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Aquavar® IPC

APPLICATION GUIDE

INSTRUCTION MANUAL

IM298

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Summary of Contents for CentiPro Aquavar IPC

Page 1: ...Aquavar IPC APPLICATION GUIDE INSTRUCTION MANUAL IM298 ...

Page 2: ...missioning 4 Single Pump Control Wiring 9 Duplex Programming and Commissioning 14 Duplex Control Wiring 17 Performing the No Flow Power Calibration 19 List of all IPC Genie Parameter Numbers 24 Speed Control Setup 26 Duplex Troubleshooting Guide 28 IPC Question and Answers 30 Support Contact Information 36 ...

Page 3: ...power wiring to terminals L1 L2 and L3 For dedicated single phase input drives Connect single phase power wiring to L1 L2 Input Terminals WIRING OUTPUT WIRING TO MOTORS Connect output motor wires to terminal block labeled U V W Apply power Ground 1 Phase Power Input 91 L1 92 L2 93 L3 95 PE ...

Page 4: ...ower on drives 2 Complete Programming Transducer fault will be present as your control wiring is not installed It is OK to continue to program 3 Power down both drives and then install control wiring Follow wiring illustration later in this guide Select Quick Menu Select Parameter 04 Start Up Genie You are now able to start the Start Up Genie ...

Page 5: ...Language and proceed with the down arrow Select YES to run the Start Up Genie and proceed with the down arrow Select Motor from Setup Selection Reference motor nameplate Select Motor Horsepower Select Motor Voltage Select Motor Frequency Select Motor Nominal Speed ...

Page 6: ...A is 11 42 FLA is 10 38 Current Limit 11 42 10 38 1 100 Carry over the decimal 2 places to the right to ensure your Current Limit percentage For Submersible motors we input SFA and use current limit at 100 Select Motor Type Select Sleep Frequency Low Limit Select Yes to Continue to the Application Setup ...

Page 7: ...gle pump application below Duplex Programming continues on page 13 Select Constant Pressure for Application type Select PSI for pressure control units Select Ramp Time Fast 5 sec accelerate 3 sec decelerate Medium 10 sec accelerate 5 sec decelerate Slow 20 sec accelerate 10 sec decelerate FOR SINGLE PUMP COMMISSIONING ...

Page 8: ...Sleep Mode Enabled Sleep Frequency 30 Hz Restart Difference 5 unit No Water Loss of Prime Fault Enabled No Water Loss of Prime Restart Time 10 min Select Setpoint 1 Proceed with the down arrow on the next two screens as you are verifying that your Pressure Transducer is a 300 PSI you are wired in on Analog Input 53 that your sleep frequency is 30 Hz and your restart difference is 5 the No Water lo...

Page 9: ...erminal 12 and 18 The IPC has been configured to require a start command on terminal 18 To apply a start signal connect a jumper wire between terminals 18 DI 18 parameter 5 10 and 12 24V dc A start command is given to the controller when terminal 18 is connected to 24V Terminal 29 and 32 This jumper allows the drive to automatically restart in the event of a no water loss of prime SINGLE PUMP CONT...

Page 10: ...k Pump and Motor Rotation by selecting Hand On If motor is running backwards power down drive wait five minutes and rotate motor wires from the drive Once rotation is verified select Off Select Auto On Verify Unit cycles into sleep mode at desired PSI ...

Page 11: ...Perform No Flow Power Calibration Select Quick Menu Select 04 Startup Genie Change Setup Selection to Pump Protection PERFORMING THE NO FLOW POWER CALIBRATION Select Enable for sleep mode Select 30 Hz for Sleep Frequency 3 Seconds for Sleep Delay ...

Page 12: ...ar IPC Start Up Genie CentriPro Select 10 for Restart difference 1 Select 3 Seconds for Minimum Run Time 10 Seconds for Minimum Sleep Time Select 0 PSI for Flow Check Window Select 10 Seconds for Flow Check Low Time ...

Page 13: ...d to withstand the suction pressure plus shutoff head pressure produced by the pump prior to starting the calibration process Follow all onscreen instructions carefully Close outlet valve before starting The drive will now run through steps 1 4 Once the calibration is completed select OK and the down arrow to proceed Run Some Production and verify that the drive is starting and cycling into sleep ...

Page 14: ...l wiring until programming is completed Press Ok to continue your programming Select psi for Pressure control units Select Ramp Time Fast 5 sec accelerate 3 sec decelerate Medium 10 sec accelerate 5 sec decelerate Slow 20 sec accelerate 10 sec decelerate DUPLEX PROGRAMMING ...

