Bell & Gossett 176R0649C User Manual

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INSTRUCTION MANUAL

176R0649

REVISION C

INSTALLER: PLEASE LEAVE THIS MANUAL FOR THE OWNER’S USE.

Technologic® 502 Series Pump Controller

WARNING

Eq u i p m E n t Ha z a r d !

WARNING

dr i v E s a n d pa n E l s c o n t a i n d a n g E r o u s v o l t a g E s w H E n

c o n n E c t E d t o l i n E v o l t a g E . it i s s t r o n g l y r E c o m m E n d E d t H a t a l l E l E c t r i c a l w o r k c o n f o r m t o t H E na t i o n a l

El E c t r i c a l co d E (nEc) a n d a l l n a t i o n a l a n d l o c a l

r E g u l a t i o n s . in s t a l l a t i o n , s t a r t -u p a n d m a i n t E n a n c E s H o u l d b E p E r f o r m E d o n l y b y q u a l i f i E d p E r s o n n E l . fa i l u r E t o f o l l o w t H E nEc o r l o c a l r E g u l a t i o n s c o u l d r E s u l t i n d E a t H o r s E r i o u s i n j u r y .

Motor control equipment and electronic controls are connected to hazardous line voltages. Extreme care should be taken to protect against shock. The user must be protected against supply voltage and the motor must be protected against overload in accordance with applicable national and local regulations. Be sure equipment is properly grounded. Wear safety glasses whenever working on electric control or rotating equipment.

un i n t E n d E d st a r t !

wH E n d r i v E o r o p t i o n p a n E l i s c o n n E c t E d t o ac i n p u t

p o w E r , m o t o r m a y s t a r t a t a n y t i m E . tH E d r i v E , o p t i o n p a n E l , m o t o r , a n d a n y d r i v E n E q u i p m E n t m u s t b E i n o p E r a t i o n a l r E a d i n E s s . fa i l u r E t o b E in o p E r a t i o n a l r E a d i n E s s w H E n p a n E l a n d d r i v E a r E c o n n E c t E d t o ac i n p u t p o w E r c o u l d r E s u l t i n d E a t H , s E r i o u s i n j u r y , o r E q u i p m E n t o r p r o p E r t y d a m a g E .

Warning Against Unintended Start

When the drive or option panel is connected to the AC line, the motor may be started by means of an external switch, a serial bus command, an input reference signal, or a cleared fault condition. Use appropriate cautions to guard against an unintended start.

gr o u n d i n g Ha z a r d !

fo r o p E r a t o r s a f E t y , i t i s i m p o r t a n t t o g r o u n d d r i v E ,

o p t i o n p a n E l , a n d m o t o r p r o p E r l y . fo l l o w t H E g r o u n d i n g g u i d E l i n E s o f l o c a l a n d n a t i o n a l c o d E s . fa i l u r E t o f o l l o w g r o u n d i n g g u i d E l i n E s c o u l d r E s u l t i n d E a t H o r s E r i o u s i n j u r y .

Grounding

Proper protective grounding of the equipment must be established in accordance with national and local codes. Ground currents are higher than 3 mA. Use high stranded wire whenever possible.

Safety Guidelines

1. The drive and option panel must be disconnected from the AC line before any service work is done.

2. DO NOT touch electrical parts of the option panel or drive when the AC line is connected. After the AC line is disconnected, wait 30 minutes before touching any electrical components.

3. The user must be protected against supply voltage and the motor must be protected against overload in accordance with applicable national and local regulations.

4. While programming parameters, the motor may start without warning. Activate the STOP/OFF key on the control keypad when changing parameters.

5. The STOP/OFF key on the local control panel keypad of the drive does not isolate the drive from the AC line voltage and is not to be used as a safety switch.

Table of Contents

Safety Guidelines ............................................................................................................................................................................... 2

Warning Against Unintended Start ...................................................................................................................................................2

Section 1 Introduction ....................................................................................................................................................................... 5

Purpose of the Manual ....................................................................................................................................................................... 5

Overview.............................................................................................................................................................................................. 5

Typical Bypass Operation .................................................................................................................................................................. 7

Overload Protection. ........................................................................................................................................................................... 7

Disconnects ........................................................................................................................................................................................ 8

Power Fusing ...................................................................................................................................................................................... 8

Drive Option Panel Congurations ................................................................................................................................................... 9

Option Panel Voltage and Frame Ratings ........................................................................................................................................9

Section 2 Pre-installation................................................................................................................................................................ 10

Pre-installation Check ...................................................................................................................................................................... 10

Installation Site Check ..................................................................................................................................................................... 10

Harsh Environments ........................................................................................................................................................................ 11

Section 3 Installation....................................................................................................................................................................... 12

Common Backpanel Mounted Units ............................................................................................................................................... 12

Branch Circuit Protection ................................................................................................................................................................ 12

Drive Fuses ....................................................................................................................................................................................... 12

Internal Option Panel Fuses ............................................................................................................................................................ 12

Tools and Equipment Required ....................................................................................................................................................... 12

Mechanical Installation .................................................................................................................................................................... 13

Lifting ................................................................................................................................................................................................. 13

Cooling .............................................................................................................................................................................................. 13

Electrical Installation........................................................................................................................................................................ 14

Wire Type Rating .............................................................................................................................................................................. 15

Terminal Tightening Torques ........................................................................................................................................................... 15

Line Input (Mains) Connection ........................................................................................................................................................ 15

Motor Wiring ..................................................................................................................................................................................... 16

Grounding (Earthing) ....................................................................................................................................................................... 17

Control Wiring ................................................................................................................................................................................... 18

Drive Control Terminals ................................................................................................................................................................... 18

MCB-101 Master Control Board ...................................................................................................................................................... 19

Pressure and Feedback Wiring ....................................................................................................................................................... 20

Control Terminal Programming ...................................................................................................................................................... 20

Serial Communication Bus Connection ......................................................................................................................................... 20

Serial Communications Programming ........................................................................................................................................... 20

Installation of Backpanel Mounted Drives and Pumps ................................................................................................................. 24

Installation of 70X Series Drives and Pumps................................................................................................................................. 25

Section 4 Start Up............................................................................................................................................................................ 28

Pre-start Procedure .......................................................................................................................................................................... 28

Inspection Prior to Start Up ............................................................................................................................................................. 29

Start Up Procedure ........................................................................................................................................................................... 30

Drive Power Up ................................................................................................................................................................................. 30

Required Drive Programming.......................................................................................................................................................... 31

System Start Up ................................................................................................................................................................................ 32

Full Speed Operation and Checkout ............................................................................................................................................... 33

Section 5 User Interface.................................................................................................................................................................. 34

Operation and Programming Through the LCP ............................................................................................................................. 34

Navigation keys ................................................................................................................................................................................ 35

Section 6 Programming and Operation ......................................................................................................................................... 36

Basic Drive Programming ............................................................................................................................................................... 36

Entering Basic Motor Data ............................................................................................................................................................... 36

Designating Master or Follower Drives .......................................................................................................................................... 36

Section 7 Status Messages ............................................................................................................................................................ 48

Status Messages .............................................................................................................................................................................. 48

Section 8 Warnings and Alarms ..................................................................................................................................................... 52

System Monitoring ........................................................................................................................................................................... 52

Warning and Alarm Displays

Description and Remedy ................................................................................................................................................................. 52

Section 9 Start Up Troubleshooting

Appendix .......................................................................................................................................................................................... 62

Serial Communication Point Maps ................................................................................................................................................. 62

Protocols

Serial Communications Programming ........................................................................................................................................... 62

Metasys N2 Point Map...................................................................................................................................................................... 63

Metasys N2 Point Map (continued) ................................................................................................................................................. 64

Modbus RTU Point Map (by parameter)

Modbus RTU Point Map (by function) ............................................................................................................................................ 66

Modbus RTU Point Map (by function) ............................................................................................................................................ 67

Floor Level Network (FLN) Set-up ................................................................................................................................................... 68

Quick Start Check List

........................................................................................................................................................................................... 62

........................................................................................................................................................... 52

.............................................................................................................................................. 59

......................................................................................................................................... 65

..................................................................................................................................................................... 73

List of Figures

1-1. Technologic 502 Pump Controller .............................................................................................................................................5

1-2. Master Drive with Three Followers 1-3. Basic 3-contactor Bypass Functions

1-4. Disconnects ................................................................................................................................................................................. 8

1-5. Tier Denitions and Features

3-1. Drive Input Fuses ...................................................................................................................................................................... 12

3-2. Cooling Air Flow 3-3. Typical Unit Components 3-4. Power Connections

3-5. Input Power Panel with Line Disconnect ................................................................................................................................ 15

3-6. Wire Access Panels (bottom view) 3-7. Sample Motor Wiring

3-8. Control Terminal Access ..........................................................................................................................................................18

3-9. Drive Control Terminals 3-10. Master Board Control Terminals

3-11. Master Board Control Terminal Location .............................................................................................................................. 19

3-12. Customer Wiring Schematic Diagram, VFD with 1 Follower

3-13. Customer Wiring Schematic Diagram, VFD with 2 or 3 Followers ..................................................................................... 22

3-14. Backpanel Mounted Drives and Pumps (front and side views)

3-15. 70X Series Drive ...................................................................................................................................................................... 26

3-16. 70X Series Customer Connection Diagram .......................................................................................................................... 27

5-1. Local Control Panel................................................................................................................................................................... 34

5-2. LCP Display Area....................................................................................................................................................................... 34

7-1. Display Status Line ................................................................................................................................................................... 48

........................................................................................................................................................................ 13

......................................................................................................................................................... 13

................................................................................................................................................................... 14

................................................................................................................................................................ 16

............................................................................................................................................................ 18

............................................................................................................................................ 6

........................................................................................................................................ 7

..................................................................................................................................................... 9

.......................................................................................................................................... 16

............................................................................................................................................ 19

............................................................................................... 21

.......................................................................................... 24

List of Tables

1-3. Panel Voltage and Frame Ratings 3-1. Tools and Equipment Required 3-2. Connection Tightening Torques

3-3. Drive Control Terminal Functions ............................................................................................................................................ 19

4-1. Inspection Prior to Start Up 6-1. Quick Menu Layout

6-2. Parameter 39-** Group, Detailed Description ......................................................................................................................... 39

7-1. Status Message Denitions...................................................................................................................................................... 48

8-1. Warnings and Alarms ................................................................................................................................................................ 53

9-1. Fault Table .................................................................................................................................................................................. 59

................................................................................................................................................................... 37

.............................................................................................................................................. 9

............................................................................................................................................... 12

..............................................................................................................................................12

...................................................................................................................................................... 29

Section 1 Introduction

Purpose of the Manual

This manual is intended to provide detailed information for the installation and operation of the option panel used in conjunction with the Technologic

502 Pump Controller. To enable efcient handling

of the equipment, requirements are provided for mechanical installation, power and control wiring, proper grounding, and environmental considerations. Pre-start and start up procedures are detailed. Also included is a detailed overview of the option panel bypass function. In addition, programming,

identication and operation of optional components,

and basic troubleshooting instructions are included as well.

Overview

The Technologic 502 Pump Controller is a variable frequency drive with embedded pump control software.

It is available in several different congurations.

Type B-3 Controller (2 Pumps/1 Drive)

The type B-3 controller consists of a Technologic 502 master with embedded pump controller software, contact motor selection, and an electronically controlled bypass. Contact motor selection allows the controller to alternate between two motors of equal size, a duty pump and a standby. The duty pump is controlled to maintain a set point. Selection between motors is made automatically by the Technologic 502 or by manual selection through a selector switch. The bypass enables either motor to be driven by 100% line power while bypassing the controller circuitry. The Technologic 502 and electronically controlled bypass are factory wired and mounted to a common backplate.

Type C-4 Controller (2 Pumps/2 Drives)

The type C-4 bypass consists of a Technologic 502 master and (1) follower drive each with embedded pump controller software and an electronically controlled automatic bypass. The C-4 controller allows for duty/standby operation where only one pump is run at any time. Selection between drive mode or automatic bypass is determined by the master. The bypass can also be activated manually through each drive’s keypad.

Figure 1-1. Technologic 502 Pump Controller

Drives on a common backpanel are factory-wired between the master and follower drives and contain

a main disconnect. Congurations may include a

fused disconnect or bypass.

Type A-1 Controller (1 Pump/1 Drive)

The type A-1 consists of a stand-alone Technologic 502 master with embedded pump controller software and an electronically controlled automatic bypass. The bypass can also be activated manually through the drive keypad.

Type D-4 Controller (2 Pumps/2 Drives)

The type D-4 bypass consists of a Technologic 502 master and (1) follower drive each with embedded pump controller software and an electronically controlled automatic bypass. The D-4 controller allows parallel operation between the master and follower drive in response to a set point. Drive mode or automatic bypass is determined by the master. The bypass can also be activated manually through each

drive’s keypad.

Type S-1 Controller (with or without manual by-

Input power panel

Master drive

Follower 1

Follower 2

Input power raceway to VFDs

pass)

The type S-1 controller comes in two different con-

gurations. One consists of a Technologic 502 master

with embedded pump controller software with up to

three follower drives. The other S-1 conguration is

the same with the addition of a manual bypass for the master and a manual bypass for each follower drive. The controller allows parallel operation between the master and follower drives in response to a set point. All drives will run at the same synchronized speed.

A-0 (1 Technologic 502 Master 0nly)

A-M (1 Technologic 502 Master only with manual bypass)

C-0 (1 Technologic 502 Master with (1) follower – No Staging)

C-M (1 Technologic 502 Master with (1) follower each with manual bypass – No Staging)

D-0 (1 Technologic 502 Master with (up to 3) followers – Staging Allowed)

D-M (1 Technologic 502 Master with (up to 3) followers each with manual bypass – Staging Allowed)

Figure 1-2. Master Drive with Two Followers

Typical Bypass Operation

Overload Protection.

With contactors M1 and M2 closed and contactor M3 open (see Figure 1-3), the pump is controlled by the drive. Opening contactor M2 removes power to the pump but allows the controller to remain powered. This is the test mode and only available in the three-

contactor conguration shown. With contactors M1

and M2 open and contactor M3 closed, the pump runs in bypass from the line input. For a two-contactor

conguration, M1 is absent. In this case, contactors

M2 and M3 control the options for running in drive or

bypass mode. The gure illustrates a drive disconnect

and fuses.

This thermally activated device provides mechanical overload protection for the pump(s) while in bypass operation. It measures motor current and is factory set to the full load amps (FLA) of the pump. A 1.2 x FLA service factor is built-in and maintained. Should the motor current increase above that value, the overload will calculate the level of increase to activate timing for the trip function. The higher the current draw, the quicker the trip response. The overload provides Class 20 motor protection.

Figure 1-3. Basic 3-contactor Bypass Functions

Disconnects

DRIVE

DISCONNECT

DRIVE

OPTION PANEL

BACKPLATE

MAIN

MOUNTING PANEL

DISCONNECT

Power Fusing

Main disconnect. The main disconnect removes

line input power to the controller and bypass. A main disconnect is available in two options. For safety, the switch must be in the OFF position before the panel door can be opened. (See Figure 1-4.)

•

Main disconnect with built-in

fuses. Two-position (ON/OFF) ro-

tary switch, with three built-in fuses, one on each phase.

Main disconnect with separate

•

fuses. Two-position (ON/OFF) rotary switch with a fuse block mounted separately from the disconnect. Three fuses, one on each phase, are located on the fuse block.

Drive disconnect. Two-position (ON/OFF) rotary switch disconnects main AC line input power to the

drive only.

Motor Alternation Selector Switch

The B3 option includes contactor motor selection. It provides motor alternation with one drive alternating operation between two motors. The panel mounted Motor 1/Auto/Motor 2 selector switch provides local control of either motor along with an auto setting that allows auto selection through the master drive.

Two types of fusing are available for the units—main and drive fusing. For all power fuses, use the speci-

ed fuse or an equivalent replacement only. See the

fuse ratings label on the inside cover of the unit for ratings.

Main fusing. Main fuses are located ahead of the drive. Main fuses are designed to protect the circuitry within the panel but are not adequate to protect the drive. Main fuses are dual-element, time-delay type and mount inside the bypass enclosure.

Drive fusing. Drive fuses are located ahead of the drive and are a fast-acting type. Drive fuses are standard in two-contactor and three-contactor bypasses. A fuse/disconnect enclosure may be used if no options other than a fuse block and disconnect switch are required.

Figure 1-4. Disconnects

Drive Option Panel Congurations

contains the bypass as in Tier 2. Two option panels

are provided in Tier 3 with one containing the bypass The Technologic 502 Drive Series has three tiers of option panel enclosure types. The option panel

and the other the contactor motor selector. (See

Figure 1-5)

Tier 1 Tier 2 Tier 3

Drive with fuses

Drive with bypass Drive with bypass and contactor

and disconnect

Figure 1-5. Tier Denitions and Features

Option Panel Voltage and Frame Ratings

Table 1-1 denes the voltage and hp ratings of the

frames sizes for the drive and option panel. See the mechanical drawing shipped with the unit for dimensions.

Frame A2 - A5

Volts VAC hp

208-230 2-5

460-480 3-10

575-600 3-10

Frame B1

Volts VAC hp

208-230 7.5-15

460-480 15-25

575-600 15-25

Frame B2

Volts VAC hp

208-230 15-20

460-480 30-40

575-600 30-40

motor selector (B3)

Frame C1

Volts VAC hp

208-230 25-30

460-480 50-75

575-600 50-75

Frame C2

Volts VAC hp

208-230 40-60

460-480 100-125

575-600 100-125

Frame D1

Volts VAC hp

460-480 150-200

575-600 150-200

Frame D2

Volts VAC hp

460-480 250-350

575-600 250-400

Table 1-1. Panel Voltage and Frame Ratings

Section 2 Pre-installation

Pre-installation Check Installation Site Check

1. Compare model number to what was

ordered.

2. Ensure each of the following are rated for

same voltage:

• Power line

• Drive

• Option panel

• Motor

3. Ensure that option panel output rating is

equal to or greater than motor total full load current for full motor performance.

• Motor power size and option panel must

match for proper overload protection.

• If panel rating is less than motor, full motor

output cannot be achieved.

4. Check motor wiring:

• Any disconnect between drive and motor

should be interlocked to drive safety interlock circuit to avoid unwanted drive trips.

• Because the option panel relies on the

ambient air for cooling, it is important to observe the limitations on ambient air temperature. Derating starts above 40°C (104°F) and 3300 feet (1000m) elevation above sea level.

• It is important with backpanel mounted units

to check support strength. Make sure that the proper mounting screws or bolts are used.

• Keep the option panel interior free from dust

and similar dirt. In construction areas, if the unit is not powered, provide a protective covering. It is important to ensure that the components stay as clean as possible. It may be necessary to clean the interior once construction is completed.

• Keep wiring diagrams, drawings and

manuals accessible for detailed installation and operation instructions. It is important that the manuals be available for equipment operators.

