Smart Pump
Multizone Installation &
Start Up Manual
Commercial Flow Center Series
866-646-6724
712-652-3424
www.bdmfginc.com
ALL THE PUMP YOU NEED AND MORE
Product Data
System Introduction –
For applications that require a little more than it’s
Multizone cousin can provide, the Smart Pump
Multizone utilizes the latest in “Variable Speed
Technology”. Designed for the high end residential or
commercial application, the Smart Pump Multizone
can be used with single phase power to keep things
simple. With no added controls to complicate your
system, the Smart Pump Multizone is very user
friendly, easy adjustable and customized for your
source side geothermal systems.
Efficient Operation –
When you look at pump motor efficiency, you will
notice that the smaller the motor, the less efficient
its operation. The Smart Pump Multizone utilizes
efficient motor technology with its one single motor.
In fact, less horse power will be used with a single
pump/motor combination, verses several small
circulators for your multizone heat pump system .
Installation Simplicity –
With only one pump and motor to install, contractor
installation time is reduced. All the work consis ts of:
setting the GT canister, mounting the pump to the
provided flange, mount the motor to the pump,
mount the variable speed drive unit on the adjacent
wall and the electrical power. Its that simple and
your system will be ready to run.
Competitive Installed Costs –
When you look at the cost of purchasing and
installing several pumps, switching to the Smar t
Pump Multizone will save more than just energy.
Maintenance Simplicity –
The Smart Pump Multizone utilizes one of the
industries most popular in-line circu lators. This
bullet proof pump is very reliable, howev er in the
event of a pump failure, parts and qualified
technicians are readily available.
Sealable Lid –
Provides for a closed, sealed system, while allowing for
ease of access to sample fluid and measure flow rate.
Inlet Connection –
Stainless Steel MPT connection is provided as
standard, with various transitions available upon
request. Size based on canister size (see chart —
Smart Pump Multizone Dimensions).
Check Valve –
Provided before the pump, assuring proper flow and
reliable pump operation.
Canister –
Provides a standing column of water on the suction
side of the pump to insure a flooded volute and
reliable pump operation. Size required is based on
max load design flow rate.
Optional Isolation Valve –
An isolation valve is available on the pump
discharge for ease of maintenance (not shown).
Variable Speed Pump Control –
The Smart Pump drive is robust and designed to
operate in some of the harshest conditions.
Insulation –
3/8” Armaflex insulation, factory provided, to
prevent condensation.
Dimensions –
D
P
H
Smart Pump Multizone Dimensions (in)
Size H D
B 62 12 2 17.5
C 70 12 3 20.8
D 70 14 4 29.5
2
P
(IPT)
ALL THE PUMP YOU NEED AND MORE
Volume
(gal)
Revised 7-5-12
Product Data
Performance Curve –
Head
Pump Information –
FT
120
100
80
C
R
60
40
20
0
0 20 40 60 80 100 120 140 160 180 200
1
CR 45-1-1
C
R
4
5
-
1
-
1
C
R
3
2
-
0
-
2
GPM
C
R
1
3
2
-
1
-
1
Pump Model
CR 10-2 45 66 0-55 30
CR32-1-1 140 76 0-180 35
CR32-1 140 76 0-180 35
CR45-1-1 180 78 0-200 39
Nominal
Flow Rate
Maximum
Pump Efficiency
(%)
Flow Range
(GPM)
Max Operating
Pressure
(PSI)
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ALL THE PUMP YOU NEED AND MORE
Revised 7-5-12
Installation
Installation Guidelines & Procedures for B & D MFG., INC.
Smart Pump Multizone Flow Center
SAFETY INSTRUCTIONS:
This safety alert symbol will be used in this manual to draw attention to safety
related instructions. When used, the safety alert symbol means: ATTENTION!
BECOME ALERT! YOUR SAFETY IS INVOLVED!
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN A SAFETY HAZARD.
WARNING: Electrical shock and potential circ uit damage. Disconnect power supply
before beginning installation. Fail ure to follow these instructions could resu lt in serious
personal injury or death and property damage.
WARNING: Improper wiring (including wire used) can cause electric shock and/or fire.
Wiring connections must be made in accordance with all applicable electric codes/
ordinances. Use copper wire only. Failure to f o llow these instructions could result in serious
personal injury, death and/or prope r ty damage.
