card supply 247 Pwr card temp X X 248 Illegal PS config X X 250 New spare parts X 251 New Type Code X X X Dependent on parameter 1 Cannot be Auto reset via 14 20 Reset Mode A trip i...

Page 138: ...tion matches the reference sign Profibus OFF1 active 3 00000008 8 Ctrl Card Temp A65 ServiceTrip reserved Ctrl Card Temp W65 reserved Slow Down slow down command active e g via CTW bit 11 oe DI Profib...

Page 139: ...Warning Out of Speed Range Freeze Output 15 00008000 32768 AMA not OK reserved No Motor W3 Auto DC Braking OVC Active Jog Request 16 00010000 65536 Sensor Fault A2 reserved Sensor Fault W2 AC Brake Jo...

Page 140: ...Mech brake low A63 Dangerous failure A72 Extended Status Word Protection Mode 7 4 Warnings and alarms Table 35 Warnings and alarms Warning Alarm Description Cause Remedy 1 10 V low The control card vo...

Page 141: ...s connected If no 24 VDC backup supply is connected the frequency converter trips after a fixed time delay The time delay varies with unit size Check that the supply voltage matches the frequency conv...

Page 142: ...p time If the generator torque limit is exceeded during ramp down extend the ramp down time If torque limit occurs while running possibly increase the torque limit Be sure the system can operate safel...

Page 143: ...uirements 18 Start failed The speed has not been able to exceed 1 77 Compressor Start Max Speed RPM during start within the allowed time set in 1 79 Compressor Start Max Time to Trip This may be cause...

Page 144: ...heatsink temperature The trip and reset points are based on the frequency converter power size Check for the following conditions Ambient temperature too high Motor cable too long Incorrect airflow c...

Page 145: ...or overload of digital output on X30 7 For X30 6 check the load connected to X30 6 or remove short circuit connection Check 5 32 Term X30 6 Digi Out MCB 101 For X30 7 check the load connected to X30 7...

Page 146: ...r are outside of the acceptable range AMA will not run 56 AMA interrupted by the user The AMA has been interrupted by the user 57 AMA timeout Try to restart AMA again Repeated restarts may overheat th...

Page 147: ...er operating at high speed may indicate a the pump is out of water or has lost prime 22 26 No Water Loss of Prime Function North America Dry Pump Function International is set for alarm The 22 39 No W...

Page 148: ...issing motor With a frequency converter operating multi motors an under load condition was detected This could indicate a missing motor Inspect the system for proper operation 204 Locked rotor With a...

Page 149: ...e display continues to cut out follow the procedure for display dark Motor not running Service switch open or missing motor connection Check if the motor is connected and the connection is not interru...

Page 150: ...ts Open power fuses or circuit breaker trip Phase to phase short Motor or panel has a short phase to phase Check motor and panel phase for shorts Eliminate any shorts detected Motor overload Motor is...

Page 151: ...encies by using parameters in parameter group 4 6 Speed Bypass Check if noise and or vibration have been reduced to an acceptable limit Turn off over modulation in 14 03 Overmodulation Change switchin...

Page 152: ...tinuous at 460 480V A 183 231 291 348 427 Maximum cable size line power motor brake and load share mm2 AWG2 2 x 70 2 x 2 0 2 x 150 2 x 300 mcm Maximum external pre fuses A 1 300 350 400 500 630 Estima...

Page 153: ...4 0 98 Output frequency 0 600 Hz Heatsink Overtemp trip 230 F 110 C Power card ambient trip 154 4 F 68 C Table 39 Line power supply 525 690 V AC Three Phase 150 to 300 HP Frequency Converter Type Desi...

Page 154: ...osure IP54 D7 D7 E1 Enclosure IP20 IP00 D4 D4 E2 Enclosure 3R D2 D2 Output current Continuous at 550 V A 360 418 470 Intermittent 60 sec overload at 550 V A 396 460 517 Continuous at 575 690 V A 344 4...

Page 155: ...A 498 568 Continuous KVA at 575 V KVA 498 568 Continuous KVA at 690 V KVA 598 681 Maximum input current Continuous at 550 V A 504 574 Continuous at 575 V A 482 549 Continuous at 690 V A 482 549 Maximu...