• Do not connect power factor correction

capacitors between drive and motor.

• Two speed motors must be wired

permanently for full speed.

• Y-start, -run motors must be wired

permanently for run.

Harsh Environments

The mechanical and electrical components within the option panel can be adversely affected due to the environment. The effects of contaminants in the

air, either solid, liquid, or gas, are difcult to quantify

and control. Depending upon the severity of the environment, optional NEMA 12, NEMA 3R or NEMA 4 enclosures may be used.

Airborne Liquids

Liquids in the air can condense in components. Water vapor carried in the air is easily measured as relative

humidity, but other vapors are often more difcult

to measure or control. Steam, oil, and salt water vapor (near sea locations) may cause corrosion of components. In such environments, use NEMA 12 enclosures to limit the exchange of outside air into the option enclosure. Extremely harsh environments may require a higher level of protection.

Airborne Solids

Particles in the air may cause mechanical, electrical or thermal failure in components. A NEMA 1 enclosure provides a reasonable degree of protection against falling particles, but it will not prevent the fan from pulling dirty air into the enclosure. A typical indicator of excessive levels of airborne particles is dust around the fan. In dusty environments, use NEMA 12 enclosures.

Corrosive Chemicals

In environments with high temperatures and humidity,

corrosive gases such as sulfur, nitrogen and chlorine

compounds cause corrosion to occur in components.

Indications of corrosion are blackened copper or rust

on steel or oxidized aluminum. In such environments,

it is recommended that the equipment be mounted in

a cabinet with fresh air ventilation and that corrosive

compounds be kept away. A non-ventilated cabinet

tted with an air conditioner as a heat exchanger may

be used. Conformal coated circuit boards may be

specied to reduce the corrosive effects of a harsh

environment.

Section 3 Installation

WARNING

TOOLS Spreader bar capable of lifting up to 1000 lbs. Max diameter 0.875 in. Forklift, crane, hoist or other lifting device capable of handling up to 1000 lbs. (Qualified device operator available for operating the equipment.) Metric socket set: 7 - 19mm Socket extensions: 4 & 6 in Torx driver set: T10 - T40 Torque wrench: 6 - 170 in-lbs

Common Backpanel Mounted Units

Branch Circuit Protection

br a n c H ci r c u i t pr o t E c t i o n rE q u i r E d !

pr o v i d E b r a n c H c i r c u i t pr o t E c t i o n i n a c c o r d a n c E w i t H

t H E na t i o n a l E l E c t r i c a l co d E . fa i l u r E t o p r o v i d E b r a n c H c i r c u i t pr o t E c t i o n in a c c o r d a n c E w i t H t H E nEc m a y r E s u l t i n E q u i p m E n t o r p r o p E r t y d a m a g E .

Drive Fuses

If specied as an option, drive input fuses will be

factory installed in the enclosure. If not factory supplied, they must be provided by the installer as part of installation.

Internal Option Panel Fuses

Use the specied fuse or an equivalent replacement

only for internal option panel fuses. Fuse options include the drive disconnect and contactor fuses.

Tools and Equipment Required

In addition to the standard tool kit, the tools and devices in Table 3-1 are recommended for installation of the unit.

Table 3-1. Tools and Equipment Required

Figure 3-1. Drive Input Fuses

Table 3-2. Connection Tightening Torques

Power (hp) Torque (in-lbs)

Frame 200-240 V 380-480 V 525-600 V Line Motor DC Brake Ground Relay

A2 2 - 5 3 - 5 3 - 5 17 17 17 28 5

A3 5 10 5 - 10 17 17 17 28 5

A5 1.5 - 5 1.5 - 10 1.5 - 10 17 17 17 28 5

B1 7.5 - 15 15 - 25 -- 17 17 13 28 5

B2 20 30 - 40 -- 22, 40 22, 40 32 29 5

C1 25 - 40 50 - 75 -- 88 88 88 28 5

C2 50 - 60 100 - 125 -- 124, 212 124, 212 124 29 5

D1 -- 150-200 150-200 168 168 84 29 7

D2 -- 250-350 250-400 168 168 84 29 7

Mechanical Installation

4.0 in min.

CEILING

FLOOR

AIRFLOW

4.0 in min.

AIRFLOW

Input power panel

Master drive

Follower 1

Follower 2

Input power raceway to VFDs

Drive disconnect

Mains (line) disconnect

Hoist ring

Lift unit by hoist ring only

Lifting

Check the weight of unit to determine the safety of the lifting method. (See the mechanical drawing supplied with the equipment for unit weight.) Ensure that the lifting device is suitable for the task. If necessary, plan for a hoist, crane or forklift with appropriate rating to move the units. For lifting, use hoist rings provided.

Cooling

• Mount the controller and panel vertically.

• Option panels rely on the ambient air

for cooling. It is important to observe the limitations on ambient air temperature. Derating start above 104oF (40oC) and 3300 feet elevation above sea level.

• Top and bottom clearance is required for

cooling (Figure 3-2). Generally, 4 to 10 inches (100 to 250 mm) minimum clearance is required, depending upon the hp of the unit. See the mechanical drawing shipped

with the unit for specic requirements.

Figure 3-2. Cooling Airow

Figure 3-3. Typical Unit Components

WARNING

Electrical Installation

EquipmEnt Hazard!

rotating sHafts and ElEctrical EquipmEnt can bE

Hazardous. it is strongly rEcommEndEd tHat all E l E c t r i c a l w o r k c o n f o r m t o a l l n a t i o n a l a n d l o c a l r E g u l a t i o n s . in s t a l l a t i o n , s t a r t -u p , a n d m a i n t E n a n c E s H o u l d b E p E r f o r m E d o n l y b y q u a l i f i E d p E r s o n n E l . fa i l u r E t o f o l l o w l o c a l r E g u l a t i o n s c o u l d r E s u l t i n d E a t H o r s E r i o u s i n j u r y .

• Motor control equipment and electronic

controls are connected to hazardous line voltages. Extreme care should be taken to protect against electrical hazard.

• Proper protective grounding of the

equipment must be established. Ground currents are higher than 3 mA.

• A dedicated ground wire is required.

• Wear safety glasses whenever working on

electric control or rotating equipment.

notE

ma k E a l l p o w E r c o n n E c t i o n s w i t H m i n i m u m 75o c r a t E d

c o p p E r w i r i n g f o r i n s t a l l a t i o n s i n no r t H am E r i c a .

in d u c E d vo l t a g E !

ru n o u t p u t m o t o r c a b l E s f r o m m u l t i p l E d r i v E s s E p a r a t E l y .

in d u c E d v o l t a g E f r o m o u t p u t m o t o r c a b l E s r u n t o g E t H E r

c a n c H a r g E E q u i p m E n t c a p a c i t o r s E v E n w i t H t H E E q u i p m E n t t u r n E d o f f a n d l o c k E d o u t . fa i l u r E t o r u n o u t p u t c a b l E s s E p a r a t E l y c o u l d r E s u l t i n d E a t H o r s E r i o u s i n j u r y .

notE

ru n d r i v E i n p u t p o w E r , m o t o r w i r i n g , a n d c o n t r o l

w i r i n g i n t H r E E s E p a r a t E m E t a l l i c c o n d u i t s o r r a c E w a y s f o r H i g H f r E q u E n c y n o i s E i s o l a t i o n . fa i l u r E t o i s o l a t E p o w E r , m o t o r , a n d c o n t r o l w i r i n g c o u l d r E s u l t i n l E s s t H a n o p t i m u m c o n t r o l l E r a n d a s s o c i a t E d E q u i p m E n t p E r f o r m a n c E .

• Because the wiring from the option

enclosure to the motor carries high frequency electrical pulses, it is important that no other wires are run in this conduit. If the incoming power wiring is run in the same conduit as the motor wiring, these pulses can couple electrical noise back onto the building power grid.

At least three separate conduits must be connected to the panel option. (See Figure 3-4.)

• Power wiring into the enclosure (and ground

back to the distribution panel)

• Power wiring from the enclosure to the

motor (and earth ground)

• Control wiring

Control wiring should always be isolated from the high voltage power wiring.

Avoid getting metal chips into electronics.

Follow the connection procedures as illustrated in the drawing provided with the unit.

For internal component identication, see Figure

3-5.

Figure 3-4. Power Connections

OT 45...100 M3

Ground lug

Line (mains) disconnect

Ground bar

L1 L2

Wire Type Rating

WARNING

• Use wiring corresponding to the wire rating specication provided.

• The wire rating specication is located

on the wire rating label inside the cover of the option panel.

Terminal Tightening Torques

• Tighten all connections to the torque specication provided in Table 3-2.

Line Input (Mains) Connection

• Size wiring based upon the input current

of the drive. Recommended wire sizes are provided on the connection drawing of the unit.

• Local codes must be complied with for cable

sizes.

ru n i n p u t p o w E r , m o t o r w i r i n g a n d c o n t r o l w i r i n g in

t H r E E s E p a r a t E m E t a l l i c c o n d u i t s o r r a c E w a y s f o r H i g H f r E q u E n c y n o i s E i s o l a t i o n . fa i l u r E t o i s o l a t E p o w E r , m o t o r a n d c o n t r o l w i r i n g c o u l d r E s u l t i n l E s s t H a n o p t i m u m d r i v E a n d a s s o c i a t E d E q u i p m E n t p E r f o r m a n c E .

• Connect 3-phase AC input power wire

to terminals L1, L2, and L3 on the main disconnect located in the input power panel (see Figure 3-3).

• Depending on the conguration of the

equipment, input power may be connected to a circuit breaker or input disconnect.

• Use with Isolated Input Source. Many utility power systems are referenced to earth ground. Although not as common, the input power may be an isolated source. All drives may be used with an isolated input source as well as with ground reference power lines.

notE

sE E f i g u r E s 3-12 a n d 3-13 f o r p o w E r , m o t o r a n d c o n t r o l

w i r i n g d i a g r a m s .

Exterior

Interior

Figure 3-5. Input Power Panel with Line Disconnect

Motor Wiring

WARNING

NOTE: CONNECT MOTOR LEADS DIRECTLY TO VFD THROUGH ACCESS PANEL. DO NOT ROUTE THROUGH RACEWAY.

notE

sE E fi g u r E s 3-12 a n d 3-13 f o r p o w E r , m o t o r a n d

c o n t r o l w i r i n g d i a g r a m s .

in d u c E d vo l t a g E !

ru n o u t p u t m o t o r c a b l E s f r o m m u l t i p l E d r i v E s s E p a r a t E l y . in d u c E d v o l t a g E f r o m o u t p u t m o t o r c a b l E s r u n t o g E t H E r

c a n c H a r g E E q u i p m E n t c a p a c i t o r s E v E n w i t H t H E E q u i p m E n t t u r n E d o f f a n d l o c k E d o u t . fa i l u r E t o r u n o u t p u t m o t o r c a b l E s s E p a r a t E l y c o u l d r E s u l t i n d E a t H o r s E r i o u s i n j u r y .

wi r i n g is o l a t i o n !

ru n i n p u t p o w E r , m o t o r w i r i n g a n d c o n t r o l w i r i n g in

• Motor wiring access panels are provided at

the base of the units as shown in Figure 3-6:

• Torque terminals in accordance with the

information provided in Table 3-2.

• Motor wiring should never exceed the

following maximum distances:

1000 ft (300m) for unshielded 500 ft (150m) for shielded

• Motor wiring should always be as short as

practical.

Motor terminals T1, T2, T3

Ground

• Connect the 3-phase motor wiring to bypass

terminals T1 (U), T2 (V), and T3 (W). See the connection drawing provided with unit.

• Depending on the conguration of the

equipment, motor wiring may be connected to an electrical or mechanical overload, a contactor, or terminal block (see Figure 3-7).

Figure 3-6. Wiring Access Panels (bottom view)

Motor wiring

Figure 3-7. Sample Motor Wiring

Grounding (Earthing)

WARNING

gr o u n d i n g Ha z a r d !

fo r o p E r a t o r s a f E t y , i t i s i m p o r t a n t t o g r o u n d d r i v E a n d

o p t i o n p a n E l p r o p E r l y . fa i l u r E t o g r o u n d d r i v E a n d o p t i o n p a n E l p r o p E r l y c o u l d r E s u l t i n d E a t H o r s E r i o u s i n j u r y .

no t E

it i s t H E r E s p o n s i b i l i t y o f t H E u s E r o r c E r t i f i E d E l E c t r i c a l

i n s t a l l E r t o E n s u r E c o r r E c t g r o u n d i n g (E a r t H i n g ) o f t H E E q u i p m E n t in a c c o r d a n c E w i t H n a t i o n a l a n d l o c a l E l E c t r i c a l c o d E s a n d s t a n d a r d s .

• Follow all local and national codes for proper

electrical equipment grounding (earthing).

• Proper protective grounding of the

equipment must be established. Ground currents are higher than 3 mA.

• A dedicated ground wire is required.

• Do not use conduit connected to the option

panel as a replacement for a ground wire.

• Do not ground one panel to another in a

“daisy chain” fashion. Each panel must have a dedicated ground connection.

• A high strand count ground wire is preferred

for dissipating high frequency electrical noise.

• Keep the ground wire connections as short

as possible.

notE

sE E f i g u r E s 3-12 a n d 3-13 f o r p o w E r , m o t o r a n d c o n t r o l

w i r i n g d i a g r a m s .

• Connect the ground wire directly to a reliable

earth ground. Grounding studs are provided on the back plate of the option panel for grounding.

Control Wiring

WARNING

ru n i n p u t p o w E r , m o t o r w i r i n g a n d c o n t r o l w i r i n g i n

• It is recommended that control wiring is

rated for 600 volts for 480 V and 600 V drives and 300 volts for 200-240 V drives.

Drive Control Terminals

Denitions of the drive terminals are summarized in

Table 3-3. Figure 3-9 shows the removable controller connectors and terminals.

• Connector 1 provides four programmable digital inputs, two additional digital terminals programmable as input or output, a 24 VDC terminal supply voltage, and a common for optional customer supplied 24 VDC voltage.

• Isolate control wiring from high power

components in the drive.

Control Wiring Access

• For units 5 hp or less (208 V) and 10 hp or

less (480 V), remove access cover plate with screw driver. (See Figure 3-8.)

• For larger size units, remove front cover of

unit to access internally mounted control terminals. (See Figure 3-8.)

• Connector 2 is for the serial communications EIA-485 connector with terminal 68 (+) and 69 (-).

• Connector 3 provides two analog inputs, one analog output, 10 VDC supply voltage, and commons for the inputs and output.

• Connector 4 is a USB port available for use with the MCT-10 drive programming software.

• Also provided are two Form C relay outputs

that are in various locations depending upon

the controller conguration and size.

Figure 3-8. Control Terminals Access

Figure 3-9. Drive Control Terminals

Table 3-3. Drive Control Terminals Functions

Terminal No.

Function

01, 02, 03 04, 05, 06

Form-C relay output. Useable for AC or DC voltage and resistive or inductive loads. See drive support materials for details on voltage and current ratings and relay location.

12, 13

24 VDC digital sup ply voltage. Useable f or digital inputs and external transducers. T o use the 24 VDC for digital input common, program param eter 5-00 for PNP operation. Maximum output current is 200 mA total for all 24V loads.

18, 19, 32, 33

Digital inputs. Selectable for NPN or PNP function in parameter 5-00. Default is PNP.

27, 29

Digital inputs or outputs. Programmable for either. Parameter 5-01 for terminal 27 and 5- 02 for 29 selects input/output function. Default setting is input.

Common for digital inputs. To use for digital input common, program parameter 5-00 for NPN operation.

Common for analog output.

Analog output. Programm able for various functions in parameter 6-5x. The analog signal is 0 to 20 mA or 4 to 20 mA at a maximum of 500 Ω.

10 VDC analog supply voltage. 15 mA maximum commonly used for a potentiometer or thermistor.

53, 54

Analog input. Selectable for voltage (0-10 V) or current (0- or 4-20 mA). Closed is for current and open is for voltage. Switches are located on the drive control card behind the removable LCP. See drive support materials for details.

Common for analog inputs.

Common for serial communication. Do not use to terminate shields. See drive support materials for proper shield termination.

68 (+), 69 (-)

RS-485 interface. When the drive is connected to an RS-485 serial communication bus, a drive control card switch is provided for termination resistance. ON for term ination and OFF for no termination. See drive support materials for details.

MCB101 master board

Drive terminals

249W

3 4 765 9 101

MCB-101 Master Board

11 12

X30A

13 14

D in

COM

D in 8 D in 9

(1)

GND3Dout4Dout

Out

+24V

(2)

GND

A in 3 A in 4 Out

+24V

Out

+24V

249W

MCB-101 Master Control Board

The Master drive only contains the MCD-101 Master Board which features additional programmable connection terminals (see Figure 3-10). Typically, differential pressure switches, remote system run and system status, and an optional low suction pressure switch are connected to these terminals. (See Figure 3-12, Control Wiring Schematic Diagram.)

Figure 3-10. Master Board Control Terminals

notE

sE E f i g u r E s 3-12 a n d 3-13 f o r p o w E r , m o t o r a n d c o n t r o l

w i r i n g d i a g r a m s .

notE

sE E f i g u r E s 3-12 a n d 3-13 f o r p o w E r , m o t o r a n d c o n t r o l

w i r i n g d i a g r a m s .

Figure 3-11. Master Board Terminals Location

Pressure and Feedback Wiring

Serial Communications Programming

Connect differential pressure wiring and feedback transmitter wiring to terminals as shown in Figure 3-9.

Control Terminal Programming

Control terminals must be programmed. Terminals are multi-functional. Each terminal has a parameter associated with it for setting the desired function. It is essential for operation of the equipment that the control terminals are programmed correctly. Installation programming for units is factory set. See programming in this manual for more details.

See Figure 3-13 for the control terminals schematic diagram.

Serial Communication Bus Connection

The bypass reports serial communication data to host systems through the drive. Connection to the serial communication network is made either through the EIA-485 terminals on the controller (Figure 3-9) or, for other protocols, terminals located on the communication option card. For option card connection, see the option card instructions provided with the unit.

• For bypass serial communication protocols

using the EIA-485 terminals, make connections in the following manner.

Select the serial communication protocol type in Quick Menu item Q8, Communications.

Press the OK key to access the parameter choices

and scroll to parameter 8-30, Protocol to select the protocol in use.

notE

dE t a i l E d s E r i a l c o m m u n i c a t i o n i n s t r u c t i o n s a r E s H o w n in

t H E a p p E n d i x a t t H E E n d o f t H i s m a n u a l .

notE

it i s r E c o m m E n d E d t o u s E b r a i d E d -s H i E l d E d , t w i s t E d -p a i r

c a b l E s t o r E d u c E n o i s E b E t w E E n c o n d u c t o r s .