Electrical Service & Connections –
The Smart Pump Multizone Flow Center requires a dedicated 240 volt single phase circuit. W ir e and fuse sizes
shall be in accordance with local codes and that of the National Electric Code. Low voltage wiring must be
isolated from primary voltage lines and connecti ons.
Maximum Rated Amperage of Yaskawa VFD –
Input Voltage: 1x230V
Output Voltage: 3x230V
2HP & 3 HP Drive (0012): 12 Amps
5HP (0018): 17.5 Amps
Stop Function –
The system must be able to maintain a static pressure between the solenoid valves and the check valve before
the pump. If the system is not able to maintain this static pressure, then the system will not have a stop
function. This can be done by allowing continuous flow through the smallest heat pump and still allowing the
solenoid valves to close on all other heat pump s to reduce the flow. resulting in less energy consumption.
(refer to diagram on page 13)
Flow Center Canister Placement Requirement –
A level location with 36" of clearance around the canister is required. This allows enough room to hook-up the
CR series pump and associated piping. An allowance for 36" of clearance on the top of the canister (between
lid and ceiling) for insertion of an optional flow meter tool and system fluid access.
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ALL THE PUMP YOU NEED AND MORE
Revised 7-5-12
Installation
WARNING: It can be extremely dangerous to touch the electrical parts, even when the
main supply has been disconnected. Wait at least four minutes after the input power has
been removed before servicing the V10 00.
Variable Speed Drive Placement Requirements –
Install the drive upright as illustrated to maintain proper cooling.
Minimum Clearance Dimensions –
A = 1.25”
B = Airflow Direction
C = 4”
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Revised 7-5-12
Installation
Installation Recommendations –
It is recommended that an isolation valve be installed on the discharge side of the pump. This will allow
for ease of service and can also aid in the start up procedures.
All pipe, valves and fittings should be at least the same diameter as the discharge pipe or sized in
accordance with good piping practices to reduce excessive fluid velocities and pipe friction losses.
Before the pump is installed, it is recommended that the disc harge piping be pressure checked to at least
40 psi or as required by codes and local r egulations.
Whenever possible avoid high pressure loss fittings, such as elbows or branch tees.
It is recommended that the discharge pipe is ten pipe diameters in length bef ore the nearest fitting.
The piping should be adequately supported to reduce thermal and mechanical stresses on the pump.
Good installation practice recommends that the sy stem be thoroughly cleaned and flushed of all foreign
materials and sediment prior to pump installat ion.
It is recommended to adequately support all elbows and tees immediately after pump connection. Excess
turbulence can be created when pipe fittin gs are installed close to the pump discharge, causing vibration
or movement if not properly supported.
Unpacking Instructions –
The CR pump end will ship separate from the motor. The seal is not installed, due to the potential damage that
may be caused during shipping to the ceram ic f a ce. There is a white teflon support bushing ho lding the pump
shaft stationary. The seal carrier must be taken off the pump and the white teflon support bushing must be
removed prior to installation.
Located the box with the shaft seal & follow instructions in the shaft seal box .
Proceed to the next step.
Motor/Pump Assembly –
1. Remove key from motor shaft, if present, and
discard.
2. Thoroughly clean the surfaces of the motor and pump
end mounting flange. The motor and shaft must be
clean of all oil/grease and other contaminants where
the coupling attaches. Set the motor on the pump
end.
3. Place the terminal box in the desired pos ition by
rotating the motor.
4. Insert the mounting bolts, then tighten in a cross
pattern evenly. For 3/8” bolts (2 HP) torque to 17 ft.lbs., for 1/2” bolts (3 to 5 HP) torque to 30 ft.-lbs.
WARNING: Be sure to anchor piping properly as two-way control valves may cause water
hammer resulting in excessive pipe movement. Possi ble pump and pipe damage may
occur if the system is not properly anchored.
WARNING: The following instructions are specific for the pump noted. Please take note of
the pump being installed. Pump model is designated as CR__-_ (i.e. CR31-1).
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Revised 7-5-12
Installation
CR 32 & 45 –
1. Place the plastic adjustment fork under
the cartridge seal collar (see Figure 7) .
2. Fit the coupling on the shaft so that the
top of the pump shaft is flush with the
bottom of the clearance chamber in the
coupling (see Figure 8).
3. Lubricate the coupling screws with an
anti-seize and lubricating compound.
Tighten the coupling screws (finger tight)
while keeping the coupling separation
equal on both sides and the motor shaft
keyway centered in the coupling as shown
in Figure 6a (page 6).