Page 156: ...g on output Unlimited Ramp times 0 01 3 600 s 1 Voltage and power dependent Torque characteristics Starting torque constant torque maximum 110 for 60 s1 Starting torque maximum 135 up to 0 5 s1 Overlo...

Page 157: ...resistance Ri Approximately 10 k Maximum voltage 20 V Current mode Switch A53 I fixed Switch A54 I right position Current level 0 4 to 20 mA scaleable Input resistance Ri Approximately 200 Maximum cur...

Page 158: ...69 The RS 485 serial communication circuit is functionally seated from other central circuits and galvanically isolated from the supply voltage PELV Digital output Programmable digital pulse outputs 2...

Page 159: ...oad AC 1 1 on 45 NO resistive load 400 V AC 2 A Maximum terminal load AC 15 1 on 45 NO inductive load cos 0 4 240 V AC 0 2 A Maximum terminal load DC 1 1 on 45 NO resistive load 80 V DC 2 A Maximum te...

Page 160: ...re during full scale operation 32 F 0 C Minimum ambient temperature at reduced performance 14 F 10 C Temperature during storage transport 13 149 158 F 25 to 65 70 C Maximum altitude above sea level wi...

Page 161: ...1500 3500 380 480 V type gG 4000 6000 380 480 V type gR UL compliance The fuses below are suitable for use on a circuit capable of delivering 100 000 Arms symmetrical 240 V 480 V 500 V or 600 V depen...

Page 162: ...URD32D08A0550 A070URD32KI0550 3500 170M4015 20 620 31 550 6 9URD32D08A0550 A070URD32KI0550 4000 170M4015 20 620 31 550 6 9URD32D08A0550 A070URD32KI0550 Table 46 Frame size E 525 690 V Size type Bussma...

Page 163: ...183 300 250 2000 200 251 231 350 300 2500 250 304 291 400 3000 300 381 348 500 450 3500 350 463 427 600 4500 450 590 531 800 700 5000 500 647 580 1000 800 5500 550 733 667 1000 6000 600 787 718 1000 T...

Page 164: ...00 350 339 2 1235 1459 1751 4000 400 390 2 1268 1522 4500 450 434 4 962 1214 1532 1930 2279 2736 3197 3656 4549 5000 500 482 4 866 1093 1380 1738 2052 2463 2879 3292 4096 6000 600 549 4 959 1211 1526...

Page 165: ...4 2 1217 1437 1726 4000 400 400 2 1236 1484 4500 450 450 4 928 1170 1478 1861 2198 2638 3084 3526 4387 5000 500 500 4 835 1053 1330 1675 1978 2374 2775 3174 3948 6000 600 570 4 924 1167 1470 1735 2083...

Page 166: ...Ramp Time 3 81 Quick Stop Ramp Time 3 82 Starting Ramp Up Time 3 9 Digital Pot Meter 3 90 Step Size 3 91 Ramp Time 3 92 Power Restore 3 93 Maximum Limit 3 94 Minimum Limit 3 95 Ramp Delay 4 Limits War...

Page 167: ...ort Config 12 98 Interface Counters 12 99 Media Counters 13 Smart Logic 13 0 SLC Settings 13 00 SL Controller Mode 13 01 Start Event 13 02 Stop Event 13 03 Reset SLC 13 1 Comparators 13 10 Comparator...

Page 168: ...y are warranted only for the balance of the warranty period on the parts that were repaired or replaced Seller shall have no warranty obligations to Buyer with respect to any product or parts of a pro...

Page 169: ...repaired by third parties other than Seller or without Seller s written approval b subject to misuse misapplication neglect alteration accident or physical damage c used in a manner contrary to Selle...

Page 170: ...he dealer from whom you purchased the product or visit www xyleminc com for the name and location of the nearest dealer providing warranty service 10 Product warranty 168 Aquavar Intelligent Pump Cont...

Page 171: ......

Page 172: ...hnologies and advanced analytics solutions for water electric and gas utilities In more than 150 countries we have strong long standing relationships with customers who know us for our powerful combin...

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