1. Connect signal wires to terminal (+) 68 and terminal (-) 69 on control terminals of controller.

2. Terminate shield to grounded restraining clip provided by stripping wire insulation at point of contact.

3. If shielded cabling is used, do not connect end of shield to terminal 61.

Figure 3-12. Customer Wiring Schematic Diagram, VFD with 1 Follower

1T1

1T2

1T3

PUMP

MOTOR #1

60 Hz

3Ø

POWER

INPUT

L13

L11

L12

DISCONNECT

GND

BAR

GND

(T1)

(T2)

(T3)

(L1)

(L2)

(L3)

WL3

GND

VL2

L1 U

MASTER

L13

L11

L12

MAIN

GND

BLOCK

DISTRIBUTION

L13

L11

L12

GND

BAR

GND

CUSTOMER

SUPPLIED

BRANCH

CIRCUIT

PROTECTION

208V-600V

POWER TO

SLAVE VFD'S

4 5 6

RELAY 2

1 2 3

RELAY 1

C NO NCC NO NC

VARIABLE

FREQUENCY

DRIVE

RS485

DP3 DP4DP2DP1

VFD4-18

2J27

GENERAL

ALARM

240VAC, 2A

MAX.

(+)

(-)

CUSTOM FIELD

CONNECTION FOR

CONFIGURABLE

ANALOG OUTPUT

COM

DISCONNECT ENCLOSURE

COMMON PANEL

USB

TO VFD4-27

2J28

VFD2-27

2K08

TO VFD3-27

2J18

VFD4-27

2K28

VFD2-18

2K07

VFD3-18

2K17

VFD1-20

VFD1-5

1R21

VFD1-4

VFD1

20333219 27 29181312

2 3 4 76 9101

MCB-101 AUX. CONNECTOR

11 12

X30A

Din

COM

Din 7 Din 8 Din 9 3

Dout

Out

+24V

(2)

GND

Ain 3 Ain 4 Out

+24V

Out

+24V

Din Din

D I/O D I/O

Din Din Din

COM

Out

+24V

61 68 69 504239 53 54 55

COM P N A Out

COM

A Out Out

+10V

Ain Ain Ain

COM

OPT. LOW SUCTION

PRESSURE SWITCH

SYSTEM RUN

REMOTE

CUSTOMER

SUPPLIED (+24V)

RUN STATUS

(+24V)

1 2

ON=0-20mA

OFF=0-10V

S201 S202

DS1

FU1

(LOCATED ON VFD)

DISCONNECT

V/S PUMP

249W

2K08

VFD2-33

2L08

VFD2-20

1K18

VFD1-12

2B02 2C02 2C02

Out

+24V

VFD3-27

2K18

FEEDBACK Ain1

4-20mA

FEEDBACK Ain2

4-20mA

FEEDBACK Ain3

4-20mA

FEEDBACK Ain4

4-20mA

(-) (+) (-) (+) (-) (+)(-) (+)

Figure 3-13.1. Customer Wiring Schematic Diagram, VFD with 2 or 3 Followers (1 of 2)

2T1

2T2

2T3

PUMP

MOTOR #2

DIST. BLK

FROM

POWER

INPUT

L13

L11

L12

GND

FOLLOWER 1

L13

L11

L12

GND

BAR

4 5 6

RELAY 2

1 2 3

RELAY 1

C NO NCC NO NC

VARIABLE

FREQUENCY

DRIVE

COMMON PANEL

LOCATED IN

ENCLOSURE

DISCONNECT

X30A-6

1N19

X30A-2

1N17

VFD1-29

1K24

VFD1-20

1L24

4T1

4T2

4T3L13

L11

L12

GND

FOLLOWER 3 (OPT.)

GND

BAR

4 5 6

RELAY 2

1 2 3

RELAY 1

C NO NCC NO NC

VARIABLE

FREQUENCY

DRIVE

USB

VFD1-5

1R24

TO DP4

1I30

PUMP

MOTOR #4

3T1

3T2

3T3

PUMP

MOTOR #3

GND

FOLLOWER 2 (OPT.)

L13

L11

L12

GND

BAR

4 5 6

RELAY 2

1 2 3

RELAY 1

C NO NCC NO NC

VARIABLE

FREQUENCY

DRIVE

X30A-7

1N20

TO DP3

1I29

VFD1-29

VFD1-20

VFD1-29

VFD1-20

VFD2 VFD4VFD3

61 68 69 504239 53 54 55

333219 27 29181312

Out

+24V

Din Din

D I/O D I/O

Din Din Din

COM

Out

+24V

COM P N A Out

COM

A Out Out

+10V

Ain Ain Ain

COM

USB

61 68 69 504239 53 54 55

333219 27 29181312

Out

+24V

Din Din

D I/O D I/O

Din Din Din

COM

Out

+24V

COM P N A Out

COM

A Out Out

+10V

Ain Ain Ain

COM

USB

61 68 69 504239 53 54 55

333219 27 29181312

Out

+24V

Din Din

D I/O D I/O

Din Din Din

COM

Out

+24V

COM P N A Out

COM

A Out Out

+10V

Ain Ain Ain

COM

DS2

FU2

(LOCATED ON VFD)

DISCONNECT

V/S PUMP

DS3

FU3

(LOCATED ON VFD)

DISCONNECT

V/S PUMP

DS4

FU4

(LOCATED ON VFD)

DISCONNECT

V/S PUMP

1B09

1B10

X30A-4

1N18

X30A-3

1N18

Figure 3-13.2. Customer Wiring Schematic Diagram, VFD with 2 or 3 Followers (2 of 2)

Installation of Backpanel Mounted

FLOW

Drives and Pumps

notE

sE E f i g u r E s 3-12 a n d 3-13 f o r p o w E r , m o t o r a n d c o n t r o l

w i r i n g d i a g r a m s .

For Installation of drives and pumps mounted on a common backpanel (see Figure 3-14), follow the installation procedures in Section 3 minus the motor wiring information since this will be factory installed. Also, the motor and system control parameters will be factory set for the Master drive and Followers prior to shipping.

Follow the pre-start up and start up procedures as described in Section 4.

Figure 3-14. Backpanel Mounted Drives and Pumps (front and side views)

Installation of 70X Series Drives and Pumps

A 70X conguration consists of one variable speed

pump (lead pump) connected to the 70X controller, and from 1 to 3 constant speed pumps connected to mains through a contactor controlled by the 70X controller. (See Figure 3-15.)

The 70X controller monitors system pressure and stages on and off constant speed pumps as needed to maintain system pressure. Parameter 27-20,

Normal Operating Range % is used to dene the

acceptable deviation from the setpoint before staging

or destaging takes place. This parameter is dened

as a % of parameter 3-03, Maximum Reference. (See Figure 3-16 for customer connection schematic diagram.)

Staging:

When the system demand increases the 70X controller will increase the speed of the lead pump until it reaches its maximum speed. If the system demand continues to increase, it will no longer be able to maintain the desired system pressure. Once the pressure drops below the Normal Operating Range for the time set in parameter 39-11, Stage Proof Timer, the controller will stage on a constant speed pump and ramp the lead pump to its minimum speed.

De-Staging:

When system demand decreases, the 70X controller will decrease the speed on the lead pump until it reaches its minimum speed. If the system demand continues to decrease, the pressure will exceed the Normal Operating Range. If this continues for the time set in parameter 39-14, De-Stage Proof Timer, the controller will destage a constant speed pump and ramp the lead pump to maximum speed.

Alternation:

Since timed alternation only applies to changing the lead pump, it is not part of a 70X system which has only one lead pump. It is possible however to manually alternate constant speed pumps using the right and left arrows on the LCP.

Pump Running Order:

Parameter 39-33, Pump Running Order can be used to determine the sequence with which constant speed pumps are staged on and off.

AFD Failure and Fixed Speed Only mode:

Parameter 39-40, AFD Fail Proof Timer is active in the 70X configuration. If the AFD fails, the 70X system will switch to Fixed Speed Only mode. In this mode, the controller will stage on and off constant speed pumps if the system pressure deviates from the setpoint more than parameter 27-22, Fixed Speed Only Operating Range. Setting 27-22 to zero disables this mode.

Pump Failures:

The DP switch inputs can be used in the 70X

conguration. If a failure is detected in the lead pump,

the controller will switch to Fixed Speed Only mode as described above. If a failure is detected in a constant speed pump, the controller will alternate to a different constant speed pump and mark the pump as failed.

Zone Failure Detection:

All of the normal Zone Failure detections can be used

in the 70X conguration. The loss of a single sensor will

disable that sensor. The loss of all sensors will pump the system into jog mode. 70X jog mode will run the designated number of pumps at full speed by default.

DENOTES RECOMMENDED WIRE ENTRY AREA

HAND AUTO

LAG PUMP #1

CS PUMP #1

CS PUMP #2

OFF

CS PUMP #1

HAND AUTO

LAG PUMP #2

OFF

CS PUMP #2

High and Low Suction Cut-out:

No Flow Shutdown:

The High and Low suction cut-out features can be

used in the 70X conguration. Low suction cut-out will

destage any running constant speed pumps before turning off the lead pump.

High and Low System Pressure:

The High and Low System Pressure feature can be

used in 70X conguration. If High System Pressure

is detected all pumps will be turned off without destaging.

The No Flow SHutdown feature can be used in the

70X conguration. It will only work when all of the

constant speed pumps are off.

Figure 3-15. 70X Series Drive (front and bottom views)

60 Hz3ØPOWER

INPUT

2L1 2L32L2

L3L2L1

BLOCK

DISTRIBUTION

L13

L11

L12

CUSTOMER

SUPPLIED

BRANCH

CIRCUIT

PROTECTION

DP3 DP4DP2DP1

249W

FEEDBACK 1

4-20mA

FEEDBACK 2

4-20mA

FEEDBACK 3

4-20mA

FEEDBACK 4

4-20mA

VFD1-53

1G29

VFD1-54

1F29

X2X1

H4H2H3H1

FU5

FU6

(A2)(A1)

X1 X2

C/S PUMP #1

CONTACTOR

1I10,1I11,1I12

PL1

GND

BAR

GND

OL1

C/S PUMP #1

LAG PUMP #1

OFF

SS1

HAND AUTO

xoo

oox

1 2

(95) (96)

(A2)(A1)

C/S PUMP #2

CONTACTOR

1I13,1I14,1I15

PL2

OL2

C/S PUMP #2

LAG PUMP #2

OFF

SS2

HAND AUTO

xoo

oox

1 5

(95) (96)

1T1

1T2

1T3

PUMP #1

VARIABLE SPEED

WL3

GND

VL2

L1 U

L13

L11

1L2

DS1

GND

FU1

GND

BAR

61 68 69 504239 53 54 55

333219 27 29181312

4 5 6

RELAY 2

1 2 3

RELAY 1

C NO NCC NO NC

VARIABLE

FREQUENCY

DRIVE

(LOCATED ON VFD)

USB

V/S PUMP VFD

C/S PUMP #1

DISCONNECT

FU2

2L11 2L312L21

(L1) (L2) (L3)

2L12 2L322L22

(L1) (L2) (L3)

(T1) (T2) (T3)

(T1)

(T2)

(T3)

C/S PUMP #1

OL1

EARTH

GROUND

3L1 3L33L2

L3L2L1

C/S PUMP #2

DISCONNECT

FU3

3L11 3L313L21

(L1) (L2) (L3)

3L12 3L323L22

(L1) (L2) (L3)

(T1) (T2) (T3)

(T1)

(T2)

(T3)

C/S PUMP #2

OL2

EARTH

GROUND

DS2 DS3

GND

DISCONNECT

5L1

5L2

2T1 2T32T2 3T1 3T33T2

GENERAL

ALARM

240VAC, 2A

MAX.

3 4 76 9101

MCB-101 AUX. CONNECTOR

11 12

X30A

RR1

(A2)(A1)

C/S PUMP #1

RUN RELAY

1K04,*,*,*

201

RR1

(X) (X)

RR2

(X) (X)

RR2

(A2)(A1)

200 202

200

1 2

ON=0-20mA

OFF=0-10V

S201 S202

RS485

(+)

(-)

CUSTOM FIELD

CONNECTION FOR

CONFIGURABLE

ANALOG OUTPUT

COM

C/S PUMP #2

RUN RELAY

1N04,*,*,*

FEEDBACK 2

1Q29

FEEDBACK 1

1Q28

13 14

OPT. LOW SUCTION

PRESSURE SWITCH

SYSTEM RUN

REMOTE

4L1 4L34L2

L3L2L1

C/S PUMP #3

DISCONNECT

FU4

4L11 4L314L21

(L1) (L2) (L3)

4L12 4L324L22

(L1) (L2) (L3)

(T1) (T2) (T3)

(T1)

(T2)

(T3)

C/S PUMP #3

OL3

EARTH

GROUND

DS4

4T1 4T34T2

(A2)(A1)

C/S PUMP #3

CONTACTOR

1I16,1I17,1I18

PL3

OL3

C/S PUMP #3

LAG PUMP #3

OFF

SS3

HAND AUTO

xoo

oox

1 8

(95) (96)

RR3

(X) (X)

RR3

(A2)(A1)

200 203

C/S PUMP #3

RUN RELAY

1P04,*,*,*

C/S PUMP 2 & PUMP 3 - OPTIONAL

Din

COM

Din 8 Din 9 3

Dout

Out

+24V

(2)

GND

Ain 3 Ain 4 Out

+24V

Out

+24V

Out

+24V

Din Din

D I/O D I/O

Din Din Din

COM

Out

+24V

COM P N A Out

COM

A Out Out

+10V

Ain Ain Ain

COM

CUSTOMER

SUPPLIED (+24V)

RUN STATUS

(+24V)

V/S PUMP

NOTE: *=UNUSED CONTACT

249W

L13

L11

L12

Din 7

204

C/S PUMP 2 & PUMP 3 - OPTIONAL

(OPTIONAL)

Figure 3-16. 70X Series Customer Wiring Diagram

Section 4 Start Up

WARNING

Pre-start Procedure

1. Input power to unit must be OFF and locked out per OSHA requirements. Do not rely on panel disconnect switches.

Hi g H vo l t a g E !

if i n p u t a n d o u t p u t c o n n E c t i o n s H a v E b E E n c o n n E c t E d

i m p r o p E r l y , t H E r E is p o t E n t i a l f o r H i g H v o l t a g E o n t H E s E t E r m i n a l s . if p o w E r l E a d s f o r m u l t i p l E m o t o r s a r E i m p r o p E r l y r u n i n s a m E c o n d u i t , t H E r E i s p o t E n t i a l f o r l E a k a g E c u r r E n t t o c H a r g E c a p a c i t o r s w it H in o p t i o n p a n E l , E v E n w H E n d i s c o n n E c t E d f r o m l i n E i n p u t . f o r in i t i al s t a r t u p , m a k E n o a s s u m p t i o n s a b o u t p o w E r c o m p o n E n t s .

fo l l o w p r E -s t a r t p r o c E d u r E s d E s c r i b E d b E l o w . fa i l u r E

t o f o l l o w p r E -s t a r t p r o c E d u r E s d E s c r i b E d b E l o w c o u l d r E s u l t i n p E r s o n a l i n j u r y o r d a m a g E t o E q u i p m E n t .

2. Use AC voltmeter to verify there is no voltage on input terminals L1, L2, and L3, phase-to-phase and phase-to-ground, and output terminals T1, T2, and T3, phase-tophase and phase-to-ground.

3. Use ohmmeter to conrm continuity of motor

by measuring T1-T2, T2-T3, and T3-T1.

7. Conrm control connections terminated

per connection diagrams supplied with the equipment.

8. Check for external devices between drive option panel output and motor. It is recommended that no devices be installed between motor and drive.

9. Record motor nameplate data; hp, voltage, full load amps (FLA), and RPM. It will be needed to match motor and drive data later on.

10. Conrm that incoming power matches drive

label voltage and motor nameplate voltage.

11. For multiple winding motors, motors must

be wired on run winding Delta, not Y-start

winding.

caution

Eq u i p m E n t da m a g E !

if m o t o r fla (f u l l l o a d a m p E r a g E ) is g r E a t E r t H a n u n i t

m a x i m u m a m p s , c o n t r o l l E r a n d o p t i o n p a n E l m u s t b E r E p l a c E d w i t H o n E o f a p p r o p r i a t E r a t i n g . do n o t a t t E m p t t o r u n u n i t . fa i l u r E t o m a t c H fla t o u n i t m a x i m u m a m p r a t i n g m a y r E s u l t i n E q u i p m E n t d a m a g E .

4. Use ohmmeter to conrm open on input by

measuring L1-L2, L2-L3, and L3-L1. Note that if an isolation transformer is between the power source and panel, continuity will

be present. In this case, visually conrm that

motor and power leads are not reversed.

5. Inspect the panel for loose connections on terminals.

6. Check for proper ground: option panel to main building distribution ground, and to motor ground.

12. Conrm motor FLA is equal to or less than

maximum option panel output current. Some motors have higher then normal NEMA currents.

13. Check that overload relay(s) is set for FLA of connected motor. Service factor is built into overload relay.

Inspection Prior to Start Up

Before applying power to the unit, inspect the entire installation as detailed in Table 4-1.

Table 4-1. Inspection Prior to Start Up

Inspect For Description

Auxiliary equipment

Cable routing

Control wiring

EMC considerations Check for proper installation with regard to electromagnetic capability.

Environmental conditions See equipment label for the maximum ambient operating temperature limits.

Fan clearance Cooling fan are located below the drive and require sufcient clearance for

Look for auxiliary equipment, switches, disconnects, or input fuses/circuit breakers that may reside on input power side of drive or output side to motor. Examine their operational readiness and ensure they are ready in all respects for operation at full speed. Check function and installation of pressure sensors or encoders (etc.) used for feedback to drive. Remove power factor correction caps on motor(s), if present.

Ensure that input power, motor wiring and control wiring are in three separate metallic conduits for high frequency noise isolation. Failure to isolate power, motor and control wiring could result in less than optimum drive and associated equipment performance.

Check for broken or damaged wires and connections. Check the voltage source of the signals, if necessary. The use of shielded cable or twisted pair is recommended. Ensure the shield is terminated correctly.

Temperature is not to exceed 104F (40ºC). Humidity levels must be less than 95% non-condensing.

fan removal. See the installation drawing supplied with the unit for clearance requirements.

Proper clearance Units require top and bottom clearance adequate to ensure proper air ow for

cooling in accordance with the unit size.

Fusing and circuit breakers

Grounding

Input and output power wiring

Panel interior Equipment interior must be free of dirt, metal chips, moisture, and corrosion.

Switches Ensure that all switch and disconnect settings are in the proper position.

Vibration Look for any unusual amount of vibration the equipment may be subjected to.

Check that all fuses are inserted rmly and in operational condition and that

all circuit breakers are in the open position.

The equipment requires a dedicated ground wire from its chassis to the building ground. It is highly recommended that the motor be grounded to the backpanel chassis. The use of conduit or mounting of the backpanel to a metal surface is not considered a suitable ground. Check for good ground connections that are tight and free of oxidation.

Check for loose connections. Check for proper fusing or circuit breakers.