4. When the screws are tight enough to keep
the couplings in place, then torque the
screws evenly in a crisscross pattern.
Torque coupling screws to 62 ft.-lbs.
5. Remove the adjustment fork from under
the cartridge seal collar and replace it to
the storage location (see Figure 9).
6. Check to see that the gaps between the
coupling halves are equal. Loosen and
readjust if necessary.
7. Be certain that the pump shaft can be
rotated by hand. If the shaft cannot be
rotated, or it binds, disassemble and
check for misalignment.
WARNING: CFC_ Multizones are a non-pressurized unit and should NEVER be pressur ize d
for any reason.
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ALL THE PUMP YOU NEED AND MORE
Revised 7-5-12
Electrical Wiring Information
Electrical Installation –
It is the responsibility of the installer to ensure
correct grounding and protection in accordance with
national and local standards.
WARNING:
dangerous whenever the drive is connected to
AC power. Incorrect installation of the motor or
drive may cause damage to the equipment,
serious injury or even death. Comply with safety
instructions in this manual, as well as local and
national safety regulations. Touching electrical
parts may be fatal even after equipment has
been disconnected from the AC power. Wait at
least four minutes for current to dissipate.
The voltage of the V1000 is
V1000 Main Wiring –
The Smart Pump variable speed drive is ca pable of
taking standard, single phase 230 volt power and
converting it to three phase power to run the Ba ldor
motor. Single phase 230 volt power shall be
connected to terminals R-L1 and S-L2 as shown in
Figure 1b.
The drive has a high leakage current and must be
grounded properly for safety. Keep all grounding
cables as short as possible. Follow all local and
national safety regulations.
Motor Wiring –
All of the Baldor motors are three phase motors
capable of running on either 208-230 voltage or 460
voltage. B & D Mfg, Inc’s Smart Pump Multizone
must be wired for low voltage 208-230 volt power.
Remove wire box cover and follow the wiring
schematic for LOW VOLTAGE as the V1000 variable
speed drive will provide three phase 23 0 voltage to
the motor. Take extra precaution as all the wires are
color coded and are labeled with the appro priate
numbers. Motor wire connections L1, L2 and L3 are
to be connected to the V1000 variable speed
terminals. The motor “L” line connections shall be
connected to the drive as follows L1-U, L2-V, L3-W
(See Figures 1a & 1b). Follow the wiring diagram on
the motor label for the correct motor wiring
combination which matches 230 supply voltage.
Once this has been confirmed, reconnect the power
supply wiring to the motor. Check the direction of
rotation by bump-starting the motor (Refer to Start
Up Procedure on page 12). Rotation must be left to
right (counter-clockwise) when looking directly at
the coupling. Shut off the power, then re-install the
coupling guards. After the coupling guards have
been installed, the power can be turned back on.
Pressure Transducer Wiring –
The pump mounted pressure transducer shall be wired
on the control terminal block to positions +V an d A2
(See Figure 1c).
“+V” = Brown & “A2” = Black
Figure 1a
Figure 1b
NOTE:
S1, SC & HC, H1
are factory provided
jumper wires.
Figure 1c
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Revised 7-5-12
Drive Display/Operation
No. Display Name Function
1
2
3
4
5
6
7
8
Data Display Area Displays the frequency reference, parameter number, etc.
ESC Key Returns to the previous menu.
RESET Key
RUN Key Starts the drive.
Up Arrow Key Scrolls up to select parameter numbers, setting values, etc.
Down Arrow Key Scrolls down to select parameter numbers, setting values, etc.
STOP Key
ENTER Key
Moves the cursor to the right.
Resets the drive to clear a fault situation.
Stops the drive.
Note:
Stop priority circuit. A fast stop is available by pressing the STOP key when
the drive detects a danger, even if the drive is running by a signal from the multifunction contact input terminal (REMOTE is set). To avoid stoppage by using the
STOP key, set o2-02 (STOP Key Function Selection) to 0 (Disabled).
Selects all modes, parameters, settings, etc.
Selects a menu item to move from one display screen to the next.
9
RUN Light Lit while the drive is operating the motor.
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Revised 7-5-12
Drive Display/Operation
Navigating and Changing Drive Parameters –
The start screen on the LED will be a frequency reference. This will show the operating frequency of the drive.
NOTE: Drive must be on this screen to start operation.
Pressing the up arrow
drive.