Page 15: ...ack 300 unit Transducer Type 4 20mA Feedback 1 Source AI 53 Sleep Frequency 30 Hz Restart Difference 5 unit No Water Loss of Prime Fault Enabled Duty Standby Disabled Lag Start Frequency 59 Hz Lag Stop Frequency 35 Hz Alternation Enabled Alternation Time 24 Hrs Pump Exercise Time 0 s Disabled Select Set point PSI Cycle through these three screens and then press OK You can now power off both drives...

Page 16: ... part 9K706 3 ft or 9K707 6 ft DIP SWITCH SELECTION Simplex Requires no action Dipswitch is correct position for 4 20MA Transducer Feedback Duplex Requires Analog 54 dipswitch to be moved over on BOTH drives To move dip switch follow these instructions 1 Remove Keypad 2 Carefully move Dipswitch A54 to the right to the I position on BOTH drives Please use care and do not break the switch Move it un...

Page 17: ...0 to Drive 2 Digital I O 20 Green Drive 1 Digital I O 29 to Drive 2 Digital I O 32 Brown Drive 1 Digital I O 32 to Drive 2 Digital I O 29 Orange Drive 2 Digital I O 13 to Drive 2 Relay 04 Internal Jumper Drive 1 Drive 2 YELLOW BROWN BROWN BLUE WHITE WHITE WHITE GREEN BROWN VIOLET JUMPER TO RUN JUMPER TO RUN BLACK ORANGE RED Analog I O 39 42 50 53 54 55 COM A OUT 10V A IN A IN COM Digital I O 12 13...

Page 18: ...is in 3 3 in upper right corner 1 Check both Pumps and Motors Rotation by selecting Hand On CAUTION If motor is running backwards power down drive wait five minutes and rotate motor wires from drive Switch any two of the motor wires labeled U V or W 2 Once rotation is verified select Off 3 Select Auto On Verify Unit cycles into sleep mode at desired PSI ...

Page 19: ...ovides the method to program the no flow power curve in to the controller In order to detect a no flow condition for the various pump s the no flow power curve needs to be programmed in to the drive Select Quick Menu Select 04 Startup Genie Change Setup Selection to Pump Protection Select Enable for sleep mode ...

Page 20: ...or Sleep Frequency 3 Seconds for Sleep Delay Select 10 for Restart difference 1 Select 3 Seconds for Minimum Run Time Select 10 Seconds for Minimum Sleep Time Select 0 PSI for Flow Check Window Select 10 Seconds for Flow Check Low Time NO FLOW POWER CALIBRATION ...

Page 21: ...ration Process requires the pump to be operated at no flow This can produce high pressure within the system Ensure the system piping and components are designed to withstand the suction pressure plus shutoff head pressure produced by the pump prior to starting the calibration process Close outlet valve before starting The drive will now run through steps 1 4 Once the calibration is completed selec...

Page 22: ...Up Genie CentriPro NO FLOW POWER CALIBRATION You will now need to run the no flow power calibration on the lag pump drive as well You will need to change the Lead pump position over to the lag pump Select Auto ON for both drives ...

Page 23: ...he same procedure for the no flow power calibration once again for this drive page 19 Once you have the no flow power calibration completed run some tests to verify they are cycling on and off and changing positions by selecting the OK and right arrow key together For troubleshooting please refer to IM290R00 Duplex Troubleshooting guide page 28 Refer to IM287 to access and change specific Genie pa...

Page 24: ...ing Delay 25 24 Duplex Control Duty Standby 5 13 5 31 Lag pump start frequency 5 4 5 40 0 5 40 1 5 41 0 5 41 1 Alternation 25 50 Smart Logic 13 44 0 Alternation Time 25 52 Smart Logic 13 20 0 Pump Exercise Time 22 40 Start Delay 1 71 Speed Control Speed Reference Source 6 Select the AI 53 or 54 you want to use and Volts or Amps Terminal 53 Low Ref Feedback 6 14 Terminal 53 High Ref Feedback 6 15 M...

Page 25: ...oss of Prime Restart 22 26 No Water Loss of Prime Protection Delay 22 27 Under Pressure Function 22 50 Under Pressure Delay Time 22 51 Under Pressure Difference 22 52 Setup Protection Through Digital Input 19 5 11 Setup Pump Protection Trough Digital Input 27 5 12 Pump Protect Delay 22 00 Digital Input Terminal 19 Digital Input 5 11 Terminal 27 Digital Input 5 12 Terminal 29 Digital Input 5 13 Ter...