Check for harmful airborne contaminates such as sulfur based compounds.

The panel should be mounted solidly or use shock mounts as necessary.

CHECKED BY:__________________________ DATE:__________________

Start Up Procedure

WARNING

5. Identify master drive in multi-unit

congurations.

In the following procedures, changing the equipment between drive mode and bypass mode is required. Be familiar with the operation of these devices in both modes prior to start up.

Drive Power Up

Eq u i p m E n t Ha z a r d !

dr i v E a n d o p t i o n p a n E l s c o n t a i n d a n g E r o u s v o l t a g E s

w H E n c o n n E c t E d t o l i n E v o l t a g E . in s t a l l a t i o n , s t a r t -u p a n d m a i n t E n a n c E s H o u l d b E p E r f o r m E d o n l y b y q u a l i f i E d p E r s o n n E l . fa i l u r E t o p E r f o r m i n s t a l l a t i o n , s t a r t -u p a n d m a i n t E n a n c E b y q u a l i f i E d p E r s o n n E l o n l y c o u l d r E s u l t in d E a t H o r s E r i o u s i n j u r y .

1. Perform pre-start up procedure.

2. Ensure that all operator devices are in OFF position. Panel door(s) closed.

3. Keep main disconnect switch in OFF

position. Apply voltage to unit. DO NOT operate drive or bypass at this time.

6. Conrm wiring matches installation diagram

supplied with unit.

7. Ensure sensor wiring matches installation application.

8. Turn main panel disconnect into ON position.

9. Turn main disconnect on Master drive to ON position.

10. Turn main disconnect on Follower drive(s) to ON position.

4. Conrm input line voltage is balanced within

3%. If not, correct input voltage imbalance before proceeding. Repeat procedure after voltage correction, when applicable.

Required Drive Programming

Both Master and Follower drives require basic operational programming, which includes nameplate motor data for the motor being operated and basic motor operation speeds. Enter this data in accordance with the following procedures. See the Section 5, User Interface in this manual for detailed programming instructions. This data needs to be entered with power ON but prior to operating the system.

notE

pr E s s qu i c k mE n u o r mE n u k E y o n d r i v E k E y p a d t o a c c E s s

p r o g r a m m i n g p a r a m E t E r s . us E u p /d o w n a r r o w k E y s o n k E y p a d t o s c r o l l t H r o u g H p a r a m E t E r l i s t s . p r E s s ok k E y t o E n t E r p a r a m E t E r a n d p r E s s ok k E y a g a i n t o a c c E s s p a r a m E t E r d a t a . on c E pa r a m E t E r is E n t E r E d , u s E s i d E a r r o w k E y s t o s c r o l l s i d E w a y s a n d u p /d o w n a r r o w k E y s t o i n c r E a s E o r d E c r E a s E a v a l u E . pr E s s ok k E y t o s t o r E s E t t i n g o r ca n c E l k E y t o c a n c E l . u s E ba c k k E y t o r E t u r n t o m E n u . pr E s s in f o k E y t o a c c E s s s H o r t d E s c r i p t i o n o f c u r r E n t p a r a m E t E r o p t i o n . sE E us E r in t E r f a c E s E c t i o n i n t H i s m a n u a l f o r d E t a i l E d i n s t r u c t i o n s .

For Master drives only:

1. Press Quick Menu key and go to parameter group Q3, System Setup. Press OK key to enter.

2. Scroll down parameter list and either

conrm default setting is appropriate to

system application, or enter new setting, as required.

3. In Quick Menu, go to Q1, My Personal Menu

and press OK key to enter.

4. Scroll down parameter list and enter setpoint values. Ensure parameter 39-55, Local/ Remote, is set for local operation.

1. Access Quick Menu on Master drive keypad.

2. Go to parameter group Q2 Motor Setup and

press OK key.

3. Scroll down list of all nine important motor data parameters in this section and enter motor data from motor nameplate, along with ramp up and down times, and high and low motor speed limits. It is important for

maximum system efciency that this data

be accurate. It is recommended to set ramp times to 10 seconds in parameters 3-41 and 3-42.

4. Repeat steps 2 and 3 for each Follower drive in system.

5. In Main Menu, go to parameter 39-** Tech

502 Setup, and press OK key to enter. In

parameter 39-0*, Conguration, scroll to 39-00, Auto Assign I/O Pins and scroll to the system type for the master drive being

programmed. Press OK key to select. See

Table 6-2, Parameter 39-** Group, Detailed Description for more details.

System Start Up

WARNING

un i n t E n d E d st a r t !

wH E n d r i v E i s c o n n E c t E d t o ac i n p u t p o w E r , m o t o r m a y

s t a r t a t a n y t i m E . tH E d r i v E , o p t i o n p a n E l , m o t o r , a n d a n y d r i v E n E q u i p m E n t m u s t b E i n o p E r a t i o n a l r E a d i n E s s .

fa i l u r E t o b E i n o p E r a t i o n a l r E a d i n E s s w H E n p a n E l a n d

d r i v E a r E c o n n E c t E d t o ac i n p u t p o w E r c o u l d r E s u l t i n d E a t H , s E r i o u s i n j u r y , o r E q u i p m E n t o r p r o p E r t y d a m a g E .

mo t o r st a r t !

En s u r E t H a t m o t o r , s y s t E m , a n d a n y a t t a c H E d E q u i p m E n t

i s r E a d y f o r s t a r t . fa i l u r E t o E n s u r E m o t o r , s y s t E m , a n d a n y a t t a c H E d E q u i p m E n t i s r E a d y f o r s t a r t c o u l d r E s u l t i n p E r s o n a l i n j u r y o r E q u i p m E n t d a m a g E .

1. Put drive in Hand Mode by pressing the Hand On key on keypad.

5. Place Master drive in OFF mode.

6. Set system into operational mode by pressing Auto On key on Master drive. Master drive is now ready to receive remote signals to operate, and Follower drives are in response mode.

7. To shut off system, press OFF key on Master drive and turn drive disconnect switch to OFF position.

2. DO NOT run motor at full speed at this time. Check motor rotation by bumping motor speed using up arrow on keypad. Ensure motor is spinning in proper direction. Put motor to OFF by pressing OFF key.

3. Set each Follower drive to Auto On by pressing the Auto On key on each Follower drive keypad.

4. Check Follower responses by putting Master drive in Hand On mode and use up arrow to increase Master drive speed. Check that each Follower responds to speed reference signal from Master drive.

CAUTION

Full Speed Operation and Checkout

fu l l sp E E d op E r a t i o n !

En s u r E t H a t t H E m o t o r , s y s t E m , a n d a n y a t t a c H E d

E q u i p m E n t is r E a d y f o r f u l l s p E E d o p E r a t i o n . us E r a s s u m E s a l l r E s p o n s i b i l i t y f o r a s s u r i n g s y s t E m i s a b l E t o s a f E l y r u n a t f u l l s p E E d . fa i l u r E t o E n s u r E t H a t t H E m o t o r , s y s t E m , a n d a n y a t t a c H E d E q u i p m E n t i s r E a d y f o r f u l l s p E E d o p E r a t i o n c o u l d r E s u l t in E q u i p m E n t d a m a g E .

1. Check full load amps in drive mode on motor terminals.

a. Put unit into drive mode by pressing

Hand On key on keypad.

b. Use up arrow to run drive up to full

speed.

c. Check full load amps on motor

terminals T1, T2, and T3. Verify mo to r a m ps ar e wit hi n dri ve and motor rated current and are balanced within 3%. If incorrect, see Troubleshooting Section in this manual for isolation procedures.

3. Check operation of any optional functions to

conrm they work, as applicable.

4. Exercise safety circuit and verify that unit stops running. Safety circuits include E-Stop, interlock, or overloads.

5. Exercise start/stop circuit and verify that unit starts and stops with system in auto mode of operation.

2. Check full load amps in bypass mode on motor terminals.

a. Put unit into bypass mode. (Motor

wi ll run at full speed from line voltage.)

b. Check full load amps on terminals

T1, T2, and T3. Verify motor amps are within motor FLA rated current and balanced within 3%. If incorrect, see Troubleshooting Section in this manual for isolation procedures.

0.000 Hz

0.51 kW

1.11 A

Auto Remote Running

15.0 Hz

Section 5 User Interface

Operation and Programming Through the LCP

The combined display and keypad on the front of the unit is the local control panel (LCP). The LCP is the user interface to the controller.

The LCP has several user functions: to start, stop, and control pump speed when in local control; to manually alternate pump selection along with displaying operational data, warnings and cautions; for programming drive functions; and to manually reset the controller after a fault when auto-reset is inactive.

Local control panel (LCP)

The LCP is divided into four functional groups (see Figure 5-1):

1. LCD display area.

2. Menu display keys for status options, programming, and error message history.

3. Navigation keys for programming functions, moving the display cursor, and speed control in local operation (along with status indicator lights).

4. Operation mode keys and reset.

LCD display values

Line 1. Drive frequency (Hz), Feedback (psi), Motor current (A) Line 2. Drive frequency (Hz) Line 3. Cascade system status Line 4. Status messages (see Section 7,

Status Messages)

Figure 5-2. LCP Display Area

Menu keys

Menu keys are used for parameter set-up, toggling through status display modes during normal operation, and viewing fault log data.

Main

Figure 5-1. Local Control Panel

Main Menu

Status Press and hold the Status key to toggle between status read-out displays in the LCP display area. Press status in any other display mode to return to the status display. Pressing Status plus UP or DOWN arrows adjusts the display brightness.

Quick Menu Allows access to the most common functions for initializing the drive.

Main Menu Provides access to all programming parameters.

Alarm Log Displays a list of the last 10 alarms along with current warnings and the maintenance log. For additional details about an alarm, select the alarm

number using the arrow keys and press OK. Details

about the drive before it entered the alarm mode are displayed.

Navigation keys

Navigation keys are used for programming functions and moving the display cursor. The up and down keys also provide speed control in local (hand) drive operation. Drive status indicator lights are also located in this area.

Back Reverts to the previous step or list in the navigation structure.

LED indicator lights The green ON LED is activated and display panel lit when the drive receives power from mains voltage, a DC bus terminal, or an external 24 V supply.

When a pending fault condition is being approached, the yellow warning light will come on and a text display appears in the display area. A fault condition causes

the alarm LED to ash red and a text display appears

in the display area.

Drive operation keys

Operation keys for local (hand) or remote (auto) control are found at the bottom of the control panel along with the OFF and Reset keys. The functions of these keys change based on whether the drive is a Master or Follower.

Cancel The last change or command will be cancelled, as long as the display mode has not changed.

Info Displays information about a parameter, command, or function in any display mode. For example,

in status mode, each display is dened. In menu

mode, menu options are explained. Exit Info mode by pressing Info, Back, Cancel, or Status.

Navigation Arrow Keys The four navigation arrows are used to move a cursor between the different items available in menu or alarm log modes. For operation in Hand Mode, the up and down arrows regulate drive speed. For the Master drive in a Master/Follower system, the arrows control the system speed.

OK Used to select a highlighted parameter from a parameter list or to enable a parameter choice.

Master drive The Hand ON, OFF and Auto On keys for the master drive control those functions for the system, made up of the Master drive and any number of Follower drives. The Hand On key starts the drive in local control so that the up/down arrows control system speed including any Follower drives. The Auto On key puts the system in operational mode depending on an external start command to run. The Reset key only resets the Master drive itself.

Follower drives The four operation keys on Follower drives control the action only for the functions of that specic Follower drive and no other drive units. Follower drives must be in Auto On mode for normal system operation.

Section 6 Programming and Operation

Basic Drive Programming

The following section demonstrates how to enter basic motor and system data into the drive’s internal memory. Most, if not all, of these functions are com-

monly factory programmed when specic applications

are known prior to shipment. For other applications, the information provided here must be entered. (See Section 5, User Interface for details on using the local control panel.)

Entering Basic Motor Data

1. Enter the Quick Menu by pressing the Quick

Menu Key on the keypad.

2. Use the up/down arrows to nd parameter Q2, Motor Setup and press the OK key.

3. Press the OK key again to access the

parameter. Use the up/down arrows to change values. From the motor nameplate, enter the correct information for the following settings.

1-21 Motor Power (HP)

1-22 Motor Voltage (VAC)

1-23 Motor Frequency (Hz)

1-24 Motor Current (A)

1-25 Motor Nominal Speed (Hz)

4-12 Motor Speed Low Limit (Hz)

4-14 Motor Speed High Limit (Hz)

Designating Master or Follower Drives

Master drives contain the optional MCB101 master board located behind the LCP (see Figure XX). Programming for the Master drive is factory installed.

Table 6-1. Quick Menu Layout

Quick Menu

Q1 My Personal Menu

20-21 Sensor Setpoint #1

20-22 Sensor Setpoint #2

20-23 Sensor Setpoint #3

20-24 Sensor Setpoint #4

39-55 Local / Remote

31-00 Bypass Mode (only available with bypass option)

39-46 Active Zone

Q2 Motor Setup

1-21 Motor Power

1-22 Motor Voltage

1-23 Motor Frequency

1-24 Motor Current

1-25 Motor Nominal Speed

4-12 Motor Speed Low Limit

4-14 Motor Speed High Limit

Q3 System Setup

39-06 Last Conguration Setting

20-93 PID Proportional Gain

20-94 PID Integral Time

20-00 Feedback 1 Source

20-03 Feedback 2 Source

20-06 Feedback 3 Source

20-09 Feedback 4 Source

39-26 Flow Measurement Source

6-15 Terminal 53 High Ref./Feedb. Value

6-18 Terminal 53 Reference/Feedback Units

6-25 Terminal 54 High Ref./Feedb. Value

6-28 Terminal 54 Reference/Feedback Units

6-35 Terminal X30/11 High Ref./Feedb. Value

6-38 Terminal X30/11 Reference/Feedback Units

6-45 Terminal X30/12 High Ref./Feedb. Value

6-48 Terminal X30/12 Reference/Feedback Units

3-03 Max Reference Units

39-20 Max Pump Flow (Old Par. 763)

39-31 Pump Alternation Time (Old Par. 770)

39-32 Start Alternation Start Delay Time (NEW)

Table 6-1. Quick Menu Layout (continued)

39-44 No. of Pumps Active In AZF (Old Par. 772)

3-11 Jog Speed

Pressure Booster Features

39-65 Suction Pressure Source

39-60 Low Suction Cut-Out Time (Old Par. 773)

39-61 Low Suction Cut-Out Pressure

39-62 High Suction Cut-Out Time

39-63 High Suction Cut-Out Pressure

39-64 High Suction Reset Pressure

39-75 Low/High System Sensor Source

39-70 High System Pressure Level(Old Par. 774)

39-71 High System Pressure Proof Time(Old Par. 775)

39-72 Low System Pressure Level

39-73 Low Pressure Proof Time

39-74 Low System Reset Pressure

39-76 Low System Pressure Alert Level

39-80 No Flow Shut Down Proof Time (Old Par. 776)

39-81 Minimum Speed Proof Time (Old Par. 777)

39-82 Restart Pressure Drop (Old Par. 778)

39-83 Minimum Run Time (Old Par. 779)

39-84 No Flow Shut Down Bandwidth (Old Par. 789)

Q5 Changes Made

Last 10 Changes

Since Factory Settings

Q6 Loggings

Q7 70X

3-03 Maximum Reference

27-20 Normal Operating Range (%) - Staging Band

27-22 Fixed Speed Only Operating Range

Q8 Communications

8-30 Protocol

8-31 Address

8-32 Baud Rate

8-33 Parity

8-70

BACnet Device Instance (only available with BACnet installed)

Table 6-2. Parameter 39-** Group, Detailed Description

No. Name Min Max Default Description

39-0*

39-00 Auto Assign I/O Pins

39-02 System Status Word Status ags used for eldbus

39-03 System Operating Mode 0 2 1 Status used for eldbus

39-04 Warning Status 1 Warning ags used for eldbus

39-05 Warning Status 2 Warning ags used for eldbus

39-06 Last Conguration Setting 0 13 13 Last Conguration setting selected

Cong.

0 - Done 1 - A0 2 - C0 - 1 Followers 3 - D0 - 1 Follower 4 - D0 - 2 Followers 5 - D0 - 3 Followers 6 - A1 7 - B3 8 - C4 9 - D4 10 - 70X - 1CS 11 - 70X - 2CS 12 - 70X - 3CS 13 - Follower

0 13 0 Selecting one of these Congurations

will automatically set the input and output parameters and default values

correctly for the conguration.

communications

communications 0 - Manual 1 - Auto 2 - Auto Bypass

communications

through P39-00. Warning: Individual

parameter settings of the conguration

may be changed manually so there is no guarantee that it is still set to this

standard conguration.

39-1* Stage/

Destage

39-10 Stage Speed (Old Par. 750) 0% 100% 95% When a variable speed pump reaches

this percentage of maximum speed, the controller will start a timer, set in parameter P39-11. After this timer expires, the controller will stage on another pump.

39-11 Stage Proof Timer (Old Par.

751)

0s 999s 30s

After a variable speed pump reaches the speed percentage set in parameter P39-10, this timer will start. After this timer expires the controller will stage on an additional pump.

Table 6-2. Parameter 39-** Group, Detailed Description (continued)

39-12 Stage Stab. Proof Timer

(Old Par. 752)

39-13 De-Stage Percentage (Old

Par. 753)

39-14 De-Stage Proof Timer (Old

Par. 754)

39-15 Min. De-Stage Speed (Old

Par. 755)

39-16 Min. De-stage Proof Timer

(NEW)

0s 999s 60s

0% 100% 80%

0s 999s 30s After a pump has been de-staged, the

0% 100% 50%

0s 999s 30s After the speed set in P39-15 is

After a new pump is staged on or off, the system will wait at least this long before allowing a pump to be staged on or off. After a pump has been staged on, the speed that the system reaches after this timer expires is used to calculate the de-stage speed.

After a pump is staged on, the controller waits until the stage stabilization proof timer expires. It then calculates the de-stage speed by multiplying the pump speed by the value in this parameter. The controller will de-stage a pump when the system speed reaches this value.

controller will wait for the time set in this parameter before allowing another pump to be staged ON or OFF.

The staging set in parameter P39-13 depends on the system speed after the time delay of parameter P39-14. If demand drops after the staging, the de-stage speed could be too low. This parameter sets an absolute minimum de-stage speed. If the system runs below this speed for the time in P39-16, a pump will de-stage.

reached, the controller will wait for the time set in this parameter before destaging.

39-2* EOC

Staging

39-20 Max Pump Flow (Old Par.

763)

39-21 EOC Staging Proof Timer

(Old Par. 764)

0.0 999999.000GPM

227124.500 M3/h

0s 999s 30s

0.000 This is used to initiate end-of-curve staging on of an additional pump. This

represents the maximum ow per pump

at the end of the pump curve. When

the ow per pump is greater than his

value times the pump speed in percent, the controller will begin to stage on an additional pump

After the feedback signal from the

ow meter indicates that the ow per

pump is greater than the expected

ow, this timer starts. The expected ow is calculated by the product of the maximum ow from the pump times the

percent of output speed If the condition continues until the timer expires, an additional pump will be staged on.