Displays “For” on the LED. This indicates the drive will turn the motor in a forward direction only.
NOTE: If the drive is NOT ABLE to produce pressure greater than 20 psi, the motor could be wired
incorrectly. Check motor rotation to verify. Rotate any two of the three motor leads for terminals U,
V & W on the drive to correct rotation.
Displays the output frequency of the drive to the motor.
Displays the output amps to the motor.
Displays the output voltage to the motor.
Displays “Mon” for Monitoring Menu. This menu displays
system operations, such as:
on the display face will allow navigation for multiple levels of information on the
Real-time output power of drive (kW): U1-08
Current fault : U3-01
Previous fault: U3-02
Accumulated operation time (hrs): U4-01
Total power consumption (kW): U4-10
Sensor feedback level: U5-01
Displays “STUP”, referring to the Set Up Menu. This allows navigation of the four parameters that can be
adjusted. (Instruction to follow on a later page.)
B5-19 System Pressure Setting Default = 0 psi (Must be set for pump to operate.)
B5-15 Sleep Frequency Default = 25 Hz (disabled)
B5-12 Dry Run Protection Default = 0 (disabled)
B1-02 Key Pad Enabled Default = 0 (enabled)
NOTE: Pressing the ESC (escape) button allows the drive menu to go back one step.
NOTE: The drive will not allow operation unless the start screen is displayed (frequency reference).
This screen can be displayed by pressing the ESC key several times.
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Revised 7-5-12
System Start Up Procedure
Figure 2
Fill canister water level to dip tube elbow.
Pressure Relief Valve
Must stay open during all purging processes.
Sensor assembly at any of
the locations on the pump.
Pump isolation valves
**Valve and flange adapter not included and are available as an option only**
WARNING: BE SURE THE MUTIZONE CANISTER DOES NOT RUN OUT OF WATER.
WARNING: During the purging process, the rate of flow is not equal. When air returns
to the canister you may see an overflow. You can control this by adjustin g the flow back to
the canister by a valve. Pressure relief valve must remain open until all air is purged or the
canister may collapse. Do not completely seal the caniste r fr om outsi de air during this
process.
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ALL THE PUMP YOU NEED AND MORE
Revised 7-5-12
Fill and Start Procedure
Fill and Start Procedure: Smart Pump –
NOTE: The Smart Pump Multizone is not designed to do a full system purge. You can use the flow
center to purge the interior piping by isolating the loop field and running a hose from the flush port
to the flow center below water level.
Default: “STUP” Set Up Menu
Description Parameter Default Setting
Stop Frequency B5-15 25 Hz
System Pressure B5-19 0 PSI
Dry Run B5-12 "0" Disabled
Key Pad Control of On/Off Buttons: B1-02 "0" Key Pad Enabled
Fill canister by water source unti l the water level reaches 2” below down tub e on the return of the
canister to prevent the system from being air locked. (If pump is running for several minutes and no
water is returning to canister, you may be air locked. Verify this by looking inside the ca nister to see if
water is returning to the canister.)
Open vent plug on top of pump head until air is no longer heard and a solid stream of water is viewed,
then tighten vent plug.
Apply power to drive. You will then see the home screen “u” = 0 (frequency reference).
Hit the down arrow three times until you see “STU P” (Set Up Menu), then press Enter. “APPL”
(Application Menu) will then be shown.
Hit up arrow until you see B5-19, then press Enter. Change system pressure from “0” (0000.0) to 25
psi (0025.0) by pressing the “right arro w/reset” key over to the desired integer, change the number by
hitting the up arrow to the desired 25 psi (002 5 .0), then press Enter.
The B5-19 will then be shown blinkin g.
Hit escape key two times (Home screen frequency reference “u” = 0).
NOTE: Drive will only operate on “home screen/frequency reference”.
Press the “Run” button to begin drive operation. Read the gauge pressure to ensure the pump is
creating 25 psi. If the gauge pressure is 20 psi or less, then the motor may be rotating backwards.
Disconnect power and rotate two of the three motor leads on the drive connection.
Stop the drive and continue to the next step.
Operating the Drive/System Start Up –
NOTE: Do not start the following process without a sufficient supply of clean potable water and a
person to help monitor the water level in the canister.
All valves in the system should be in the f u lly open position, with the exception of the supply and
return loop field valves after bypass, these should be in the closed position (refer to diagram on pg 13).