Page 26: ...Genie SETTING UP THE INTELLIGENT PUMP CONTROLLER TO RUN IN SPEED CONTROL IM295 The Intelligent Pump Controller can be configured for speed control through an analog input The controlling source can be either an external control device such as a PLC BMS Building Management System or potentiometer The output from the external control device can be either a voltage or current output signal Set the an...

Page 27: ...10V DC Input Application No function for on Fixed Speed Application The next two screens will verify that you have your dip switches setup correctly Input your Motor low reference value 0 and High reference Value 60 0 This is the scaling from your input signal either a 4 20MA or 0 10VDC For either a 4 20MA or 0 10VDC application please select Minimum speed at 0 Hz and Maximum speed to 60 Hz For fi...

Page 28: ... force is applied U 0 10 VDC I 4 20MA Switches are located behind the keypad FIGURE 1 Analog Input Dip Switches 2 If you had the wiring in place when first programming then the drives should be re initialized and reprogrammed This is a painless and easy step to perform a Power down the drives Remove the wiring terminal blocks from the drives b Perform a factory reset by holding the Status Main Men...

Page 29: ... Digital I O 20 to Drive 2 Digital I O 20 GREEN Drive 1 Digital I O 29 to Drive 2 Digital I O 32 BROWN Drive 1 Digital I O 32 to Drive 2 Digital I O 29 ORANGE Drive 2 Digital I O 13 to Drive 2 Relay 04 Internal Jumper Drive 1 Drive 2 YELLOW BROWN BROWN BLUE WHITE WHITE WHITE GREEN BROWN VIOLET JUMPER TO RUN JUMPER TO RUN BLACK ORANGE RED Analog I O 39 42 50 53 54 55 COM A OUT 10V A IN A IN COM Dig...

Page 30: ...tection page 32 12 How does No Flow Power Calibration work is this based on Horsepower page 32 13 Can I use single phase input power page 33 14 Can you program the IPC without having the IPC connected to a motor page 33 15 My display is showing 320 PSI I have no pressure in the line page 33 16 Why does the drive get to the set point and not shut down page 33 17 Why am I getting a W59 error when my...

Page 31: ... see the Smart Start 3 ANSWER You may have changed this accidentally during intimal programming Go into the Main Menu Select 0 Operation Display and Select 0 0 basic Settings and 0 01 Language If you see 0 English change this to 122 ENGLISH US Go back into the Quick Menu and 4 should list the Start Up Genie 4 QUESTION Can the IPC run more than one pump 4 ANSWER The IPC can operate in duplex mode t...

Page 32: ...rotation In Hand Mode you can select the frequency and speed you would like the motor to run manually and to also check your rotation 9 QUESTION Can I change between Two Set Points remotely 9 ANSWER Wire your external switch on DI33 terminal to change the set points When you program 2 set points in Startup Genie the logic will auto configure DI33 for the 2 set point functionality DI33 Closed Set p...

Page 33: ...hy does the drive get to the set point and not shut down 16 ANSWER There are a number of things to check if the controller is not turning off the pump and the motor Verify you have installed a spring check valve before the transducer on the discharge side of the system Please make certain that you have properly sized and pre charged your bladder tank Use the 20 20 rule 20 of Max Flow GPM for sizin...

Page 34: ...ON The drive is constantly restarting once it cycles off 23 ANSWER Please check your system for leaks a faulty check valve required bladder tank setting 20 PSI below your shutoff or a constant demand You can also adjust the restart difference in the startup Genie for longer cycle times 24 QUESTION Is there a way I can reset the drive back to factory defaults 24 ANSWER Yes Simply power off the driv...

Page 35: ...88 Accessory Bag Frame Size B1 9K689 Accessory Bag Frame Size B2 9K690 Accessory Bag Frame Size B3 9K691 Accessory Bag Frame Size B4 9K692 Accessory Bag Frame Size B4 Large 9K693 Accessory Bag Frame Size C1 9K694 Accessory Bag Frame Size C2 9K695 Accessory Bag Frame Size C3 9K696 Accessory Bag Frame Size C4 Small 9K697 Accessory Bag Frame Size C4 Large 27 QUESTION I have a Duplex setup and my lag ...

Page 36: ... com 315 239 7041 Matt Renn Fresno CA matt renn xyleminc com 559 265 4730 Alfredo Leal Orlando FL Field Service Engineer alfredo leal xyleminc com 407 773 2576 cell Julie Falsey Seneca Falls NY julie falsey xyleminc com 315 239 2389 office Xylem Inc 2881 East Bayard Street Ext Suite A Seneca Falls NY 13148 Phone 866 325 4210 Fax 888 322 5877 www centripro com CentriPro is a trademark of Xylem Inc ...

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