Table 6-2. Parameter 39-** Group, Detailed Description (continued)

39-22 EOC De-Stage Percentage

(Old Par. 765)

39-23 EOC De-Stage Proof Timer

(Old Par. 766)

39-24 Flow Destage Value (Old

Par. 767)

39-25 Flow Destage Proof Timer

(Old Par. 768)

39-26 Flow Measurement Source

- No function

- Analog input 54

- Analog input X30/11

- Analog input X30/12

0% 100% 45%

0% 100% 30s

0.0 999999.000GPM

227124.500 M3/h

0s 999s 0s When the controller initiates a ow

0.000

This parameter works with the ow

feedback sensor to determine if a pump

needs to be staged off. If the ow per

pump is less than this parameter times

the expected pump ow, the controller

will begin to stage off a pump. For this to de-stage a pump, the pressure feedback signal must also indicate a need to de-stage.

After the controller calculates that end of curve staging is required, this timer starts. If the condition continues until the timer expires, a pump will be staged off.

If the ow per pump measured by the ow meter is less than this value, the

controller will initiate the process of staging off a pump, regardless of the pressure feedback.

de-stage, this timer will start. If the condition continues until the timer expires, a pump will be staged off.

This parameter tells the controller which analog input is connected to the

system ow meter.Input scaling for the meter is dened in parameter group

P06-xx.

39-27 Flow Measurement Unit

- GPM

- M3/h

39-29 Measured Flow 0.0 999999.000GPM

227124.500 M3/h

39-3*

39-30 Transition Time (Old Par.

769)

0s 60s 20s

This parameter denes the units used in measuring the sysem ow as well as

the units used in EOC calculation and P39-20 and P39-24.

This parameter displays the current

system ow from the ow meter

attached to the input selected by parameter P39-26. Input scaling for the

meter is dened in parameter group

P06-xx.

When the alternation timer determines that it is necessary to stop one pump and start another one, the controller will

rst start the second pump and allow

both to run together for the time set by this parameter. After this timer expires, the pump that was initially running will be stopped.

Table 6-2. Parameter 39-** Group, Detailed Description (continued)

39-31 Pump Alternation Time (Old

Par. 770)

39-32 Alternation Start Delay Time 0s 999s 0s It is often desirable to have alternation

39-33 Pump Run Order

0 - Runtime Order 1 - First On First Off 2 - Sequential Order

0s 999s 0s When not all pumps are operating,

this determines the number of hours of pump operation before pump alternation occurs. When the pumps are manually alternated using the right or left arrow keys on the Local Control Panel, this timer is reset.

occur at off peak times, such as at night. To allow the system to be setup during normal hours to alternate every night this start delay parameter is used.

It denes the length of time before the

next alternation.

0 2 2 The controller selects the next pump

to stage, destage or alternate. Equal Running Hrs will cause the controller to turn on the pump with the fewest running hours and to trun off the piump with the most running hours. Sequential Order will turn on the pump to the right of the lead pump and will turn off the pump to the farthest left of the lead pump regardless of running hours.

39-34 Lead Pump Number 1 4 A display of the current lead pump

number used by the controller for sequential staging and destaging. This

is only signicant if Sequenctial Order

is selected in P39-33.

39-35 “Alternate Lead Pump Now

[0] - No [1] - yes”

39-39 Time Until Daily Alternation A display of the time remaining before

39-4* Alms/

Sensor Fault

39-40 AFD Fail Proof Timer (Old

Par. 771)

39-41 Pump Fail Proof Timer (Old

Par. 771)

0s 200s 10s After the controller commands a pump

0s 200s 10s

0 Selecting [1] Yes will cause the

immediate alternation of the lead pump. After alternation the parameter returnes to [0] No.

the next alternation will occur.

to run, it will check for conrmation that

the pump is running. If the controller

does not receive run conrmation

before the timer set in this parameter expires, it will stage on a different pump and display WARINIG, DRIVE FAILED.

After the controller commands a pump

to run, it will check for conrmation that

the pump is running. If the controller

does not receive run conrmation

before the timer set in this parameter expires, it will stage on a different pump and display WARINIG, PUMP FAILED.

Table 6-2. Parameter 39-** Group, Detailed Description (continued)

39-42 AI Low Warning Proof Time 0s 200s 5s The length of time that an analog input

is below 3 mA before it is considered to have failed.

39-43 AI High Warning Proof Time 0s 200s 60s The length of time that an analog input

is above or equal to 20 mA before it is considered to have failed.

39-44 No. of Pumps Active In AZF

(Old Par. 772)

1 4 1 All zone failure occurs when all

pressure feedback signals are lost (i.e. drop below 3 mA). During this

condition, a predened number of pumps will run at a predened speed.

This parameter sets the number of pumps and parameter P03-19 determines the speed. Parameter P39-45 sets the time delay before the controller activates all zone failure operation.

39-45 AZF Timeout (Old Par. 317) 0s 99s 10s

39-46 Active Zone Number 1 4 The number of the analog input that

39-5* Auto

Bypass/ Misc

39-50 No. Of AFD Fail To Go To

Bypass

39-51 No. Of Pumps To Run In

Bypass

1 2 1

0 2 1 This parameter selects the number of

If the feedback signal to all active analog inputs drops below 3 mA, the controller will begin its All Zone Failure mode. After the time delay set in this parameter expires, the display will show ALARM, ALL ZONE FAILURE. The controller will then activate

the number of pumps specied by

parameter P39-44 and run them at the

frequency specied in parameter P03-

19.

has the the largest deveation form it’s

dened setpoint. This is the input that

is used to determine the speed of the Drive.

In a multiple drive system, when one drive fails another drive is staged on. This parameter determines the number of drives that must fail before the system will automatically operate the number of pumps selected in parameter P39-51 in full speed bypass. Automatic bypass is not initiated if pump failure is detected.

pumps that should operate at full speed in bypass when the system goes into automatic bypass mode.

Table 6-2. Parameter 39-** Group, Detailed Description (continued)

39-53 No. Of Pumps In Duty

Standby

39-54 % Full Speed 0 ->

39-55 Run Signal

- Local

- Remote

39-6* Pressure

Suction Feat.

39-60 Low Suction Cut-Out Time

(Old Par. 773)

0 2 1 - C4

0Hz

0 1 1 This parameter allows the system to be

0s 999s 30s When control voltage is applied to

The number of pumps that must remain

0 - else

100% -> 50/60Hz A display of the current % of full speed

idle during operation. The controller will rotate between pumps but will not turn on more than then total number of pumps minus this number.

of the Drive. 100% = 60Hz. This is used

by eldbus communications.

run in local mode without an external start signal. It is used for dianostics and to run the system in the event of a remote controller failure. Selecting Local allows the motor to start and run in closed loop control just by pressing AutoOn. Selecting Remote requires a remote start signal through Pin18 or

from a eldbus.

digital input 19, the controller will display WARNING, LOW SUCTION CUT OUT. After the time delay set in this parameter, the controller will stop all pumps and display ALARM, LOW SUCTION CUT OUT. If parameter P1420 is programmed for automatic restart, after the low suction cut-out signal is removed and the timer set in parameter P14-21 expires, the drive will restart.

39-61 Low Suction Cut-Out

Pressure

39-62 High Suction Cut-Out Time 0s 999s 0s This is the timer used to determine if

0.0 Depends on P3965

0.0 If a Suction Pressure source is selected in P39-65 then this parameter sets the pressure below which the timer in P3960 is started. If the timer expires while the suction pressure remains below this value then the system is turned off.

the pumps should be shut off because they are no longer needed to maintain output pressure.

Table 6-2. Parameter 39-** Group, Detailed Description (continued)

39-63 High Suction Cut-Out

Pressure

39-64 High Suction Reset

Pressure

39-65 Suction Pressure Source

- No function

- Analog input 54

- Analog input X30/11

- Analog input X30/12

39-69 Suction Pressure A display of the current Suction

39-7* PB Sys

Press Feat.

39-70 High System Pressure

Level (Old Par. 774)

0.0 Depends on P3965

0.0 PSI 999999.0PSI 0.0 PSI If the pressure feedback signal

0.0 If a Suction Pressure source is selected in P39-65 then this parameter sets the pressure above which the timer in P3962 is started. If the timer expires while the suction pressure remains above this value then the pumps are not needed and are shut off.

0.0 If the pumps have been shut off due to High Suction Pressure and if the pressure drops below this point then

the rst pump will be turned on.

This parameter tells the controller which analog input is connected to the suction pressure sensor. Input scaling

for the sensor is dened in parameter

group P06-xx.

Pressure.

exceeds this value for the amount of time set in parameter P39-71, the controller will cause a system shutdown

and display ALARM, HIGH SYSTEM

PRESSURE. It will be necessary to cycle power to the controller to reset this alarm if P39-77 is set to Alarm Trip Lock.

39-71 High System Pressure

Proof Time (Old Par. 775)

39-72 Low System Pressure Level 0.0 Depends on

39-73 Low System Pressure Proof

Time

0s 999s 0s

P3965

0s 60s 0s

This determines the amount of time that the system must have pressure greater than the value set in parameter P39-70 before it goes into an alarm condition.

0.0 If a System Pressure source is selected in P39-75 then this parameter sets the pressure below which the timer in P3973 is started. If the timer expires while the system Pressure remains below

this value then the action dened in

P39-76 is performed.

This determines the amount of time that the system pressure must be lower than the value set in parameter P39-73 before it performs the action selected by P39-76.

Table 6-2. Parameter 39-** Group, Detailed Description (continued)

39-74 Low System Reset

Pressure

39-75 Low/High System Pressure

Source

- No function

- Analog input 53

- Analog input 54

- Analog input X30/11

- Analog input X30/12

39-76 Low System Pressure Alert

Level

- Warning

- Warning and Stop

39-8* No Flow

Shut Down

39-80 No Flow Shut Down Proof

Time (Old Par. 776)

0.0 Depends on P3965

0s 60s 0s This parameter tells the controller

0s 9999s 0s If minimum speed, as set by parameter

0.0 If the pumps have been shut off due to Low System Pressure and if the pressure increases above this point

then the rst pump will be turned on.

which analog input is connected to the System Pressure sensor. Input scaling

for the sensor is dened in parameter

group P06-xx.

Action to perform when the Low System Pressure Proof Timer P3973 expires while the system pressure remains below the value in P39-72.

P04-11 is reached, the timer set in this parameter will activate. After the timer expires, the minimum speed proof timer, set in parameter P39-81 will activate. After these timers expire, the controller stops the pump and displays WARNING, NO FLOW SHUT DOWN.

39-81 Minimum Speed Proof Time

(Old Par. 777)

39-82 Restart Pressure Drop (Old

Par. 778)

0s 9999s 0s When only one pump is running at

minimum speed, the controller will activate a sequence to stop the pump. First the timer set in parameter P39-80 must expire. Then the timer set in this parameter must expire. After these timers expire, the controller stops the pump. When the system pressure drops below the value set in parameter P39-82, the system will automatically restart.

0.0 PSI 999999.0 PSI 0.0 PSI After the system has been shut down

by the No Flow Shut Down function, it will automatically restart when the pressure in the system drops below this value. If this is set to OFF, the system will not activate No Flow Shut Down.

Table 6-2. Parameter 39-** Group, Detailed Description (continued)

39-83 Minimum Run Time (Old

Par. 779)

39-84 No Flow Shut Down

Bandwidth (Old Par. 789)

60s 600s 600s

0.0% 5.0% 2.5%

Before the controller stops a pump using No Flow Shut Down, the timers set in parameters P39-80 and P3981 must expire. If the system has previously been stopped using No Flow Shut Down, the timer set in this parameter must also expire before the No Flow Shut Down occurs.

If the difference between the setpoint and the feedback is less than this parameter’s percent of the maximum feedback value, the controller will continue to decelerate the drive.

Off

The drive does not react to any control signal until Auto On or Hand On is pres s ed.

Auto On

The drive is controlled via the control terminals and/or the serial communication.

Hand On

The drive can be controlled by up and down arrows on the LCP keypad. S

top

comm ands , alarm resets,

reversing

, DC brake, and other signals can be applied to

the control terminals that override local control.

Remote

The speed reference is given via internal pres et references and/or external s ignals (analog or digital) or via serial communication.

Local

The drive uses the reference values set via the LCP. For further information, pleas e exam ine parameter 3-13.

AC Bra k e

AC Brake was selected in param eter 2-10

Brak e Function

. The m o tor is slow ed down via the active down ramp and feeds the drive with generative energy. The AC brake over-m agnetizes the motor to achieve a controlled end of the active ramp.

AMA finish OK

Autom atic m otor adaptation (AMA) was carried out success fully.

AMA ready

Autom atic m otor adaptation (AMA) is ready to start. Press Hand On on the LCP to start.

Operation Mode

Reference Site

Operation Status

Section 7 Status Messages

Status Messages

Status messages are generated automatically and appear in the bottom line of the display as shown.

A. The rst part of the status line indicates

where the stop/start command originates.

B. The center part of the status line indicates

where the speed control originates.

C. The last part of the status line gives the

present drive status.

The table below denes the status massage display

words.

Table 7-1. Status Message Denitions

Figure 7-1. Display Status Line

AMA running

Autom atic m otor adaptation (AMA) process is in progres s.

Braking

The brake chopper is in operation. Generative energy is absorbed by the brake resis tor.

Braking m ax.

The brake chopper is in operation. The power lim it for the brake res is tor defined in parameter 2-12 Brake Power Lim it (kW) is reached.

Bypas s

Indicates the drive is operating in bypas s mode, meaning the drive control is being bypassed and the motor run off of mains power input directly.

The output frequency is corrected by the value set in param eter 3-12

Catch Up/Slow

Down Value

1. Catch up is selected as a function for a digital input (parameter group 5-1). The corres ponding terminal is active.

2. Catch up was activated via serial com m unication.

1. Coas t inverse has been selected as a function for a digital input (param eter group 5-

1). The corresponding term inal (e.g. Terminal 27) is not connected.

2. Coas t is on 0 on serial comm unication

Ctrl. Ramp-down

A function with

Ctrl. Ramp-down

was selected in param eter 14-10

Mains Failure

. The

mains voltage is below the value set in parameter 14-11

Mains Voltage

at mains

fault

. The drive ramps down the motor using a controlled ramp down.

The motor is mom entarily driven with a DC current (parameter 2-01

DC Brak e

Current

)

for a specified time (param eter 2-02

DC Brak ing Time

)

1. DC Brake is activated (OFF) in parameter 2-03

DC Brake Cut In Speed [RPM]

and a Stop command, e.g. Stop (inverse) is active.

2. DC Brake (invers e) is selected as a function for a digital input (param eter group 5-

1). The corresponding term inal is not active.

3. The DC Brake is activated via s erial communication.

Fee dback high

In parameter 4-57

Warning Feedback High

, an upper feedback lim it is set. The sum

of all active feedbacks is above the feedback lim it.

Fee dback low

In parameter 4-56

Warning Feedback Low

, a lower feedback limit is set. The s um of

all active feedbacks is below the feedback lim it.

The remote reference is active and the m omentarily given speed is saved.

1. Freeze output was selected as a function for a digital input (Group 5-1). The corres ponding terminal is active. Speed control is only pos s ible via the term inal functions speed up and speed down.

2. Hold ramp is activated via serial com munication.

Freeze output request

A freeze output command has been given, but the motor will rem ain stopped until a

run permissive

signal is received via a digital input.

Freeze Ref.

Freeze Ref. was chosen as a function for a digital input (parameter group 5-1). The corres ponding terminal is controlled. The drive saves the actual reference. Changing the reference is now only possible via terminal functions speed up and speed down.

Jog reques t

A JOG command has been given, but the motor will be stopped until a r

un permissive

signal is received via a digital input.

Coast Current High

In parameter 4-51

Warning Current High

, a current limit is set. The output current of

the drive is above this limit.

Catch up

Current Low

In parameter 4-52

Warning Speed Low

, a current limit is set. The output current of the

drive is below this limit.

DC Hold

The motor is driven with a permanent DC current, param eter 2-00

DC Hold Current

DC hold is s elected in parameter 1-80

Function at Stop

. A Stop comm and, e.g. Stop

DC Stop

Fee dback low

In parameter 4-56

Warning Feedback Low

, a lower feedback limit is set. The s um of

all active feedbacks is below the feedback lim it.

Freeze output

Table 7-1. Status Message Denitions (continued)

The m otor is running with parameter 3-19

Jog Speed [RPM]

1. Jog was selected as function for a digital input (parameter group 5-1). The corres ponding terminal (e.g. Terminal 29) is active.

2. The Jog function is activated via the serial comm unication.

3. The Jog function was selected as a reaction for a monitoring function (e.g. No signal). The monitoring function is active.

Motor chec k

In parameter 1-80

Function at Stop

, the Motor check function was s elected. A stop comm and, e.g. Stop (inverse) is active. To ensure that a motor is connected to the drive, a permanent test current is applied to the m otor.

PowerUnit Off

Only with controllers with installed option (external 24 V s upply). The mains supply to the controller is cut off, but the control card is still supplied with 24 V.

Protection md

The unit has detected a critical status (e.g. an overcurrent or overvoltage). To avoid tripping the controller (alarm ), protection mode is activated, which includes reducing the switching frequency to 4 kHz. If pos s ible, protection mode ends after approximately 10 sec. Activation of protection m ode can be restricted by adjus ting the parameter 1426 Tri p Delay at Inverter Faul t.

The motor is stopped us ing a quick stop ram p param eter 3-81

Quick Stop Ramp

Time

1. Quick stop inverse was chos en as a function for a digital input (parameter group 5-

1). The corresponding term inal (e.g. Terminal 27) is not active.

2. The Quick stop function was activated via serial com m unication.

Ramping

The motor is accelerating/decelerating using the active Ramp Up/Down. The reference, a limit value or a stands till is not yet reached.

The output frequency is corrected by the value set in param eter 3-12

Catch Up/Slow

Down Value

1. Speed down was selected as a function for a digital input (parameter group 5-1). The corres ponding terminal is active.

2. Speed down was activated via serial com munication.

Ref. high

In parameter 4-55

Warning Reference High

a reference high lim it is set. The sum of

all active references is above the reference limit.

Ref. low

In parameter 4-55

Warning Reference High

a reference low lim it is set. The sum of

all active references is below the reference lim it.

Pre-magnetize

Pre-magnetization is selected in parameter 1-80

Function at Stop

. A stop com m and (e.g. Stop inverse) is activated. A suitable constant magnetizing current is applied to the m otor.

QStop

Jogging

OVC control

Overvoltage control is activated in parameter 2-17

Over-voltage Control

. The connected motor is supplying the drive with generative energy. The Overvoltage control adjusts the V/Hz ratio to run the motor in controlled mode and to prevent the drive from tripping.