If using the Smart Pump Multizone to purge interior piping, then you must have a bypass after the heat
pumps, diverting water/air from supply of loop field to return of loop field (refer to diagram on pg 13).
Press “Run” button to start drive an d begin filling your system while check ing fluid level and supplying
clean potable water as necessary to keep the water level above the return down tube in canister.
When all air is purged from the interior piping, you can then open up the loop field to circulate fluid
through the entire system.
Inspect the level in the canister and run the system until th ere are no mic ro-bubbles returning to the
canister (may need up to a twenty-four hour run-time period).
Proceed to heat pump balancing an d system pressure adjustment.
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Fill and Start Procedure
LOOP BYPASS
VFD
FLOW
CTR
Heat Pump Balancing Procedure: How to set drive pressure setting –
1. After the complete piping system is purged of air, each heat pump circuit can then be balanced for proper flow.
2. Make sure all control valves are in a closed position.
3. Allow flow to the heat pump with the larges pressure drop by manually openin g the control valve.
4. Set the drive parameters B5-19 to operate at the following, based on nominal size of the complete heat pump
system (3 GPM/ton).
HEAT PUMP BYPASS
HP1
HP2
HPn
Systems 30 tons or less (set drive parameter B5- 19 to ‘15’). Drive pressure set to 15 psi.
Systems 30-60 tons (set drive parameter B5-19 to ‘18’). Drive pressure set to 18 psi.
5. Measure the pressure drop across this coil to ensure the proper flow rate.
If the flow rate is greater than required flow, then close a valve on the dedicated circuit until the desired flow
rate is reached.
If the flow rate is not to the design flow, then proceed to the next step.
6. You must hit the “STOP” button on the drive. Go to the Set Up Menu by hitting the up arrow until the LE D
shows “STUP”.
You will see the home screen “u” = 0 (frequency reference).
Hit the down arrow three times until you see “STUP” (Set Up Menu), then press Enter. “APPL” (Applic ation
Menu) will then be shown.
Hit up arrow until you see B5-19, then press Enter. Change system pressure from “0” (0015.0) to psi
(0017.0) by pressing the “right arrow/reset” ke y over to the desired integer, change the number by hitting
the up arrow to desired psi (0017.0), then press En ter.
The B5-19 will then be shown blinking
Hit escape key two times (Home screen frequency reference “u” = 0).
7. Press the “Run” button on the drive, then return to Step 5 above, to evaluate the flow rate for the one heat
pump, by pressure drop across the coil.
8. Once you ha ve reached this flow rate and this is the largest pressure drop, you can then set the remaining flow
rates of the other heat pumps. This can be done by allowing flow to the next heat pump in line, while the first
one remains running.
9. The remaining heat pumps can be adjusted for flow by restricting the flow of the water outside of the heat
pumps. You must follow the manufacturer’s recommendation for pressure drop to evaluate the flow rate
through each of the units. If you have any questions, please call your local distributor for further instructions.
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ALL THE PUMP YOU NEED AND MORE
Revised 7-5-12
System Start Up Procedure
Adjusting Sleep Function –
Parameter B5-15 in Set Up Menu “STUP”
Perform system static pressure test:
With pump running, allow all the control
valves to close.
Make note of the pressure on the liquid filled
gauge assembly.
Press the “STOP” button on the drive. Wait
between one and five minutes to see if the
system is able to hold the static pressure
between the check valve before the pump
and the control valves. If the system is not
able to hold the pressure maintained on the
drive, please refer to the troubleshooting
section of this manual (page 17).
NOTE: Use good quality 2-way control
valves that will provide a 100% closed
seal with no leakage.
If the system is able to maintain pressure,
then allow flow to the smallest capacity
(GPM) heat pump.
Setting the Dry Run Protection –
Parameter B5-12
By default the drive setting f o r Parameter
B5-12 = 0 (disabled).
Go to the Set Up Menu “STUP” and change
B5-12 = 2 (Dry Run Enabled) Refer to page
10 to navigate the drive menu. This setting
ensures that there is the proper amount of
water in the canister.
NOTE: The Dry Run Protection (B5-12 =
2) must be enabled to prevent damage
to the pump, motor and piping. This
setting will shut down the pump if the
canister were to run dry due to a leak.
Press the “RUN” button on the drive to allow
flow to the smallest unit. Make not of the
frequency (Hz) on the home screen of the
drive during this operation.