Run on ref.

The drive is running in the reference range. The feedback value matches the set reference value.

Run reques t

A start com m and has been given, but the motor will be stopped until a

run permissive

signal is received via digital input.

Running

The m otor is driven by the drive, the ramping phase is done and the motor revolutions are outside the

On Reference

range. Occurs when one of the motor speed lim its (Param eter 4-11/4-12/4-13 or 4-14) is set, but the maximum reference is outside this range.

Sleep Mode

The energy saving function in parameter 403

Sleep Mode Timer

is enabled. This means that at present the motor has s topped, but that it will restart automatically when required.

Speed dow n

Table 7-1. Status Message Denitions (continued)

Standby

[Auto On] The d rive s tarts the m otor us i ng a s tart s i gnal in a digi tal in put (if the parameter is program m ed accordingly) or via serial com m unication.

Start delay

In param eter 1-71 Start Delay, the delay of the starting time was set. A Start command was activated and the delay time is still running. The motor will start after the delay time has expired.

Start fwd/rev

Enab le start forward

and

Enab le start reverse

were selected as functions for two different digital inputs (param eter group 5-1). To start the motor, a direction dependent start signal has to be given and the corres ponding terminal has to be active.

Stop

OFF was pres sed on the LCP or Stop inverse was selected as a function for a digital input (Group 5-1). The corres ponding terminal is not active.

Speed low

In parameter 4-52

Warning Speed Low

a value i s s et. The s peed of th e m o tor is

below this value.

Speed high

In parameter 4-53

Warning Speed High

, a value i s s et. The s peed of th e m o tor is

above this value.

Trip lock

A serious alarm occurred. It is pos s ible, provided the caus e of the alarm was cleared, to reset the alarm after the mains have been switched off and on again. This can be done via a

reset

signal (RESET on the LCP, a control terminal or serial

comm unication).

Trip

An alarm occurred. It is pos s ible, provided the caus e of the alarm is cleared, to reset the alarm via a

Reset

signal ([RESET key on the LCP, a control terminal or serial

comm unication).

Table 7-1. Status Message Denitions (continued)

Section 8 Warnings and Alarms

System Monitoring

The variable frequency drive monitors the condition of its input power, drive output, and motor factors as well as other system performance indicators. A warning or alarm may not necessarily indicate a problem internal to the drive itself. In many cases it indicates failure conditions from input voltage, motor load, temperature, pump performance, or other areas monitored by the drive’s internal logic. Be sure to investigate those areas exterior to the drive as indicated in the alarm or warning message. A master drive in a multiple drive system also conducts limited monitoring of follower drives, but each drive has its own internal monitoring capability.

Warning and Alarm Displays

A warning will ash on display line 4 along with the

warning number.

Description and Remedy

A warning is issued when an alarm condition is impending.

An alarm is issued when the drive is tripped. The controller will continue to operate with power removed from the motor. The motor will coast to a stop. After a reset, the drive will be ready to start operation again.

A trip can be reset in any one of three ways:

1) Pressing the RESET key on the keypad

2) Digital reset input command

3) Serial communication reset input command

An alarm may also result in a trip-lock fault. A trip-lock requires that input power be removed, the cause of the fault corrected, and input power restored to reset the drive. Power must be cycled with a trip-lock.

An alarm will ash on display line 4 along with the

alarm number.

NOTE

cy c l i n g p o w E r t o t H E d r i v E is r E q u i r E d a f t E r a t r i p -l o c k

t o r E s t o r E t H E d r i v E t o a t r i p c o n d i t i o n w H E n p a r a m E t E r

14-20, rE s E t fu n c t i o n s , i s s E t t o m a n u a l . af t E r c y c l i n g

p o w E r , p r E s s t H E r E s E t k E y o n t H E k E y p a d t o p l a c E t H E d r i v E i n r u n m o d E .

The warnings and alarms denitions on the following pages will dene the condition, explain the probable

cause or troubleshooting procedure, and provide a remedy.

NOTE

fa u l t lo g E n t r i E s a r E b a s E d o n p r i o r i t y l E v E l s a n d

m a y n o t n E c E s s a r i l y b E i n t H E o r d E r i n w H i c H t H E y o c c u r r E d .

Table 8-1. Warnings and Alarms

WARNING 1, 10 volts low

The control card voltage is below 10V from terminal 50. Remove some of the load from terminal 50, as the 10V supply is overloaded. Max. 15 mA or minimum 590 ohms. This condition can be caused by a short in a connected potentiometer or improper wiring of the potentiometer. Troubleshooting: Remove the wiring from terminal 50. If the warning clears, the problem is with the customer wiring. If the warning does not clear, replace the control card.

WARNING/ALARM 2, Live zero error

This warning or alarm will only appear if programmed by the user in parameter 6-01 Live Zero Timeout Function. The signal on one of the analog inputs is less than 50% of the minimum value programmed for that input. This condition can be caused by broken wiring or faulty device sending the signal.

Troubleshooting:

Check the connections on all the analog input terminals. Control card terminals 53 and 54 for signals, terminal 55 common. Make sure that the controller programming and switch settings match the analog signal type.

WARNING/ALARM 3, No motor

No motor has been connected to the output of the controller. This warning or alarm will only appear if programmed by the user in parameter 1-80 Function at Stop. Troubleshooting: Check the connection between the controller and the motor.

WARNING/ALARM 4, Mains phase loss

A phase is missing on the supply side, or the mains voltage imbalance is too high. This mes-

sage also appears for a fault in the input rectier

on the controller. Options are programmed at parameter 14-12 Function at Mains Imbalance. Troubleshooting: Check the supply voltage and supply currents to the controller.

WARNING 5, DC link voltage high

The intermediate circuit voltage (DC) is higher than the high voltage warning limit. The limit is dependent on the controller voltage rating. The controller is still active.

WARNING 6, DC link voltage low

The intermediate circuit voltage (DC) is lower than the low voltage warning limit. The limit is dependent on the controller voltage rating. The controller is still active.

WARNING/ALARM 7, DC overvoltage

If the intermediate circuit voltage exceeds the limit, the controller trips after a time.

Troubleshooting:

Connect a brake resistor Extend the ramp time Change the ramp type Activate functions in parameter 2-10 Brake

Function Increase parameter 14-26 Trip Delay at Inverter Fault

WARNING/ALARM 8, DC undervoltage

If the intermediate circuit voltage (DC) drops below the undervoltage limit, the controller checks if a 24V backup supply is connected. If no 24V backup supply is connected, the controller trips

after a xed time delay. The time delay varies

with unit size.

Troubleshooting:

Make sure that the supply voltage matches the controller voltage.

WARNING/ALARM 9, Inverter overloaded

The controller is about to cut out because of an overload (too high current for too long). The counter for electronic, thermal inverter protection gives a warning at 98% and trips at 100%, while giving an alarm. The controller cannot be reset until the counter is below 90%. The fault is that the controller is overloaded by more than 100% for too long.

Troubleshooting:

Compare the output current shown on the LCP with the controller rated current. Compare the output current shown on the LCP with measured motor current. Display the Thermal Drive Load on the LCP and monitor the value. When running above the controller continuous current rating, the counter should increase. When running below the controller continuous current rating, the counter should decrease.

WARNING/ALARM 10, Motor overload temperature

According to the electronic thermal protection (ETR), the motor is too hot. Select whether the controller should give a warning or an alarm when the counter reaches 100% in parameter 1-90 Motor Thermal Protection. The fault is that the motor is overloaded by more than 100% for too long.

Troubleshooting:

Check if motor is overheating. If the motor is mechanically overloaded.

Table 8-1. Warnings and Alarms (continued)

Motor parameter 1-24 Motor Current is set correctly. Motor data in parameters 1-20 through 1-25 are set correctly. The setting in parameter 1-91 Motor External Fan. Run AMA in parameter 1-29 Automatic Motor Adaptation (AMA).

WARNING/ALARM 11, Motor thermistor overtemp

The thermistor or the thermistor connection is disconnected. Select whether the controller gives a warning or an alarm when the counter reaches 100% in parameter 1-90 Motor Thermal Protection.

Troubleshooting:

Check if motor is overheating. Check if the motor is mechanically overloaded. Check that the thermistor is connected correctly between terminal 53 or 54 (analog voltage input) and terminal 50 (+10V supply), or between terminal 18 or 19 (digital input PNP only) and terminal 50. If a KTY sensor is used, check for correct connection between terminal 54 and 55. If using a thermal switch or thermistor, check the programming of parameter 1-93 Thermistor Resource matches sensor wiring.

If using a KTY sensor, check the programming of

parameters 1-95, 1-96, and 1-97 match sensor wiring.

WARNING/ALARM 12, Torque limit

The torque is higher than the value in parameter 4-16 Torque Limit Motor Mode (in motor opera- tion) or the torque is higher than the value in parameter 4-17 Torque Limit Generator Mode (in regenerative operation). parameter 14-25 Trip Delay at Torque Limit can be used to change this from a warning only condition to a warning followed by an alarm.

WARNING/ALARM 13, Overcurrent

The inverter peak current limit (approx. 200% of the rated current) is exceeded. The warning lasts about 1.5 sec., then the controller trips and issues an alarm. If extended mechanical brake control is selected, trip can be reset externally.

Troubleshooting:

This fault may be caused by shock loading or fast acceleration with high inertia loads. Turn off the controller. Check if the motor shaft can be turned. Make sure that the motor size matches the controller. Incorrect motor data in parameters 1-20 through 1-25.

ALARM 14, Earth (ground) fault

There is a discharge from the output phases to earth, either in the cable between the frequency converter and the motor or in the motor itself.

Troubleshooting:

Turn off the controller and remove the earth fault. Measure the resistance to earth of the motor leads and the motor with a meter to check for earth faults in the motor.

ALARM 15, Hardware mismatch

A tted option is not operational with the present control board hardware or software. Contact your supplier.

ALARM 16, Short circuit

There is short-circuiting in the motor or on the motor terminals. Turn off the controller and remove the short-circuit.

WARNING/ALARM 17, Control word time-out

There is no communication to the controller. The warning will only be active when parameter 8-04 Control Word Timeout Function is NOT set to OFF. If parameter 8-04 Control Word Timeout Function is set to Stop and Trip, a warning appears and the controller ramps down until it trips, while giving an alarm.

Troubleshooting:

Check connections on the serial communication cable. Increase parameter 8-03 Control Word Timeout Time. Check the operation of the communication equipment. Verify a proper installation based on EMC requirements.

WARNING 22, Hoist mechanical brake

The report value will show what kind it is. 0 = The torque reference was not reached before time-out. 1 = There was no brake feedback before the time-out.

WARNING 23, Internal fan fault

The fan warning function is an extra protective function that checks if the fan is running/ mounted. The fan warning can be disabled in parameter 14-53 Fan Monitor ([0] Disabled).

Troubleshooting:

Check fan resistance. Check soft charge fuses.

Table 8-1. Warnings and Alarms (continued)

WARNING 24, External fan fault

The fan warning function is an extra protective function that checks if the fan is running/ mounted. The fan warning can be disabled in parameter 14-53 Fan Monitor ([0] Disabled).

Troubleshooting:

Check fan resistance. Check soft charge fuses.

WARNING 25, Brake resistor short circuit

The brake resistor is monitored during operation. If it short circuits, the brake function is disconnected and the warning appears. The controller still works, but without the brake function. Turn off the controller and replace the brake resistor.

WARNING/ALARM 26, Brake resistor power limit

The power transmitted to the brake resistor is calculated: as a percentage, as a mean value over the last 120 seconds, on the basis of the resistance value of the brake resistor, and the intermediate circuit voltage. The warning is active when the dissipated braking power is higher than 90%. If Trip [2] has been selected in parameter 2-13 Brake Power Monitoring, the controller cuts out and issues this alarm, when the dissipated braking power is higher than 100%.

Warning: There is a risk of substantial power being transmitted to the brake resistor if the brake transistor is short-circuited.

WARNING/ALARM 27, Brake chopper fault

The brake transistor is monitored during operation and if it short-circuits, the brake function disconnects and issues a warning. The controller is still able to run, but since the brake transistor has short-circuited, substantial power is transmitted to the brake resistor, even if it is inactive. Turn off the controller and remove the brake resistor. This alarm/warning could also occur should the brake resistor overheat. Terminal 104 to 106 are available as brake resistor.

WARNING/ALARM 28, Brake check failed

Brake resistor fault: the brake resistor is not connected or not working. Check parameter 2-15 Brake Check.

ALARM 29, Heatsink temp

The maximum temperature of the heatsink has been exceeded. The temperature fault will not be reset until the temperature falls below a

dened heatsink temperature. The trip and reset

point are different based on the controller power size.

Troubleshooting:

Ambient temperature too high. Motor cable too long. Incorrect clearance above and below the controller. Dirty heatsink.

Blocked air ow around the controller.

Damaged heatsink fan. Check fan resistance. Check soft charge fuses. IGBT thermal sensor.

ALARM 30, Motor phase U missing

Motor phase U between the controller and the motor is missing. Turn off the controller and check motor phase U.

ALARM 31, Motor phase V missing

Motor phase V between the controller and the motor is missing. Turn off the controller and check motor phase V.

ALARM 32, Motor phase W missing

Motor phase W between the controller and the motor is missing. Turn off the controller and check motor phase W.

ALARM 33, Inrush fault

Too many power-ups have occurred within a short time period. Let the unit cool to operating temperature.

WARNING/ALARM 34, Fieldbus communication fault

The eldbus on the communication option card

is not working.

WARNING/ALARM 35, Out of frequency range:

This warning is active if the output frequency has reached the high limit (set in parameter 4-53) or low limit (set in parameter 4-52). In Process Control, Closed Loop, parameter 1-00 Congu- ration Mode this warning is displayed.

WARNING/ALARM 36, Mains failure

This warning/alarm is only active if the supply voltage to the controller is lost and parameter 14-10 Mains Failure is NOT set to OFF. Check the fuses to the controller

ALARM 38, Internal fault

It may be necessary to contact your supplier.

Table 8-1. Warnings and Alarms (continued)

ALARM 39, Heatsink sensor

No feedback from the heatsink temperature sensor. The signal from the IGBT thermal sensor is not available on the power card. The problem could be on the power card, on the gate drive card, or the ribbon cable between the power card and gate drive card.

WARNING 40, Overload of Digital Output Terminal 27

Check the load connected to terminal 27 or remove the short-circuit connection. Check parameter 5-00 Digital I/O Mode and parameter 5-01 Terminal 27 Mode.

WARNING 41, Overload of Digital Output Terminal 29

Check the load connected to terminal 29 or remove the short-circuit connection. Check parameter 5-00 Digital I/O Mode and parameter 5-02 Terminal 29 Mode.

WARNING 42, Overload of Digital Output on X30/6 or Overload of Digital Output on X30/7

For X30/6, check the load connected to X30/6 or remove the short-circuit connection. For X30/7, check the load connected to X30/7 or remove the short-circuit connection.

ALARM 46, Power card supply

The supply on the power card is out of range. There are three power supplies generated by the switch mode power supply (SMPS) on the power card: 24V, 5V, +/- 18V. When powered with three phase mains voltage, all three supplied are monitored.

WARNING 47, 24V supply low

The 24 VDC is measured on the control card. The external 24 VDC backup power supply may be overloaded, otherwise contact your supplier.

WARNING 48, 1.8V supply low

The 1.8 Volt DC supply used on the control card is outside of allowable limits. The power supply is measured on the control card.

WARNING 49, Speed limit

The speed is not within the specied range in

parameter 4-11 Motor Speed Low Limit [RPM] and parameter 4-13 Motor Speed High Limit [RPM].

ALARM 50, AMA calibration failed

Contact your supplier.

ALARM 51, AMA check U

nom

and I

nom

The setting of motor voltage, motor current, and motor power is presumably wrong. Check the settings.

ALARM 52, AMA low I

nom

The motor current is too low. Check the settings.

ALARM 53, AMA motor too big

The motor is too big for the AMA to work.

ALARM 54, AMA motor too small

The motor is too big for the AMA to work.

ALARM 55, AMA parameter out of range

The parameter values found from the motor are outside acceptable range.

ALARM 56, AMA interrupted by user

The AMA has been interrupted by the user.

ALARM 57, AMA time-out

Try to start the AMA again a number of times, until the AMA is carried out. Please note that repeated runs may heat the motor to a level where the resistances Rs and Rr are increased. In most cases, however, this is not critical.

ALARM 58, AMA internal fault

Contact your supplier.

WARNING 59, Current limit

The current is higher than the value in parameter 4-18 Current Limit.

WARNING 60, External interlock

External interlock has been activated. To resume normal operation, apply 24 VDC to the terminal programmed for external interlock and reset the controller (via serial communication, digital I/O, or by pressing the reset button on LCP).

WARNING 61, Tracking error

An error has been detected between the calculated motor speed and the speed measurement from the feedback device. The function for Warning/Alarm/Disable is set in parameter 4-30 Motor Feedback Loss Function, error setting in parameter 4-31 Motor Feedback Speed Error, and the allowed error time in parameter 4-32 Motor Feedback Loss Timeout. During a commissioning procedure the function may be effective.

WARNING 62, Output frequency at maximum limit

The output frequency is higher than the value set in parameter 4-19 Max Output Frequency.

ALARM 63, Mechanical brake low

The actual motor current has not exceeded the release-brake current within the start-delay time window.

WARNING 64, Voltage limit

The load and speed combination demands a motor voltage higher than the actual DC link voltage.

WARNING/ALARM/TRIP 65, Control card overtemperature

Control card overtemperature. (The cutout temperature of the control card is 80° C.)

Table 8-1. Warnings and Alarms (continued)

WARNING 66, Heatsink temperature low

This warning is based on the temperature sensor in the IGBT module.

Troubleshooting:

The heatsink temperature measured as 0° C could indicate that the temperature sensor is defective, thereby causing the fan speed to increase to the maximum. If the sensor wire between the IGBT and the gate drive card is disconnected, this warning is produced. Also, check the IGBT thermal sensor.

ALARM 67, Option module conguration has

changed

One or more options have either been added or removed since the last power-down.

ALARM 68, Safe stop activated

Safe stop has been activated. To resume normal operation, apply 24 VDC to terminal 37, then send a reset signal (via bus, digital I/O, or by pressing the reset key. See parameter 5-19 Terminal 37 Safe Stop.

ALARM 69, Power card temperature

The temperature sensor on the power card is either too hot or too cold.

Troubleshooting:

Check the operation of the door fans.

Make sure that the lters for the door fans are

not blocked. Make sure that the gland plate is properly installed on IP21 and IP54 (NEMA 1 and NEMA

12) controllers.

ALARM 70, Illegal FC Conguration

The current control board and power board combination is illegal.