To enable the stop function, you must
change parameter B5-15 to 1-3 Hz below
the operating frequency on the smallest unit.
NOTE: The drive must be in the stop
position to make this change.
After this has been set, go back to the home
screen by pressing “ESC” key three times.
Press the “RUN” button At this point the stop
function has been set. You can cycle through
all the individual heat pumps to ensure that
the stop function is working prope rly. If the
motor is not stopping or cycling, please refer
to page 17 to troubleshoot the stop function.
NOTE: If you have any questions, please
contract your distributor.
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Revised 7-5-12
SYSTEM CHECKS
System Checks –
1. Once the system settings have been adjusted and the V1000 adjusts/reacts to the heat pump outlet
valves opening and closing, the system is ready to operate on its own.
2. Return each heat pump 2-way control valve to its normal o pe rating setting, so it is allowed to open
and close based on the heat pump status.
3. Monitor the system as it reacts to the heat pump 2-way control valves. It is recommended that each
heat pump shall manually meet its set point to allow the 2-w a y control valve to close, ensuring they
provide a 100% off position, allowing the V1000 to power down.
4. Once all the set up procedures and tests have been perf ormed, the Smart Pump Multizone can now
operate as a self contained system.
FINAL DRIVE PARAMETERS
Description Parameter Default Setting
Stop Frequency B5-15 1-3 Hz Below Minimum Operating Frequency
System Pressure B5-19 User Input (PSI)
Dry Run B5-12 "2" Enabled
Key Pad Control of On/Off Buttons: B1-02 "1" Key Pad Dis abled
(Allows memory in case of power outage.)
STOP FREQUENCY: This parameter needs to be set 1-3 Hz below minimum operating frequency for
the lowest flow rate heat pump.
SYSTEM PRESSURE: This parameter is what allows the smart pump to maintain pressure and allows
efficient operation o the geothermal system.
DRY RUN: This parameter must be set to ensure pump protection in case the canister runs dry.
KEY PAD CONTROL OF ON/OFF BUTTONS: This can be selected in the fiel d.
A. If the B1-02 = 0 the “RUN” and “STOP” buttons are ACTIVE on the drive. This is helpful
during set up.
NOTE: If the drive experiences a power loss in this mode, then the drive will have to be
manually restarted by pressing the “RUN” button.
B. If the B1-02 = 1, then the “RUN” and “STOP” buttons are DISABLED on the drive. This allows
the drive to keep its memory in case of a power loss to the drive and there’ll be no need to
restart the drive manually.
NOTE: Faults can not be reset unless the jumper between S1 and SC is cycled, or
parameter B1-02 is changed to “0”.
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Troubleshooting- Faults
Faults Description Suggestion(s)
oL1/
oL2
oC Over Current
Motor/Drive
Overload
Reason(s)
Motor/Drive current has
exceeded service factor
amps.
Motor insulation damage.
One of the motor cables
has shorted.
Load too heavy.
Pressure set too high.
Leave power to drive off for three minutes. Check to make
sure the motor coupling spins freely by hand.
System may not be balanced for flow.
Exceeding the flow rate of the pump design.
Supply voltage too low.
Meg the motor to determine the insulation resista n ce is
within specification (refer to back of manual).
Inspect the motor leads and terminal wires for exposed
shorts or grounds.
Leave power to drive off for three minutes. Check to make
sure the motor coupling spins freely by hand.
Maximum PSI Ratings:
CR32-1-1 = 30 PSI
CR32-1 = 35 PSI
CR45-1-1 = 39 PSI
FbL
OH
LF
oU Over Voltage Main out of range.
Uu Under Voltage
Feedback
Loss
Heatsink Over
Temperature
Phase Loss on
Output Side
of Drive
Transducer out of range.
Temperature limit of the
drive is exceeded.
Wiring issue.
Main out of range.
Make sure the wiring for the transducer is correct. Check
for loose wires on the connection of the transducer “+V”
and “A2”.
+V = Brown
A2 = Black
Check water level in canister.—Must have a minimum of
three feet of water above inlet.
Make sure the fan is in operation when the drive is
operating.
Make sure all leads to motor are connected to the drive
and are solid connections. Motor may be incorrect ly wired
for 3x460V, the motor MUST be wired for 3x230V.
Wire connections in motor terminal box may be loose,
double check connections.
Make sure voltage supply (1x230) to the V1000 is
between 200 and 240 volts.