WARNING/ALARM 71, PTC 1 safe stop

Safe Stop has been activated from the MCB 112 PTC thermistor card (motor too warm). Normal operation can be resumed when the MCB 112 applies 24 VDC to T-37 again (when the motor temperature reaches an acceptable level) and when the digital input from the MCB 112 is deactivated. When this happens, a reset signal is sent (via serial communication, digital I/O, or by pressing reset button on LCP). Note that if automatic restart is enabled, the motor may start when the fault is cleared.

ALARM 72, Dangerous failure

Safe stop with trip lock. Unexpected signal levels on the safe stop and digital input from the MCB 112 PTC thermistor card.

Warning 73, Safe stop auto restart

Safe stopped. Note that with automatic restart enabled, the motor may start when the fault is cleared.

ALARM 79, Illegal power section conguration

The scaling card is the incorrect part number or

not installed. Also, the MK102 connector on the

power card is not installed.

ALARM 80, Drive initialized to default value

Parameter settings are initialized to default settings after a manual reset.

WARNING 81, CSIV corrupt

CSIV le has syntax errors.

WARNING 82, CSIV parameter error

CSIV has failed to record a parameter.

ALARM 91, Analog input 54 wrong settings

Switch S202 must be set in the position OFF

(voltage input) when a KTY sensor is connected

to analog input terminal 54.

ALARM 92, No ow

A no-load situation has been detected in the system. See parameter group 22-2.

ALARM 93, Dry pump

A no-ow situation and high speed indicate that

the pump has run dry. See parameter group 22-2.

ALARM 94, End of curve

Feedback stays lower than the setpoint which may indicate leakage in the pipe system. See parameter group 22-5.

ALARM 95, Broken belt

Torque is below the torque level set for no load, indicating a broken belt. See parameter group 22-6.

ALARM 96, Start delayed

Motor start has been delayed due to short-cycle protection active. See parameter group 22-7.

WARNING 97, Stop delayed

Stopping the motor has been delayed due to short cycle protection is active. See parameter group 22-7.

WARNING 98, Clock fault

Clock Fault. The time is not set or the RTC clock (if mounted) has failed. See parameter group 0-7.

WARNING 220, Bypass Overload Trip

Motor overload has tripped. Indicates excess motor load. Check motor and driven load. To reset press the OFF/Reset key. Then, to restart the system, press the Auto ON or Hand ON key.

WARNING 221, Bypass Interlock

Bypass interlock has opened and caused the motor to stop. Correct the problem. Depending on the setting of parameter 14-20, the system will either automatically reset this alarm or require the OFF/Reset key to be pressed.

Table 8-1. Warnings and Alarms (continued)

WARNING 222, M2 Open Failed

The contactor that connects the drive to the motor failed to open. The motor cannot be operated.

WARNING 223, M2 Close Failed

The contactor that connects the drive to the motor failed to close. The motor cannot be operated.

WARNING 224, M3 Open Failed

The contactor that connects the motor to the power line has failed to open.

WARNING 226, M3 Close Failed

The contactor that connects the motor to the power line has failed to close. The motor cannot be operated.

WARNING 227, Bypass Com Error

Communication between the main control card and the bypass option has been lost. Motor control lost. It will be possible to run the motor using Manual Bypass Override.

WARNING 228, APU Low Voltage

The option panel power supply has failed, or there is a power problem.

WARNING 229, Motor Disconn

Terminal 3 on connector X57 of the ECB control card shows an open. This generally means that neither motor has been selected in contactor motor select. Select a motor.

ALARM 252, LOW_SUCTION_CUT_OUT

Indicates that the pump suction pressure is

below the value specied in P39-61 for the time specied in P39-60.

ALARM 253, LOW_SUCTION_CUT_OUT

Indicates that the System Pressure (output pres-

sure) is above the value specied by P39-70 for the time specied in P39-71.

ALARM 254, HIGH_SYSTEM_PRESSURE

Indicates that the System Pressure (output pres-

sure) is below the value specied by P 39-72 for the time specied in P39-73.

ALARM 255, ALL_ZONE_FAILURE

Indicates that all of the feedback sensors are disconnected or have failed. The Drive proceeds

to Jog speed after the time specied in P39-45.

ALARM 256, ANALOG_INPUT_53_HIGH

Indicates that the designated Feedback is equal to 20ma and may be shorted. It will no longer be

used after the time specied in P39-43

ALARM 257, ANALOG_INPUT_54_HIGH

Indicates that the designated Feedback is equal to 20ma and may be shorted. It will no longer be

used after the time specied in P39-43

ALARM 258, ANALOG_INPUT_X30_11_HIGH

Indicates that the designated Feedback is equal to 20ma and may be shorted. It will no longer be

used after the time specied in P39-43

ALARM 259, ANALOG_INPUT_X30_12_HIGH

Indicates that the designated Feedback is equal to 20ma and may be shorted. It will no longer be

used after the time specied in P39-43

ALARM 260, ANALOG_INPUT_53_LOW

Indicates that the designated Feedback is less than 3ma and may be disconnected. It will no longer be used after the time P39-42.

ALARM 261, ANALOG_INPUT_54_LOW

Indicates that the designated Feedback is less than 3ma and may be disconnected. It will no longer be used after the time P39-42.

ALARM 262, ANALOG_INPUT_X30_11_LOW

Indicates that the designated Feedback is less than 3ma and may be disconnected. It will no longer be used after the time P39-42.

ALARM 263, ANALOG_INPUT_X30_12_LOW

Indicates that the designated Feedback is less than 3ma and may be disconnected. It will no longer be used after the time P39-42.

ALARM 264, VFD_1_FAILED_TO_START

Indicates that the specied Drive has failed or is

not responding.

ALARM 265, VFD_2_FAILED_TO_START

Indicates that the specied Drive has failed or is

not responding.

ALARM 266, VFD_3_FAILED_TO_START

Indicates that the specied Drive has failed or is

not responding.

ALARM 267, VFD_4_FAILED_TO_START

Indicates that the specied Drive has failed or is

not responding.

ALARM 268, PUMP_1_FAILED_TO_START

Indicates that the pump suction pressure is

above the value specied in P39-63 for the time specied in P39-62.

ALARM 269, PUMP_2_FAILED_TO_START

Indicates that the specied Pump is indicating

no difference in pressure between the pump input and output.

ALARM 270, PUMP_3_FAILED_TO_START

Indicates that the specied Pump is indicating

no difference in pressure between the pump input and output.

ALARM 271, PUMP_4_FAILED_TO_START

Indicates that the specied Pump is indicating

no difference in pressure between the pump input and output.

ALARM 272, HIGH_SUCTION_CUT_OUT

Indicates that the pump suction pressure is

above the value specied in P39-63 for the time specied in P39-62.

Section 9 Start Up Troubleshooting

Symptom

Possible cause

Test

Solution

Missing input power

See startup guide for voltage checks.

Correct voltage at source.

Missing or open

fuses or circuit

breaker tripped

See open fuses and tripped circuit breaker in this section for

possible causes.

Reset circuit breaker. If fuses, check for opens with power

removed from panel.

Loose connections

in panel

Perform pre-startup check for loose connections.

Tighten loose connections in panel.

Missing customer

connections

Missing customer connections can cause the safety circuit or

start signal to be open.

See customer connections and make sure all applicable

connections are made or jumpers installed especially

customer interlock.

Loose customer

connections

Check all customer connections for tightness. Loose

customer connections can act like an open circuit.

Tighten loose customer connections.

Customer wires

incorrectly

terminated

See customer connection drawing and make sure wires are

connected to correct terminals.

Correct any wrong connections. This could potentially

case damage to panel.

Improper voltage

applied

See pre-startup check list.

Correct voltage mismatch. This could potentially damage

panel caution on applying power recommended.

Power connections

connected wrong

See pre-startup check list to see if motor and power leads

were swapped.

Correct any wrong connections. This could potentially

case damage to panel.

Power disconnect

open

Verify that disconnect or circuit breaker is closed.

Correct any wrong connections. This could potentially

case damage to panel.

Operator switches

off

Verify that operator devices are in operating position per

startup procedures.

Set switches to correct position.

No function

OL tripped

A tripped OL will disable the motor from running. Verify that

OL relay is in normal operating position per manual.

Perform pre-startup check list and set OL per instructions.

Improper voltage

applied

See pre-startup check list and correct if wrong.

Correct voltage mismatch. This could potentially damage

panel caution on applying power recommended.

Power connections

connected wrong

Motor and line voltage swapped. Make sure the line in and

motor out are on the correct terminals. See pre-startup check

list.

Correct any wrong connections. This could potentially

case damage to panel.

Power ground fault

Check motor and panel power wires to ground.

Eliminate any ground faults detected.

Phase to phase

short

Motor or panel has a short phase to phase. Check motor and

panel phase to phase for shorts.

Eliminate any shorts detected.

Motor overload

Motor is overloaded for the application.

Perform startup and verify motor current is within

specifications. If motor current is exceeding nameplate

FLA reduce the load on the motor.

Drive overload

Drive is overloaded for the application.

Perform startup and verify drive current is within

specifications. If not reduce the load on the motor.

Open power

fuses or

circuit

breaker trip

Loose connections

Perform pre-startup check for loose connections.

Tighten loose connections.

Table 9-1. Fault Table

Table 9-1. Fault Table (continued)

Symptom

Possible cause

Test

Solution

Application problem

Perform startup procedures. Check panel output motor

current at full speed and check for excessive over current.

If current is to high reduce load on motor.

Panel problem

Perform startup procedures. Check panel input current at full

speed and verify it is within acceptable range.

If current is to high reduce load on motor.

Power problem

Monitor incoming power for surges and sags and overall

quality.

Correct any problems found.

Repeated

fuse or circuit

breaker

Motor problem

Test motor for correct function.

Repair or replace motor if a problem is found.

Improper voltage

applied

See pre-startup check list.

Correct voltage mismatch. This could potentially damage

panel caution on applying power recommended.

Customer wires

incorrectly

terminated

See customer connection drawing and make sure wires are

connected to correct terminals.

Correct any wrong connections. This could potentially

case damage to panel.

Control ground fault

Check all control wires for a short to ground.

Correct any ground faults found. This could potentially

case damage to panel.

Open control

fuse

Control short

Check control wires for a short in supply voltage.

Correct any shorts. This could potentially case damage to

panel.

Improper voltage

applied

See pre-startup check list.

Correct voltage mismatch. This could potentially damage

panel caution on applying power recommended.

Customer wires

incorrectly

terminated

See customer connection drawing and make sure wires are

connected to correct terminals.

Correct any wrong connections. This could potentially

case damage to panel.

Control ground fault

Check all control wires for a short to ground.

Correct any ground faults found. This could potentially

case damage to panel.

Open SMPS

fuse

Control short

Check control wires for a short in supply voltage.

Correct any shorts. This could potentially case damage to

panel.

Motor

rotation

incorrect

Rotation incorrect in

bypass, drive or

both

Motor rotation is backwards in drive mode, bypass mode, or

both.

Perform motor rotation procedure in startup section of

manual.

Table 9-1. Fault Table (continued)

Symptom

Possible cause

Test

Solution

Motor overloaded

Motor is drawing too much current for the application.

Perform startup and verify motor current is within

specifications. If not, reduce the load on the motor.

Loose connections

Look for signs of overheating on connections to OL.

Perform pre-startup check for loose connections and

tighten. Replace any overheated components and wires.

Overload

trips

OL not set correctly

An improperly set OL can cause the OL to trip too soon. See

pre-startup procedure for correct setting.

Set correct motor current on OL.

Contamination

Remove contactor and check for contamination.

If contamination found, repair or replace.

Defective coil

Compare coil resistance to functional contactors of the same

size. Inspect coil for signs of overheating and damages.

If readings are not the same or visible signs of damage,

replace coil or contactor.

Contactor

fails to pull in

Auxiliary contact

binding action

Remove auxiliary contacts and test contactor action.

If contactor operates with auxiliaries removed, replace

auxiliary contacts.

Contamination

Remove contactor and check for contamination.

If contamination found, repair or replace.

Defective coil

Compare coil resistance to functional contactors of the same

size.

If readings are not the same or visible signs of damage,

replace coil or contactor.

Contactor

fails to drop

out

Auxiliary contact

binding action

Remove auxiliary contacts and test contactor action.

If contactor operates with auxiliaries removed, replace

auxiliary contacts.

Problem with mains

power

Rotate incoming power leads into option panel one position; A

to B, B to C, and C to A.

If imbalanced leg follows the wire it is a power problem.

Causes can vary contact electrician or power expert for

solution.

Mains current

imbalance

greater than

Problem with option

panel

Rotate incoming power leads into option panel one position; A

to B, B to C, and C to A.

If imbalance leg stays on same option panel input terminal

it is a problem with the option panel. Contact factory for

assistance.

Problem with motor

or motor wiring

Rotate out going motor leads one position; U to V, V to W,

and W to U.

If imbalanced leg follows motor lead the problem is in the

motor or wiring to the motor. Causes can vary contact

electrician or motor expert for a solution.

Motor current

imbalance

greater than

Problem with option

panel

Rotate out going motor leads one position; U to V, V to W,

and W to U.

If imbalance leg stays on same option panel output

terminal it is a problem with the option panel. Contact

factory for assistance.

Appendix

Serial Communication Point Maps

Protocols

Metasys N2: starts on page 63

Modbus RTU: starts on page 65

FLN: starts on page 68

Serial Communications Programming

Select the serial communication protocol type in Quick Menu item Q8, Communications.

Press the OK key to access the parameter choices

and scroll to parameter 8-30, Protocol to select the protocol in use.

Metasys N2 Point Map

NPT NPA POINT DESCRIPTION RANG/VALUE UNITS

BI 162

BI 163

BI 164

BI 166

BI 167

BI 168

BI 169

BI 170

BI 171

BI 172

BI 173

BI 174

BI 175

BI 176

BI 177

BI 155

System Start/Stop 1 = Start 0 = Stop

Pump Standby Enabled 1 = Enabled 0 = Disabled

General Alarm Output 1 = Failure 0 = O.K.

Pump #1 On/Off 1 = On 0 = Off

Pump #2 On/Off 1 = On 0 = Off

Pump #3 On/Off 1 = On 0 = Off

Pump #4 On/Off 1 = On 0 = Off

Pump #1 Congured 1 = Congured 0 = Disabled

Pump #2 Congured 1 = Congured 0 = Disabled

Pump #3 Congured 1 = Congured 0 = Disabled

Pump #4 Congured 1 = Congured 0 = Disabled

Pump #1 Running In Bypass Mode 1 = In Bypass 0 = Not In Bypass

Pump #2 Running In Bypass Mode 1 = In Bypass 0 = Not In Bypass

Pump #3 Running In Bypass Mode 1 = In Bypass 0 = Not In Bypass

Pump #4 Running In Bypass Mode 1 = In Bypass 0 = Not In Bypass

Pump #1 Bypass Overload 1 = Failure 0 = O.K.

Size in

Bits

BI 10

BI 146

BI 145

BI 144

BI 143

BI 142

BI 141

BI 140

BI 139

BI 138

BI 178

BI 179

BI 180

BI 181

System Reset Required 1 = Yes 0 = No

All Zone Failure 1 = Failure 0 = O.K.

Analog Input #1 High Failure 1 = Failure 0 = O.K.

Analog Input #2 High Failure 1 = Failure 0 = O.K.

Analog Input #3 High Failure 1 = Failure 0 = O.K.

Analog Input #4 High Failure 1 = Failure 0 = O.K.

Analog Input #1 Low Failure 1 = Failure 0 = O.K.

Analog Input #2 Low Failure 1 = Failure 0 = O.K.

Analog Input #3 Low Failure 1 = Failure 0 = O.K.

Analog Input #4 Low Failure

Pump #1 VFD Failure 1 = Failure 0 = O.K.

Pump #2 VFD Failure 1 = Failure 0 = O.K.

Pump #3 VFD Failure 1 = Failure 0 = O.K.

Pump #4 VFD Failure 1 = Failure 0 = O.K.

1 = Failure 0 = O.K.

Metasys N2 Point Map (continued)

BI 182

BI 183

BI 184

BI 185

BI 186

BI 147

BI 148

BI 149

BI 187

BO 6

BO 5

ADF 96

ADF 97

ADF 98

ADF 99

ADF 103

ADF 104

ADF 105

ADF 106

Pump #1 Pump Failure 1 = Failure 0 = O.K.

Pump #2 Pump Failure 1 = Failure 0 = O.K.

Pump #3 Pump Failure or VFD 1 = Failure 0 = O.K.

Pump #4 Pump Failure or VFD 1 = Failure 0 = O.K.

High Suction Alarm 1 = Failure 0 = O.K.

Low Suction Alarm 1 = Failure 0 = O.K.

High System Alarm 1 = Failure 0 = O.K.

Low System Alarm 1 = Failure 0 = O.K.

NFSD Warning 1 = Warning 0 = O.K.

System Reset Request 1 = Yes 0 = No

System Start / Stop 1 = Start 0 = Stop

Process Variable #1 0 to Span (in Technologic User Setup Menu)

Process Variable #2 0 to Span (in Technologic User Setup Menu)

Process Variable #3 0 to Span (in Technologic User Setup Menu)

Process Variable #4 0 to Span (in Technologic User Setup Menu)

Setpoint #1 0 to Span (in Technologic User Setup Menu)

Setpoint #2 0 to Span (in Technologic User Setup Menu)

Setpoint #3 0 to Span (in Technologic User Setup Menu)

Setpoint #4 0 to Span (in Technologic User Setup Menu)

ADF 100

ADF 7

ADI 127

ADF 107

AI 4

ADI 128

ADI 129

AI 43

AI 44

AI 45

System Flow Rate 0 to Span (in Technologic User Setup Menu) GPM

AFD #1 Power 0 to Span (in Technologic User Setup Menu) KW

System Operation Mode 0=Manual,1=Auto, 2=Auto Bypass.