Make sure voltage supply (1x230) to the V1000 is
between 200 and 240 volts.
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Troubleshooting- Stop Function
The “STOP Function” for the Yaskawa V1000 Drive is Based on Two Conditions –
1. When all solenoid valves are closed and the pump is in a ‘no flow’ condition, the pump must be able to
maintain system pressure as set in parameter B5-19 (Co nstant Pressure Setting).
2. The drive setting for the “STOP Function” B5-15 should be 1-3 Hz below the operating Hz for the
lowest capacity (GPM) heat pump in the system. Refer to page 14 for “Adjusting the Sleep Function”.
Addition of a Bladder Tank to the System –
1. If the piping between the pump and the solenoid valves isn’t a sig nificant distance (less than fifteen
feet), a bladder tank may be need to enable the stop function.
NOTE: Attempt the “STOP Function” before adding a bladder tank. A 2.2 gallon bladder tank
set to a pre-charge of 70% of the system pressure in parameter B5-19.
Example: B5-19 = 20 psi, then the pre-charge pressure of the bladder should be at 14 psi.
Static Pressure Test –
This test will determine if the system is able to maintain pressure. The system must be able to ho ld pressure
to enable the stop function. Follow the steps below to determine if you have any bypass of fluid in the system
past the solenoid valves or the check valve prior to the pump.
1. Go into the Set Up Menu “STUP” and change B1-02 from “1” to “0”. This will enable you to start/stop
the drive via the “Run/Stop” button on the face of the drive (Refer to menu navigation on page 10).
2. Press the “RUN” button on the drive and visually look at the gauge to determine the pressure setting
and make note of this pressure.
3. Allow all solenoid valves to close in the system.
4. Immediately hit the “Off” button on the drive and wait three to five minut es.
5. Determine if the pressure gauge is able to hold the original pressure. (The pressure is trapped
between the check valve before the pump and th e solenoid valves.)
6. If the gauge doesn’t hold pressure, you have fluid bypassing the valv es in the system.
7. Hit the run button on the drive until it reaches the set pressure.
8. If ball valves are place d in the system before the solenoid valves, then close all bu t one to see if the
system is losing pressure because the exposed solenoid valve is bypassing f luid.
9. If this isn’t the case, open the next ball valve to see if the additional solenoid valve is losing pressure.
Continue this process until all solenoid valv es are exposed to the pressure created by t h e pump.
10. If there is a solenoid valve that is allowing the fluid to bypass (pressure loss d ue to not fully seating),
then the valve must be cleaned and checked for proper operation.
If the system is still having problem s or loss of static pressure, please contact your local distributor for help. If
the VFD is cycling on and off continuously, this co uld result in motor failure.
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ALL THE PUMP YOU NEED AND MORE
Revised 7-5-12
Motor Testing
Motor Winding Resistance –
(Lead to Lead)
1. Turn the power “OFF”.
2. Disconnect all electrical leads to motor.
3. Set the scale selector on the ohmmeter
to R x 1 (if you expect ohm values under
10 or R x 10 (for ohm values over 10).
4. Touch the leads of the ohmmeter to the
two motor leads. Touching the leads of
the ohmmeter to any two hot leads will
measure the winding’s resistance. R epeat
for all three possible lead combinations
(L1 and L2; L2 and L3; L1 and L3).
5. Watch the ohmmeter scale and compare
this figure with the appropriate chart.
Evaluation –
If all ohm values are normal, the motor windings are neither shorted nor open.
If any one ohm value is less than normal, then that motor winding may be starting
to short. If any one ohm value is greater than normal, then that winding may be
starting to open. If some ohm values are greater than normal (more than 25%),
then the leads may be connected incorrectly.
Insulation Resistance –
(Lead to Ground)
1. Turn the power “OFF”.
2. Disconnect all electrical leads to motor.
3. Set the scale selector on the
megohmmeter to R x 100, touch its leads
together and adjust the indicator to zero.
4. Touch the leads of the megohmmeter to
each of the motor leads as you connect
to the ground (i.e. L1 to ground, then L2
to ground, etc.).
5. Watch the megohmmeter scale and
compare this figure with the appropriate
chart.
Evaluation –
The resistance values of new motors must excee d 1,000,000 ohms.
If they do not, replace the motor.
18
ALL THE PUMP YOU NEED AND MORE
Revised 7-5-12
Notes
19
ALL THE PUMP YOU NEED AND MORE
Revised 7-5-12
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