Speed % 0 to 100 %

Frequency Output 0 to 50/60 Hz

Lead Pump Number 1 to Pump # (in Technologic User Setup Menu)

Active Zone Number 1 to Zone # (in Technologic User Setup Menu)

Run Time, Tech500 Unit 0-32767 Hours

Run Time, Pump #2 0-32767 Hours

Run Time, Pump #3 0-32767 Hours

Run Time, Pump #4 0-32767 Hours

Modbus RTU Point Map (by parameter)

PNU Name Size (in bits) Address(es) Indexed

16-03 Status Word

16-10 Power (kW)

16-13 Frequency

16-15 Frequency (%)

16-54 Feedback 1 (Unit)

16-55 Feedback 2 (Unit)

16-56 Feedback 3 (Unit)

16-57 Feedback 4 (Unit)

16-91 Alarm Word 2

16-93 Warning Word 2

20-21 Setpoint 1

20-22 Setpoint 2

20-23 Setpoint 3

20-24 Setpoint 4

27-01 Pump Status

27-03 Current Runtime Hours

27-93 Cascade Option Status

16 16030

32 16100,1

16 16130

32 16150,1

32 16540,1

32 16550,1

32 16560,1

32 16570,1

32 16910,1

16 16930

32 20210

32 20220

32 20230

32 20240

8 27010

32 27030,1

8 27930

31-10 Bypass Status Word

39-02 System Status Word

39-03 System Operating Mode

39-29 Measured Flow

39-34 Lead Pump Number

39-46 Active Zone Number

39-49 Warning Word 3

39-53 No. of Pumps in Duty Standby

16 31100

16 39020

8 39030

32 39290,1

16 39340

16 39460

32 39490,1

16 39530

Modbus RTU Point Map (by function)

Param

Number

39-02 # 00

39-02 # 01

39-02 # 02

39-02 # 04

39-02 # 05

39-02 # 06

39-02 # 07

39-02 # 08

39-02 # 09

39-02 # 10

39-02 # 11

39-02 # 12

39-02 # 13

39-02 # 14

39-02 # 15

Index

(Modbus

Status

Word Bit #

Modbus

Function

Code

Modbus DESCRIPTION RANGE/VALUE

05 12 Pump Sequence Alternation 1 = Yes 0 = No

05 8 System Reset Request 1 = Yes 0 = No

05 7 System Start / Stop 1 = Start 0 = Stop

39020

System Start/Stop 1 = Start 0 = Stop 16

Pump Standby Enabled 1 = Enabled 0 = Disabled 16

General Alarm Output 1 = Failure 0 = O.K. 16

Pump #1 On/Off 1 = On 0 = Off 16

Pump #2 On/Off 1 = On 0 = Off 16

Pump #3 On/Off 1 = On 0 = Off 16

Pump #4 On/Off 1 = On 0 = Off 16

Pump #1 Congured 1 = Congured 0 = Disabled 16

Pump #2 Congured 1 = Congured 0 = Disabled 16

Pump #3 Congured 1 = Congured 0 = Disabled 16

Pump #4 Congured 1 = Congured 0 = Disabled 16

Pump #1 Running In Bypass Mode 1 = In Bypass 0 = VFD 16

Pump #2 Running In Bypass Mode 1 = In Bypass 0 = VFD 16

Pump #3 Running In Bypass Mode 1 = In Bypass 0 = VFD 16

Pump #4 Running In Bypass Mode 1 = In Bypass 0 = VFD 16

SIZE IN

BITS

16-03 #03

16-93 #20

16-93 #21

16-93 #22

16-93 #23

16-93 #24

16-93 #25

16-93 #26

16-93 #27

16-93 #28

16-91 #20

16-91 #21

16-91 #22

16-54

16-55

16-56

16-57

03 16030 System Reset Required 1 = Yes 0 = No 32

03 16930 All Zone Failure 1 = Failure 0 = O.K. 32

03 16930 Analog Input #1 High Failure 1 = Failure 0 = O.K. 32

03 16930 Analog Input #2 High Failure 1 = Failure 0 = O.K. 32

03 16930 Analog Input #3 High Failure 1 = Failure 0 = O.K. 32

03 16930 Analog Input #4 High Failure 1 = Failure 0 = O.K. 32

03 16930 Analog Input #1 Low Failure 1 = Failure 0 = O.K. 32

03 16930 Analog Input #2 Low Failure 1 = Failure 0 = O.K. 32

03 16930 Analog Input #3 Low Failure 1 = Failure 0 = O.K. 32

03 16930 Analog Input #4 Low Failure 1 = Failure 0 = O.K. 32

03 16910,1 Low System Alarm 1 = Failure 0 = O.K. 32

03 16910,1 High System Alarm 1 = Failure 0 = O.K. 32

03 16910,1 Low Suction Alarm 1 = Failure 0 = O.K. 32

03 16540,1 Process Variable #1 0 to Span (in Technologic User Setup Menu) 32

03 16550,1 Process Variable #2 0 to Span (in Technologic User Setup Menu) 32

03 16560,1 Process Variable #3 0 to Span (in Technologic User Setup Menu) 32

03 16570,1 Process Variable #4 0 to Span (in Technologic User Setup Menu) 32

Modbus RTU Point Map (by function)

20-21

20-22

20-23

20-24

39-03

39-29

16-10

16-15

16-13

39-34

39-46

27-03.01

27-03.02

27-03.03

27-03.04

03 20210,1 Setpoint #1 0 to Span (in Technologic User Setup Menu) 32

03 20220,1 Setpoint #2 0 to Span (in Technologic User Setup Menu) 32

03 20230,1 Setpoint #3 0 to Span (in Technologic User Setup Menu) 32

03 20240,1 Setpoint #4 0 to Span (in Technologic User Setup Menu) 32

03 39030 System Operation Mode 0=Manual,1=Auto, 2=Auto Bypass. 8

03 39290,1 System Flow Rate (GPM) 0 to Span (in Technologic User Setup Menu) 32

03 16100,1 AFD #1 Power (kW) 0 to Span (in Technologic User Setup Menu) 32

03 16150,1 Speed % 0 to 100 32

03 16130 Frequency Output (Hz) 0 to 50/60 16

03 39340 Lead Pump Number 1 to Pump # (in Technologic User Setup Menu) 16

03 39460 Active Zone Number 1 to Zone # (in Technologic User Setup Menu) 16

1 03 27030,1 Run Time, Pump #1 0-32767 Hours 32

2 03 27030,1 Run Time, Pump #2 0-32767 Hours 32

3 03 27030,1 Run Time, Pump #3 0-32767 Hours 32

4 03 27030,1 Run Time, Pump #4 0-32767 Hours 32

Floor Level Network (FLN) Set-up

1. Connect FLN to RS-485 connector on drive.

2. Set parameter 8-30, Protocol to FLN.

3. Each drive must have a unique address assigned in parameter 8-31, Address.

4. Check that the baud rate selected in parameter 8-32, Baud Rate is correct.

The table below lists the parameters associated with FLN functions in the drive. Additional setting are provided to apply customizing of the FLN communication protocol.

FLN Programmable Functions

Parameter Title Default Setting Desired Setting

8-30 Control Timeout 0

8-04 Control Timeout Function OFF

8-30 Protocol FC FLN

8-31 Address 1 through 98

8-32 Baud Rate 9600 4800 or 9600

8-50 Coasting Select Logic or

8-52 DC Brake Select Logic or

8-53 Start Select Logic or

8-54 Reversing Select Digital Input

8-55 Set-up Select Logic or

8-56 Preset Reference Select Logic or

See the FLN Point Map Table on the following pages.

Only Parameter# Bit

Read

Type

Class

Type

Point

Min

(SI)

Value

(SI)

Max

Value

Off

Text Range

16383 -16383 3 LAI Yes 1655

FLN Point Map Table

Text

(SI)

Slope

(SI)

Units

(SI)

Default

Factory

Point

Num. Descriptor

0 SYS CHAR 0 1 0 ON OFF 255 255 0 2 LDO No

1 CTRL ADDRESS 0 1 0 255 255 0 2 LAO Yes 831

2 APPLICATION 2760 1 0 16383 16383 0 2 LAO Yes

3 FREQ OUTPUT 0 HZ 0.1 0 16383 16383 0 3 LAI Yes 1613

4 PCT OUTPUT 0 PCT 0.01 -163.83 32767 16383 -16383 3 LAI Yes 1615

5 --Free Point--

6 CURRENT 0 A 0.1 0 32767 32767 0 3 LAI Yes 1614

7 OUTPUT VOLT 0 V 1 0 4095 4095 0 3 LAI Yes 1612

KW 0.1 0 32767 32767 0 3 LAI Yes 1610

9 DC BUS VOLT 0 V 1 0 4095 4095 0 3 LAI Yes 1630

8 POWER KW 0

10 KWH 0 KWH 1 0 1023 1023 0 3 LAI Yes 1502

11 RUNTIME PMP1 0 HRS 4 0 32767 131068 0 3 LAI Yes 2703.01

12 RUNTIME PMP2 0 HRS 4 0 32767 131068 0 3 LAI Yes 2703.02

13 RUNTIME PMP3 0 HRS 4 0 32767 131068 0 3 LAI Yes 2703.03

14 RUNTIME PMP4 0 HRS 4 0 32767 131068 0 3 LAI Yes 2703.04

16 LEAD PUMP 1 1 0 255 255 0 3 LAI Yes 3934

15 PUMP SEQ ALT 0 1 0 YES NO 255 255 0 1 LDO No 3935

17 FEEDBACK 1 0 UNITS 0.01 -163.83 32767 16383 -16383 3 LAI Yes 1654

19 FLOW 0 UNITS 0.01 -163.83 32767 16383 -16383 3 LAI Yes 3929

18 FEEDBACK 2 0 UNITS 0.01 -163.83 32767

20 OVRD TIME 0 HRS 1 0 255 255 0 2 LAO No

21 FEEDBACK 3 0 UNITS 0.01 -163.83 32767 16383 -16383 3 LAI Yes 1656

22 FEEDBACK 4 0 UNITS 0.01 -163.83 32767 16383 -16383 3 LAI Yes 1657

23 --Free Point--

29 DAY.NIGHT 0 1 0 NIGHT DAY 255 255 0 1 LDO No

30 CUR LMT PMP1 0 A 0.1 0.1 16383 5000 0 3 LAI Yes 418

31 ACCEL TIME 1 0 SEC 1 1 4095 360000 1 1 LAO No 341

32 DECEL TIME 1 0 SEC 1 1 4095 360000 1 1 LAO No 342

Only Parameter# Bit

Read

Type

Class

Type

Point

Min

(SI)

Value

(SI)

Max

Value

Off

Text Range

Text

(SI)

Slope

(SI)

Units

(SI)

Default

Factory

255 0 3 LDI Yes 3904 15

1000000 1 1 LAO No 2094

1 0 RUN STOP 255 255 0 3 LDI Yes 3902 5

33 --Free Point--

Point

Num. Descriptor

41 PUMP 2 FAIL 0 1 0 FAULT OK 255 255 0 3 LDI Yes 3905 1

42 DRIVE 2 STAT 0 1 0 RUN STOP 255 255 0 3 LDI Yes

43 DRIVE 2 FAIL 0 1 0 FAULT OK 255 255 0 3 LDI Yes 3904 13

44 PUMP 3 STAT 0 1 0 RUN STOP 255 255 0 3 LDI Yes 3902 6

45 PUMP 3 FAIL 0 1 0 FAULT OK 255 255 0 3 LDI Yes 3905 2

46 DRIVE 3 STAT 0 1 0 RUN STOP 255 255 0 3 LDI Yes

34 HAND.AUTO 0 1 0 HAND AUTO 255 255 0 3 LDI Yes 1695 1

35 CMD RUN.STOP 0 1 0 RUN STOP 255 255 0 1 LDO No 1685 6

36 PUMP 1 STAT 0 1 0 RUN STOP 255 255 0 3 LDI Yes 3902 4

37 PUMP 1 FAIL 0 1 0 FAULT OK 255 255 0 3 LDI Yes 3905 0

38 DRIVE 1 STAT 0 1 0 RUN STOP 255 255 0 3 LDI Yes

39 DRIVE 1 FAIL 0 1 0 FAULT OK 255 255 0 3 LDI Yes 3904 12

40 PUMP 2 STAT 0

47 DRIVE 3 FAIL 0 1 0 FAULT OK 255 255 0 3 LDI Yes 3904 14

48 DRIVE 4 STAT 0 1 0 RUN STOP 255 255 0 3 LDI Yes

49 DRIVE 4 FAIL 0 1 0 FAULT OK 255

50 REF MIN 0 UNIT 0.1 -1638.3 32767 1638.3 -1638.3 3 LAI No 302

51 REF MAX 0 UNIT 0.1 -1638.3 32767 1638.3 -1638.3 3 LAI No 303

54 FREQ MAX 1000 HZ 0.1 0 16383 1000 0 1 LAO Yes 414

55 --Free Point--

52 REF STAT 0 1 0 ON.REF OFFREF 255 255 0 1 LDO Yes 1603 8

53 FREQ MIN 0 HZ 0.1 0 16383 1000 0 1 LAO Yes 412

59 ADJUSTD STPT 0 UNIT 0 0 32767 1000000 3 LAI Yes 1659

60 --Free Point--

61 ACTIVE AI 1 1 0 255 0 0 3 LDI Yes 3946

62 ACTIVE AI FB 0 UNIT 0.1 -1638.3 32767 1638.3 -1638.3 3 LAI Yes 1652

63 PI GAIN 50 0.01 0 1023 1000 0 1 LAO No 2093

64 PI I TIME 2000 SEC 0.305 0.01 32767

65 PID D GAIN 50 0.1 0 511 500 10 1 LAO No 2096

Only Parameter# Bit

Read

Type

Class

Type

Point

Min

(SI)

Value

(SI)

Max

Value

Off

Text Range

Text

(SI)

Slope

(SI)

Units

(SI)

Default

Factory

PUMP1 0 1 0 READY NOTRDY 255 255 0 3 LDI Yes 1603

PUMP1 0 1 0 ENABLE DISABL 255 255 0 3 LDI Yes 1603 2

DRV ENA

DRV RDY

0 255 255 0 3 LAI Yes

66 PID D TIME 0 SEC 0.01 0 16383 1000 0 1 LAO No 2095

Point

Num. Descriptor

67 --Free Point--

69 SETPOINT 1 0 UNIT 0.1 -1638.3 32767 1638300 1 LAO No 2021

68 FB FUNCTION 7 1 0 255 255 0 1 LDO No 2020

70 SETPOINT 2 0 UNIT 0.1 -1638.3 32767 1638300 1 LAO No 2022

71 SETPOINT 3 0 UNIT 0.1 -1638.3 32767 1638300 1 LAO No 2023

72 SETPOINT 4 0 UNIT 0.1 -1638.3 32767 1638300 1 LAO No 2024

73 --Free Point--

75 BUS FBK 1 0 PCT 0.01 -163.83 32767 16383 -16383 1 LAO No 894

76 BUS FBK 2 0 PCT 0.01 -163.83 32767 16383 -16383 1 LAO No 895

77 BUS FBK 3 0 PCT 0.01 -163.83 32767 16383 -16383 1 LAO No 896

78 --Free Point--

82 DRV CTL PUMP1 0 1 0 READY NOTRDY 255 255 0 3 LDI Yes 1603 0

83 --Free Point--

88 LOW SUCTION 0 1 0 ALARM OK 32767 32767 0 3 LDI Yes 3905 8

89 HI SYS PRESS 0 1 0 ALARM OK 32767 32767 0 3 LDI Yes 3905 7

90 OK WARNING 0 1 0 WARN OK 255 255 0 3 LDI Yes 1603 7

91 CRNT WARNING 0 1 0 32767 32767 0 3 LAI Yes

92 GEN ALARM 0 1 0 FAULT OK 255 255 0 1 LDO Yes 3902 2

93 LAST FAULT 0 1 0 255 255 0 3 LAI Yes 1530

94 RESET FAULT 0 1 0 YES OK 255 255 0 1 LDO No 1685 7

95 ACTIVE SETUP 0 1 0 255 255 0 3 LAI Yes 10

96 --Free Point--

99 ERROR STATUS 0 1

Quick Start Check List

Conrm job site voltage. Do not apply power or close the disconnect until the following items are completed.

Ch ec k a ll p ow er w ir in g c on ne ct io ns a nd s ec ur e a s

•

required.

Conrm with the owner/installing contractor if there will be any

•

building automation or remote connections required. Inspect and/or install any customer remote terminations

•

required.

Make note of the design data supplied on the B&G data label

•

(inside of the control panel door) Use a volt meter to measure phase to phase voltage on the

•

entering power terminals at the disconnect. Compare available voltage to the nameplate data.

•

Bladder storage tank

•

Precharge the bladder storage tank before connecting to the system. The air precharge should be 5 to 10 psi less than the system operating pressure. If the storage tank has already been installed and not

•

precharged, disconnect system piping from the tank and equalize to atmospheric pressure, if an isolation valve and drain are provided, use them.

•

Apply air pressure to bladder through the air charging valve and pressurize to eld conditions (equal to the NFSD restart pressure or 5 to 10 psi below operating pressure). Reconnect to the system piping.

•

Enter/Conrm nameplate information

•

Go to the Quick Menu and enter motor nameplate

information.

•

Prove pump rotation for each pump

•

Press the Hand Start key to start the pump and then quickly press the Pump Enable key to stop it.

•

Observe the spinning shaft for rotation.

•

Repeat for each pump. Reverse two leads on the pump motors that are incorrect.

•

If your system has PRVs, set the system operating pressure. Skip next section if system has check valves only.

Open a faucet or some other demand for water from the

•

discharge of the package. This can be anywhere in the building being served by the package. Run one pump manually by pressing Hand Start.

•

Adjust the PRV to the desired discharge pressure plus 2 to 5 psi for the building being served. (The PRVs should be set slightly higher than the desired system setpoint.) Repeat for each pump in the package, running only one

•

pump at a time. All PRVs should be adjusted to the same pressure as seen

•

on the display.

Set system specic parameters

Press the Quick Menu button.

•

Navigate and setup the system parameters.

•

Check for available suction water

Open all supply and discharge valves.

•

Close bypass valve if installed in the piping by others. Inspect the capillary tubing from the pump discharge to the

•

suction header.

•

Open petcocks feeding the tubing. Ensure that the plastic tubing is not touching any

•

metal surface. Protect tubing with insulation to prevent abrasion where it may be touching metal. Use the pump vent plugs and or the vent cocks on the main

•

PRV to prove available water for suction. Open a faucet to create a demand for water on the system pressure piping.

•

Start the package Close the disconnect to apply power to the package.

•

If the unit starts, press the stop button on the drives to stop

•

the unit.

Testing the package

Exit the Setup Menu.

•

Stop the package.

•

Press the Auto Start key to put the system into

•

Auto operation. Observe the pressures and temperatures for normal

•

operation.

Press the Right Arrow key to initiate alternation and observe

•

each pump’s operation. Close the running water faucet. It should be assumed that no

•

demand for water is required. (No Flow) Wait for the no ow shut down sequence to engage. All

•

minimum run timers must elapse for this to occur. Demand water from the system again and observe the

•

restart of the package.

No problems? You are done!

Xylem

1) The tissue in plants that brings water upward from the roots;

2) a leading global water technology company.

We’re 12,000 people uniﬁed in a common purpose: creating innovative solutions to meet our world’s water needs. Developing new technologies that will improve the way water is used, conserved, and re-used in the future is central to our work. We move, treat, analyze, and return water to the environment, and we help people use water efﬁciently, in their homes, buildings, factories and farms. In more than 150 countries, we have strong, long-standing relationships with customers who know us for our powerful combination of leading product brands and applications expertise, backed by a legacy of innovation.

For more information on how Xylem can help you, go to www.xyleminc.com

Xylem Inc.

10661 Newkirk Street Dallas, TX 75220 Phone: (469) 221-1201 Fax: (214) 357-5861

www.bellgossett.com

Bell & Gossett is a trademark of Xylem Inc. or one of its subsidiaries.

Bell & Gossett 176R0649C User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual