Bell & Gossett P2001489 User Manual

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Page 1

INSTRUCTION MANUAL

Integrated Technologic with Sensorless Control

Page 2

Page 3

Table of Contents

Introduction and Safety..................................................................................................................2

Introduction..................................................................................................................................2

Safety.............................................................................................................................................2

Safety message levels............................................................................................................. 2

User safety.................................................................................................................................... 3

Environmental safety...................................................................................................................4

Transportation and Storage.......................................................................................................... 6

Inspect the delivery.....................................................................................................................6

Inspect the package................................................................................................................6

Inspect the unit........................................................................................................................ 6

System lifting................................................................................................................................6

Transportation guidelines.......................................................................................................... 6

Storage guidelines...................................................................................................................... 6

Product Description........................................................................................................................8

System description......................................................................................................................8

Table of Contents

Electrical Installation.................................................................................................................... 10

Preinstallation............................................................................................................................ 10

Line input (mains) connection................................................................................................. 11

Control terminal connections.................................................................................................. 12

Control terminal conﬁgurations.............................................................................................. 15

Common terminal wiring conﬁgurations............................................................................... 16

Local control panel....................................................................................................................22

Menu keys.................................................................................................................................. 23

Navigation keys......................................................................................................................... 23

Operation keys.......................................................................................................................... 24

Programming the controller.................................................................................................... 25

System Setup and Operation......................................................................................................27

Pre-start procedure...................................................................................................................27

Pre-startup inspections.............................................................................................................28

Start-up procedure....................................................................................................................28

Setup and commissioning....................................................................................................... 29

Troubleshooting........................................................................................................................... 38

Troubleshooting menus...........................................................................................................38

Reset the frequency converter................................................................................................ 38

Warnings and alarms................................................................................................................41

Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL 1

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Introduction and Safety

Introduction

Purpose of this manual

The purpose of this manual is to provide necessary information for:

• Installation

• Operation

• Maintenance

CAUTION:

Read this manual carefully before installing and using the product. Improper use of the product can cause personal injury and damage to property, and may void the warranty.

NOTICE:

Save this manual for future reference, and keep it readily available at the location of the unit.

Safety

WARNING:

• The operator must be aware of safety precautions to prevent physical injury.

• Any pressure-containing device can explode, rupture, or discharge its contents if it is

over-pressurized. Take all necessary measures to avoid over-pressurization.

• Operating, installing, or maintaining the unit in any way that is not covered in this

manual could cause death, serious personal injury, or damage to the equipment. This includes any modiﬁcation to the equipment or use of parts not provided by Xylem. If there is a question regarding the intended use of the equipment, please contact a Xylem representative before proceeding.

• Do not change the service application without the approval of an authorized Xylem

representative.

CAUTION:

You must observe the instructions contained in this manual. Failure to do so could result in physical injury, damage, or delays.

Safety message levels

About safety messages

It is extremely important that you read, understand, and follow the safety messages and regulations carefully before handling the product. They are published to help prevent these hazards:

• Personal accidents and health problems

• Damage to the product

• Product malfunction

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Deﬁnitions

Safety message level Indication

DANGER:

A hazardous situation which, if not avoided, will result in death or serious injury

Introduction and Safety

User safety

General safety rules

WARNING:

CAUTION:

Electrical Hazard:

NOTICE:

These safety rules apply:

• Always keep the work area clean.

• Pay attention to the risks presented by gas and vapors in the work area.

• Avoid all electrical dangers. Pay attention to the risks of electric shock or arc

hazards.

• Always bear in mind the risk of drowning, electrical accidents, and burn injuries.

A hazardous situation which, if not avoided, could result in death or serious injury

A hazardous situation which, if not avoided, could result in minor or moderate injury

The possibility of electrical risks if instructions are not followed in a proper manner

• A potential situation which, if not avoided, could result in undesirable conditions

• A practice not related to personal injury

ﬂash

Safety equipment

Use safety equipment according to the company regulations. Use this safety equipment within the work area:

• Hard hat

• Safety goggles, preferably with side shields

• Protective shoes

• Protective gloves

• Gas mask

• Hearing protection

• First-aid kit

• Safety devices

NOTICE:

Never operate a unit unless safety devices are installed. Also see speciﬁc information about safety devices in other chapters of this manual.

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Introduction and Safety

Electrical connections

Electrical connections must be made by certiﬁed electricians in compliance with all international, national, state, and local regulations. For more information about requirements, see sections dealing speciﬁcally with electrical connections.

Precautions before work

Observe these safety precautions before you work with the product or are in connection with the product:

• Provide a suitable barrier around the work area, for example, a guard rail.

• Make sure that all safety guards are in place and secure.

• Make sure that you have a clear path of retreat.

• Make sure that the product cannot roll or fall over and injure people or damage

• Make sure that the lifting equipment is in good condition.

• Use a lifting harness, a safety line, and a breathing device as required.

• Allow all system and pump components to cool before you handle them.

• Make sure that the product has been thoroughly cleaned.

• Disconnect and lock out power before you service the pump.

• Check the explosion risk before you weld or use electric hand tools.

Precautions during work

property.

Observe these safety precautions when you work with the product or are in connection with the product:

Wash the skin and eyes

• Never work alone.

• Always wear protective clothing and hand protection.

• Stay clear of suspended loads.

• Always lift the product by its lifting device.

• Beware of the risk of a sudden start if the product is used with an automatic level control.

• Beware of the starting jerk, which can be powerful.

• Rinse the components in water after you disassemble the pump.

• Do not exceed the maximum working pressure of the pump.

• Do not open any vent or drain valve or remove any plugs while the system is pressurized. Make sure that the pump is isolated from the system and that pressure is relieved before you disassemble the pump, remove plugs, or disconnect piping.

• Never operate a pump without a properly installed coupling guard.

Follow these procedures for chemicals or hazardous ﬂuids that have come into contact with your eyes or your skin:

Condition Action Chemicals or hazardous ﬂuids in

eyes

Chemicals or hazardous ﬂuids on skin

1. Hold your eyelids apart forcibly with your ﬁngers.

2. Rinse the eyes with eyewash or running water for at least 15 minutes.

3. Seek medical attention.

1. Remove contaminated clothing.

2. Wash the skin with soap and water for at least 1 minute.

3. Seek medical attention, if necessary.

Environmental safety

The work area

Always keep the station clean.

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Waste and emissions regulations

Observe these safety regulations regarding waste and emissions:

• Appropriately dispose of all waste.

• Handle and dispose of the processed liquid in compliance with applicable environmental regulations.

• Clean up all spills in accordance with safety and environmental procedures.

• Report all environmental emissions to the appropriate authorities.

WARNING:

Radiation Hazard. Do NOT send the product to Xylem if it has been exposed to any nuclear radiation.

Electrical installation

For electrical installation recycling requirements, consult your local electric utility.

Recycling guidelines

Always follow local laws and regulations regarding recycling.

Introduction and Safety

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Transportation and Storage

Inspect the delivery

Inspect the package

1. Inspect the package for damaged or missing items upon delivery.

2. Note any damaged or missing items on the receipt and freight bill.

3. File a claim with the shipping company if anything is out of order. If the product has been picked up at a distributor, make a claim directly to the

distributor.

Inspect the unit

1. Remove packing materials from the product. Dispose of all packing materials in accordance with local regulations.

2. Inspect the product to determine if any parts have been damaged or are missing.

3. If applicable, unfasten the product by removing any screws, bolts, or straps. For your personal safety, be careful when you handle nails and straps.

4. Contact the local sales representative if there is any issue.

System lifting

WARNING:

• Assembled units and their components are heavy. Failure to properly lift and support this equipment can result in serious physical injury and/or equipment damage. Lift equipment only at the speciﬁcally identiﬁed lifting points. Lifting devices such as eyebolts, slings, and spreaders must be rated, selected, and used for the entire load being lifted.

• Crush hazard. The unit and the components can be heavy. Use proper lifting methods and wear steel-toed shoes at all times.

Transportation guidelines

Precautions

DANGER:

Disconnect and lock out electrical power before installing or servicing the unit.

WARNING:

• Stay clear of suspended loads.

• Observe accident prevention regulations in force.

Storage guidelines

Storage location

The product must be stored in a covered and dry location free from heat, dirt, and vibrations.

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Transportation and Storage

NOTICE:

• Protect the product against humidity, heat sources, and mechanical damage.

• Do not place heavy weights on the packed product.

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Product Description

System description

The Technologic Sensorless Pump Controller is a variable frequency drive that has been conﬁgured for pump control applications. The controller utilizes four different setups to allow the user to easily setup the controller for 4 different applications.

Set-up 1 Constant pressure control with wire pressure transducer. The controller setpoint

is preconﬁgured at 15 psi. The analog input AI53 is conﬁgured for a 40 psi pressure transducer.

Set-up 2 Flow control with wired ﬂow transducer. The controller setpoint is preconﬁgured

at 150 GPM. The analog input AI53 is conﬁgured for a 300 GPM ﬂow transducer.

Set-up 3 Sensorless pressure control The controller setpoint is preconﬁgured at the

factory based on the order request.

Set-up 4 Sensorless ﬂow control. The controller setpoint is preconﬁgured at the factory

based on the order request.

• Set-up 3 is the active set-up for the factory default conﬁguration.

Enclosure rating

Ambient temperature

WARNING:

The enclosure rating of the controller must be maintained by using the appropriate wire or conduit connectors and installing the controller in the appropriate environment. Failure to use the appropriate connectors or to install in the appropriate environment may create a dangerous condition and will void the warranty.

• The standard enclosure rating for the controller is IP55 or NEMA12.

• The controller is intended for indoor use only.

• Ensure the installation environment complies with the controller rating.

• Make sure all cable glands and unused holes for glands are properly sealed and the cover is properly installed.

• Ensure that the system is installed in an environment that complies with the motor ingress protection rating. Refer to the motor IOM manual for details.

WARNING:

The ambient temperature rating of the controller must be maintained by installing the controller in the appropriate environment. Failure to operate the controller in the appropriate environment may create a dangerous condition and will void the warranty.

• To ensure proper cooling of the controller, there must be adequate space above and below the controller chassis. Refer to the Technologic Pump Controller IOM for details.

• The controller can be operated with full load output current at maximum ambient temperature up to the maximum altitude of 1000 m above sea level. For altitudes above 1000 m, the maximum output current and/or maximum ambient temperature must be derated. Refer to the Technologic Pump Controller IOM for details. Contact the factory for installation above 2000 m.

Maximum Temperature Minimum Temperature 113°F (45°C) 32°F (0°C)

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Maximum Temperature Minimum Temperature The output current rating is derated 2% for every degree

above 113°F(45°C).

The controller will operate with reduced performance down to 14°F (-10°C)

At 122°F (50°C), the maximum output current rating of the controller will be reduced by 10%.

Product Description

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Electrical Installation

Preinstallation

Precautions

Electrical Hazard:

• Branch circuit protection required. Provide branch circuit protection in accordance with the National Electrical Code.

• 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.

WARNING:

• Rotating shafts and electrical equipment can be hazardous. It is strongly recommended that all electrical work conform to all National and Local regulations. Installation, Start-up, and Maintenance should be performed only by qualiﬁed personnel.

• Wear safety glasses whenever working on electric control or rotating equipment.

NOTICE:

Make all power connections with minimum 75°C rated copper wiring for installations in North America.

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91 (L1) 92 (L2) 93 (L3)

88 (-) 89 (+)

50 (+10 V OUT)

53 (A IN)

54 (A IN)

55 (COM A IN)

0/4-20 mA

12 (+24V OUT)

13 (+24V OUT)

18 (D IN)

20 (COM D IN)

15mA 200mA

(U) 96

(V) 97 (W) 98 (PE) 99

(COM A OUT) 39

(A OUT) 42

0/4-20 mA

0-10Vdc

+10Vdc

0-10Vdc

0/4-20 mA

240Vac, 2A

24Vdc

240Vac, 2A

24V (NPN) 0V (PNP)

0V (PNP)

24V (NPN)

19 (D IN)

24V (NPN) 0V (PNP)

24V

(D IN/OUT)

0V (PNP)

24V (NPN)

(D IN/OUT)

24V

24V (NPN) 0V (PNP)

0V (PNP)

24V (NPN)

33 (D IN)

32 (D IN)

1 2

A53/S201

A54/S202

ON=0-20mA OFF=0-10V

400Vac, 2A

P 5-00

(R+) 82

(R-) 81

37 (D IN)

+ - + -

130BA544.12

(P RS-485) 68

(N RS-485) 69

(COM RS-485) 61

S801

RS-485

BUS TER./S801

3 Phase power

input

DC bus

Switch Mode

Power Supply

Motor

Analog Output

Interface

relay1

relay2

ON=Terminated OFF=Open

Brake resistor

(NPN) = Sink

(PNP) = Source

Electrical Installation

Fuses

Figure 1: Basic wiring schematic drawing

For models with an optional fused disconnect installed, input fuses have been factory installed in the enclosure. For models without a fused disconnect option, appropriate fuse protection must be provided by the installer. Refer to the Technologic Pump Controller IOM for a list of appropriate fuses for each model.

Electrical Hazard:

• Replacement fuses must be of the same continuous rating, fuse type and have the

Line input (mains) connection

Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL 11

same maximum interrupting rating as the fuse being replaced.

• Before replacing a blown fuse or resetting a circuit breaker, the source of the fault causing the fuse to blow must be found and remedied.

• Before connecting the input power wiring or fusing, ensure all input disconnects or breakers are set and locked to the off position.

Electrical Hazard:

For operator’s safety, it is important to ground drive properly. Failure to ground drive properly could result in death or serious injury.

Page 14

130BT334.10

Electrical Installation

NOTICE:

It is the responsibility of the user or certiﬁed electrical installer to ensure correct grounding (earthing) of the equipment in accordance with national and local electrical codes and standards.

Requirements:

• 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 the 3 mA.

• A dedicated ground wire is required.

• Do not use conduit as a replacement for a ground wire.

• Do not ground one controller to another in a “daisy chain” fashion. Each controller 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.

1. Ensure the input power source for the controller is locked in the off position.

2. Connect metalized conduit to the controller.

3. Route the power wiring through the conduit.

4. Connect the input power wires to terminals labeled L1, L2, L3 and (Ground) on the input side of the disconnect.

Refer to the Technologic Pump Controller IOM for details on wire sizing and routing.

Control terminal connections

Make sure that the following are adhered to:

• Run input power and control wiring in separate metallic conduits or raceways for high frequency isolation. Failure to isolate power, motor, and control wiring could result in less than optimum drive and associated equipment performance.

• Use control wiring rated for 600 V for 480 V and 600 V drives and 300 V for 200–240 V drives.

• Make sure to isolate the control wiring from high-power components in the drive.

Control wiring access

• Remove front cover of unit to access internally mounted control terminals.

Figure 2: Control terminals access

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Removable control terminal connectors

130BA012.12

Electrical Installation

Figure 3: Drive control terminals

Connector 1

Connector 2 For serial communications EIA-485 connector with terminal 68 (+) and 69

Connector 3 Analog Input and Output Terminals

Connector 4 A USB port available for use with the MCT-10 drive programming

Relay Terminals Also provided are two Form C relay outputs that are in various locations

Connecting to the control terminals

1. To connect control wiring to the control terminals, do the following:

2. To remove the wire from the terminal:

Digital Input and Output terminals

• Four programmable digital outputs

• Two digital terminals programmable as input or output

• A common for optional customer supplied 24 VDC voltage

• A 24 VDC supply used for digital inputs and external transducers.

(-).

• Two analog inputs conﬁgurable as current or voltage inputs

• One analog output

• A 10 VDC supply for voltage output transducers

• A common for analog inputs and outputs

software.

depending upon the controller conﬁguration and size.

a. Strip the control wire back 9–10mm (0.35–0.40 in) b. Insert a screwdriver (0.4 x 2.5 mm) in the rectangular hole. c. Insert the cable in the adjacent circular hole. d. Remove the screwdriver. The wire is now mounted to the terminal.

a. Insert a screwdriver (0.4 x 2.5 mm) in the rectangular hole. b. Pull out the cable.

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130BA150.10

9 - 10 mm

(0.37 in)

130BT311.10

130BT312.10

1. 2. 3.

130BT310.10

Electrical Installation

Figure 4: Connecting and disconnecting control wiring

Analog input conﬁguration

If an analog input is used, the analog input conﬁguration switches must be set properly. To set the conﬁguration switches, remove the local control panel and set the appropriate switch as required.

• To conﬁgure the analog input as a voltage input, set the conﬁguration switch to U.

• Set the conﬁguration switch to I to enable the input as a current input.

• Switch A53 is used to conﬁgure analog input 53.

• Switch A54 is used to conﬁgure analog input 54.

Figure 5: Conﬁguration switch location

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Electrical Installation

Control terminal conﬁgurations

Table 1: Control terminal descriptions

Terminal number Parameter Default setting Description

Relay Outputs 01, 02, 03 5-40 Relay1 [160] No Alarm Form C Relay Output.

04, 05, 06 5-40 Relay2 [5] Running

Digital I/O 12, 13 - +24 V DC 24 V DC supply voltage.

18 5-10 [8] Start Start/Stop digital input

19 5-11 [0] No Operation Unused digital input 27 5-12 [0] No Operation Unused digital input 29 5-13 [0] No Operation Unused digital input 32 5-14 [0] No Operation Unused digital input 33 5-15 [0] No Operation Unused digital input 20 - Common Common for digital inputs

Analog I/O 39 - AO Common Common for analog output

42 6-50 4-20mA Motor Freq Analog output. Default

50 - +10 V DC 10 V DC analog supply

53 6-1 [0] No Operation Analog input 53. 54 6-2 [0] No Operation Analog input 54. 55 - AI Common Common for analog input

Common 61 - Shield Connection Integrated RC ﬁlter for

68 8-3 + RS485 Interface + 69 8-3 - RS485 Interface -

Usable for AC or DC voltages and either resistive or inductive loads. Refer to the relay wiring section for relay contact current and voltage ratings.

Maximum output current is 200 mA total for all 24 V loads. Useable for digital inputs and external transducers.

signal for the drive. Connect input to 24 V to start. Open the input to stop.

and reference for 24 V supply

setting is 4-20mA signal (500 Ω max) based on motor speed

voltage. 15mA maximum.

cable shield. ONLY for connecting the shield when experiencing EMC problems.

Refer to the Technologic Controller IOM for details on control terminal wiring.

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Electrical Installation

Common terminal wiring conﬁgurations

Relay wiring

Each controller has two programmable form C relay outputs. The relay terminals are located in various locations on the controller depending on the frame size.

Figure 6: Relay terminal wiring

Table 2: Relay terminal ratings

Programmable relay outputs 2 Relay 01 Terminal number 1–3 (break), 1–2 (make) Maximum terminal load (AC-1)1 on 1–3 (NC), 1–2 (NO) (Resistive load) 240 V AC, 2A Maximum terminal load (AC-15)1 (Inductive load @ cosφ 0.4) 240 V AC, 0.2A Maximum terminal load (DC-1)1 on 1–2 (NO), 1–3 (NC) (Resistive load) 60 V DC, 1A Maximum terminal load (DC-13)1 (Inductive load) 24 V DC, 0.1A Relay 02 Terminal number 4–6 (break), 4–5 (make) Maximum terminal load (AC-2)1 on 4–5 (NO) (resistive load) Maximum terminal load (AC-15)1 (Inductive load @ cosφ 0.4) 240 V AC, 0.2A Maximum terminal load (DC-1)1 on 4–5 (NO) (Resistive load) 80 V DC, 2A Maximum terminal load (DC-13)1 on 4–5 (NO) (Inductive load) 24 V DC, 0.1A Maximum terminal load (AC-1)1 on 4–6 (NC) (Resistive load) 240 V AC, 2A Maximum terminal load (AC-15)1 on 4–6 (NC) (Inductive load @ cosφ

0.4) Maximum terminal load (DC-1)1 on 4–6 (NC) (Resistive load) 50 V DC, 2A Maximum terminal load (DC-13)1 on 4–6 (NC) (Inductive load) 24 V DC, 0.1A Minimum terminal load on 1–3 (NC), 1–2 (NO), 4–6 (NC), 4–5 (NO) 24 V DC 10mA, 24 V AC 20mA Environment according to EN 60664–1 overvoltage category III/pollution degree 2

2,3

400 V AC, 2A

240 V AC, 0.2A

Factory default setup

conﬁguration utilizes the controller factory default settings for I/O. The factory default

This settings are conﬁgured for Set-up 3, sensorless pressure control with no external transducer installed. There are no parameters that need to be adjusted to use this conﬁguration. Set-up 4, sensorless ﬂow control, also uses these default settings for I/O. Set-ups are changed by adjusting parameter 0-10 Active Set-up. Refer to the Commissioning section in this manual for details on changing set-ups.

NOTICE:

The factory default settings are conﬁgured to require a start signal wired to DI18 as shown below.

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Figure 7: Terminal connections when using factory defaults

Adding an external interlock

This setup adds an external interlock signal to the factory default conﬁguration. An external interlock can be used in applications that operate at extreme temperatures and/or pressures to turn off the controller and issue an alarm during an abnormal system condition. The external interlock signal is connected to digital input 27 on the controller. This input can be controlled by an external device such as a suction pressure switch, an over pressure switch, temperature switch, a differential pressure switch, etc. When the input is disconnected from the 24V supply, an alarm is issued and the controller stops the motor. The controller will attempt to automatically restart if the Reset Mode [14-20] and Automatic Restart Time [14-21] are set to allow automatic restarting. To prevent an automatic restart set the Reset Mode [14-20] to Manual Reset.

Electrical Installation

Figure 8: Terminal connections for external interlock

Table 3: Parameter settings for using an external interlock

Parameter number Description Set to 5–12 Terminal 27 Digital Input External Interlock 14–20 Reset Mode Set to the desired number of

14–21 Automatic Restart Time This is the time between when an

Adding transducer feedback

This conﬁguration adds a transducer for closed loop control or for external monitoring. Use Set-up 1 for pressure control using a wired pressure transducer and Set-up 2 for ﬂow control using a wired ﬂow transducer. Refer to the Commissioning section in this manual for detail on changing set-ups.

automatic resets. If a fault occurs more than this setting a manual reset is required. Set to Manual Reset if no resets are allowed. Default setting is: Automatic reset x 3.

alarming/warning is issued and when the controller attempts the next restart. Default setting is 30 seconds.

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Electrical Installation

NOTICE:

Be sure to properly set the analog input conﬁguration switches prior to using the analog input.

Figure 9: Terminal connections for 4–20mA wired sensor

Figure 10: Terminal connections for 0–10V wired sensor

In order to set up the controller for closed loop control based on the feedback from an external transducer, set the following parameters:

Table 4: Parameter settings for using a wired sensor for feedback

Parameter number Description Set to 0–10 Active Set-up For wired pressure transducer select

Set-up 1. For wired ﬂow transducer select Set-up 2.

6-14* Terminal 53 Low Ref./Feedb. Value Minimum transducer feedback value.

For example, for a 0–40 psi DP transducer, set to 0.

6-15* Terminal 53 High Ref./Feedb. Value Maximum transducer feedback value.

For example, for a 0–40 psi DP

transducer, set to 40. 6-17* Terminal 53 Live Zero Enabled 20-00 Feedback 1 Source Analog Input 53* 20-12 Reference/Feedback Select as appropriate for application.

For example, set to psi when using a

pressure transducer. 20–13 Minimum Reference/Feedback Minimum transducer feedback value.

For example, for a 0–40 psi DP

transducer, set to 0 psi. 20–14 Maximum Reference/Feedback Maximum trnasducer feedback value.

For example, for a 40 psi DP

transducer, set to 40 psi.

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Electrical Installation

* To use AI 54, conﬁgure parameters 6–24, 6–25, 6–27 and set 20–00 to Analog Input 54. In order to set up the controller with a transducer that is used for external monitoring,

rather than feedback to the controller, set the following parameters:

Table 5: Parameter settings for using a wired sensor for external monitoring

Parameter number Description Set to 0-24 Display Line 3 Large Ext. 1 Feedback [Unit] 21-14 Ext. 1 Feedback Source Analog Input 53* 21–10 Ext. 1 Ref./Feedback Unit Select as appropriate for application.

For example, set to psi when using a

pressure transducer. 21–11 Ext. 1 Minimum Reference Minimum transducer feedback value.

For example, for a 0–40 psi DP

transducer, set to 0 psi. 21–12 Ext. 1 Maximum Reference Maximum transducer feedback value.

For example, for a 40 psi DP

transducer, set to 40 psi. 6–14* Terminal 53 Low Ref./Feedb. Value Minimum transducer feedback value.

For example, for a 0–40 psi DP

transducer, set to 0 psi. 6–15* Terminal 53 High Ref./Feedb. Value Maximum transducer feedback value.

For example, for a 40 psi DP

transducer, set to 40 psi. 6–17* Terminal 53 Live Zero Disabled

* To use AI 54, conﬁgure parameters 6–24, 6–25, 6–27 and set 21–14 to Analog Input 54.

Speed control with external potentiometer

This setup allows the speed of the motor to be controlled via an external potentiometer. In order to use this setup the analog input must be conﬁgured as a voltage input.

Figure 11: Terminal connections for external speed reference from a potentiometer

To set up the controller for speed control with an external potentiometer, set the following parameters:

Parameter number Description Set to 1-00 Conﬁguration Mode Open Loop 3-15 Reference 1 Source Analog Input 53 6-10 Terminal 53 Low Voltage* 0 V 6-11 Terminal 53 High Voltage* 10 V 6-14 Terminal 53 Low Ref./Feedb. Value 0

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Electrical Installation

Parameter number Description Set to 6-15 Terminal 53 High Ref./Feedb. Value Maximum motor speed. For example,

6-17 Terminal 53 Live Zero Disabled. 20-00 Feedback 1 Source No Function

* Set switch A53 = U

Control from external PLC/BMS through Analog Input

This setup allows the controller to receive either the process variable, the setpoint or a speed reference from an external control source such as a PLC or BMS controller. The output from the external control device can be either a voltage or current output signal. Be sure to set the analog input conﬁguration switches based on the type of output signal. The diagram below shows the connections for an external reference signal.

3450 Hz.

Figure 12: Terminals connections for external control source

Table 6: Parameter settings for using an external control signal

Parameter Number Parameter Description For process variable from

BMS/PLC*

For setpoint from BMS/ PLC**

For speed reference from

BMS/PLC*** 1-00 Conﬁguration Mode Closed Loop Closed Loop Open Loop 3-15 Reference 1 Source No Function Analog Input 53* Analog Input 53* 6-14 Terminal 53 Low Ref./

Feedb. Value

6-15 Terminal 53 High Ref./

Feedb. Value

Minimum value of process variable. For example, for a 0-40psi DP transducer, set to 0.

Maximum value of process variable. For example, for a 40psi DP transducer, set to

40.

Minimum reference/ setpoint value. For example, for a 0-40psi DP transducer, set to 0.

Maximum reference/ setpoint value. For example, for a 40psi DP transducer, set to 40.

Minimum motor speed.

For example, 0 RPM.

Maximum motor speed.

For example, 3450 RPM for

a 2 pole motor.

6-17 Terminal 53 Live Zero Enabled Enabled Disabled 20-00 Feedback 1 Source Analog Input 53 Select as appropriate for

No Function

application. This can be any selection except the setting of parameter 3-15.

20-12 Reference/Feedback Unit Select as appropriate for

application. For example, set to psi when using pressure feedback.

20-13 Minimum Reference/

Feedback

Minimum transducer feedback value. For example, for a 0-40psi DP transducer, set to 0 psi.

Select as appropriate for application. For example, set to psi when using pressure reference.

Minimum reference/ setpoint value. For example, for a 0-40psi DP transducer, set to 0 psi.

20 Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL

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Electrical Installation

Parameter Number Parameter Description For process variable from

BMS/PLC*

20-14 Maximum Reference/

Feedback

Maximum transducer feedback value. For example, for a 40psi DP transducer, set to 40 psi.

* To use AI 54,

conﬁgure parameters 6-24, 6-25, 6-27 and set 20-00 to Analog Input 54 ** To use AI 54, conﬁgure parameters 6-24, 6-25, 6-27 and set 3-15 to Analog Input 54 *** To use AI 54, set 3-15 to Analog Input 54

Control from external PLC/BMS through communications port

A BMS or PLC can also be connected to the controller through the communications port. In this conﬁguration the BMS or PLC can control the drive by overriding the setpoint. Control cables must be braided screened/shielded and the screen must be connected by means of a cable clamp at both ends to the metal cabinet of the controller. Be sure to terminate the bus connections by turning the BUS TER switch to the on position. The BUS TER switch is located under the LCP as shown in Figure 5: Conﬁguration switch location (page 14).

For setpoint from BMS/ PLC**

Maximum reference/ setpoint value. For example, for a 40psi DP transducer, set to 40 psi.

For speed reference from BMS/PLC***

Figure 13: Terminal connections for external control source connected through comm. port

Table 7: Parameter settings for Modbus RTU and BACnet protocols

Parameter Number Parameter Description Protocol

Modbus RTU BACnet 8-02 Control Source FC Port FC Port 8-30 Protocol Modbus RTU BACnet 8-31 Address 1 1 8-32 Baud Rate 19200 9600 8-33 Parity/Stop bit Even Parity, 1 Stop bit No Parity, 1 Stop bit 8-34 Estimated cycle time 0 ms 0 ms 8-35 Minimum Response Delay 10 ms 10 ms 8-36 Maximum Response Delay 5000 ms 5000 ms 8-37 Maximum Inter-Char Delay 0.86 ms 25 ms

The parameters above show an example of typical settings used for Modbus RTU or BACnet protocols. The parameters must be set according to the devices on the network. 8-32 Baud Rate and 8-33 Parity/Stop Bit should be set to match the other devices on the network. For detailed communication setup information for Modbus RTU, refer to the document number MG92B102. For detailed communication setup information for BACnet, refer to documents MG14C102 and MG11D202. The documents referenced above are available for download at www.danfoss.com.

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Electrical Installation

Local control panel

The controller comes equipped with a local control panel (LCP). The panel allows the user to view the status of the controller, pump, and system without entering the parameter list. Consult the Technologic Pump Controller IOM for details on programming the controller. The default conﬁguration is shown in the following ﬁgure.

Figure 14: Default conﬁguration

1. Controller Status

2. Motor HP (Parameter 0–24)

3. Feedback / actual pressure (Parameter 0–20)

22 Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL

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Menu keys

Electrical Installation

4. Pressure setpoint (Parameter 0–21)

5. Menu current (Parameter 0–22)

6. Motor frequency (Parameter 0–23)

7. Menu keys

8. Navigation keys and indicator LEDs

9. Operation keys The parameters shown are the factory default settings. To display other values, modify

parameters 0–20, 0–21, 0–22, 0–23, or 0–24.

Status Key

Quick Menus Key

Main Menu

Alarm Log

Navigation keys

Pressing the [Status] key toggles between different status screens. There are 3 different status screens: 5 line readouts (default), 4 line readouts or Smart Logic Control. Use the [Status] key for selecting the mode of the LCP or for changing back to Display mode from either Quick Menu mode, Main Menu mode or the Alarm mode. The LCP display contrast can also be adjusted by pressing [Status] and the up or down arrow for a darker or brighter display.

The [Quick Menus] key brings up a set of menus that allow easy access to some common parameters. The Quick Menu consists of My Personal Menu, Quick Set-up, Function Set-up, Changes Made and Loggings. My Personal Menu has been conﬁgured to contain some commonly used parameters in pumping applications.

The [Main Menu] key allows access to the complete parameter set. My Personal Menu provides the simplest and quickest access to the required parameters for most applications.

The [Alarm Log] key allows access to the 5 latest alarms numbers A1-A5. To obtain details about an alarm, use the arrow keys to highlight the alarm number and press OK.

Pressing the [Back] button reverts to the previous step or layer in the navigation structure.

Pressing the [Cancel] button will cancel the last change or command as long as the display has not been changed.

Pressing the [Info] button will display information about a command, parameter, or function in any display window. [Info] provides detailed information when needed. Exit the Info mode by pressing either [Info], [Back], or [Cancel].

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Electrical Installation

The four navigation arrows are used to navigate between the different choices available in [Quick Menu], [Main Menu] and [Alarm Log]. Use these keys to move the cursor.

[OK] is used for choosing a parameter marked by the cursor and for enabling the change of a parameter.

If certain threshold values are exceeded, the Alarm and/or Warning (Warn.) LED will turn on. If an alarm or warning is active, a status or alarm text will appear on the control panel.

• Yellow Warn. LED: Indicates a warning is active

• Red Flashing Alarm LED: Indicates an alarm is active

The On LED is activated when the controller receives power.

• Green On LED: Control section is powered and working.

Operation keys

The [Hand on] key enables control of the drive via the LCP interface. Pressing [Hand on] also starts the motor and the speed can be manually adjusted using the arrow keys. The [Hand on] key can be enabled or disabled via parameter 0-40 [Hand on] key on LCP. If [Hand on] is active the drive can be stopped by:

• Start signal on DI 18

• The [Off] button

• Stop command from serial communication

Pressing the [Off] key will stop the motor. The [Off] key can be enabled or disabled via parameter 0-41 [Off] key on LCP. If no external stop function is selected and the [Off] key is disabled, the motor can only be stopped by disconnecting the mains supply.

Pressing the [Auto on] key enables the drive to be controlled via the control terminals and/or serial communication. When a start signal is applied on the control terminals and/or serial communication, the drive will start. This key can be enabled or disabled via 0-42 [Auto on] key on LCP.

The [Reset] key is used for resetting the frequency converter after an alarm (trip). The key can be enabled or disabled via parameter 0-43 [Reset] key on LCP.

24 Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL

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Programming the controller

The controller can be programmed by using either the Quick Menu mode or the Main Menu mode. The Main Menu mode allows access to all parameters. To view or modify a parameter in either the Main Menu or Quick Menu mode follow this procedure:

1. To enter the Quick Menu mode press or to enter the Main Menu press .

2. Select the desired sub-menu in Quick Menus or parameter group in Main Menu by using the up and down arrows.

3. Press to enter the selected menu in Quick Menus or the selected parameter

group in Main Menu.

4. Once in the menu or parameter group use the up and down arrows to highlight the

Electrical Installation

Quick Menu

desired parameter. Press to select the parameter and enable editing.

5. To edit the parameter use the up and down arrows to scroll through the parameter settings. For numeric values, use the left and right keys to select the position within the number. The highlighted area can be modiﬁed by using the up and down arrows.

6. Press

The Quick Menu mode contains various submenus that allow quick and easy access to common parameters. There are six submenus under Quick Menus. The six submenus are shown in the following table.

Table 8: Quick Menus

Submenu Submenu Group Name Description Q1 My Personal Menu Contains parameters commonly used to

Q2 Quick setup Contains parameters commonly used to

Q3 Function setups Provides quick access to parameters

Q4 Smart Start Prompts the used to set common

Q5 Changes Made Shows the last 10 changed parameters,

Q6 Loggings Displays graph line readouts of the LCP

to accept the change or to disregard the change.

conﬁgure pump applications

conﬁgure the controller

commonly required for HVAC applications

parameters required to set up the controller

changes since factory defaults and input assignments

parameters. To change displayed LCP parameters use parameters 0–20 to 0–24

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Electrical Installation

My personal menu

Main Menu

My Personal Menu has been conﬁgured at the factory to contain 20 parameters that are commonly used in pumping applications. The parameters that are shown in My Personal Menu vary depending on which setup is active. Refer to the Setup and Commissioning section for details on My Personal Menu parameters.

NOTICE:

Quick Setup, Function Setups, and Smart Start submenus contain motor parameters. The motor parameters have been conﬁgured at the factory for the motor that has been shipped with the system. Improperly conﬁguring motor parameters may cause controller malfunction.

The parameters in the Main Menu are grouped by category. Note that some groups are not visible unless the appropriate option card is installed. For a complete list and detailed description for each parameter refer to document number MG11CD02, available for download at www.danfoss.com. The parameter groups in the Main Menu are:

Table 9: Main menu parameter groups

Parameter Group Name 0 Operation/Display 1 Load and Motor 2 Brakes 3 Reference/Ramps 4 Limits/Warnings 5 Digital In/Out 6 Analog In/Out 8 Comm. and Options 9 Proﬁbus* 10 CAN Fieldbus* 11 LonWorks* 13 Smart Logic 14 Special Functions 15 Drive Information 16 Data Readouts 18 Info & Readouts 20 Drive Closed Loop 21 Ext. Closed Loop 22 Appl. Functions 23 Time-based Functions 24 Appl. Functions 2 25 Cascade controller 26 Analog I/O Option MCB 109*

* Appropriate option card must be installed

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System Setup and Operation

Pre-start procedure

1. Make sure input power to unit is OFF and locked out per OSHA requirements. Do not rely on panel disconnect switches.

Electrical Hazard:

If input and output connections have been connected improperly, there is potential for high voltage on these terminals. If power leads for multiple motors are improperly run in same conduit, there is potential for leakage current to charge capacitors, even when disconnected from line input. For initial start up, make no assumptions about power components. Follow pre-start procedures described below. Failure to follow pre-start procedures described below could result in personal injury or damage to equipment.

2. Use an 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 an ohmmeter to conﬁrm continuity of the motor by measuring T1–T2, T2–T3, and T3–T1.

4. Use an ohmmeter to conﬁrm open on input by measuring L1–L2, L2–L3, and L3–L1. If an isolation transformer is between the power source and panel, continuity will be

present. In this case, visually conﬁrm that motor and power leads are not reversed.

5. Inspect the controller for loose connections on terminals.

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

7. Conﬁrm control connections are terminated per connection diagrams that are supplied with the equipment.

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

9. Record motor nameplate data; hp, voltage, full load amps (FLA), and RPM. Ensure the nameplate data matches the drive ratings.

10. Conﬁrm 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:

EQUIPMENT DAMAGE. If motor FLA (full load amperage) is greater than unit maximum amps, controller must be replaced with one of appropriate ratings. Do not attempt to run the unit. Failure to match FLA to the unit maximum amp rating may result in equipment damage.

12. Conﬁrm that the motor FLA is equal to or less than the maximum controller output current. Some motors have higher than normal NEMA currents.

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System Setup and Operation

Pre-startup inspections

Item to Inspect Description Checked Auxiliary equipment 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 and encoders, etc. used for feedback to drive. Remove power factor correction caps on motor(s), if present.

Cable routing 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.

Control wiring 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.

EMC considerations Check for proper installation with regard to electromagnetic capability. Environmental conditions See equipment label for the maximum ambient operation temperature limits. Temperature is

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

Proper clearance Units require top and bottom clearance adequate to ensure proper air ﬂow for cooling in

accordance with the unit size.

Fusing and circuit breakers Check that all fuses are inserted ﬁrmly and in operational condition and that all circuit breakers

are in the open position.

Grounding The equipment requires a dedicated ground wire from its chassis to the building ground. Check

for good ground connections that are tight and free of oxidation.

Input and output power wiring

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

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. The panel should

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

airborne contaminants such as sulfur-based compounds.

be mounted solidly or use shock mounts as necessary.

Checked by: Date:

Start-up procedure

Electrical Hazard:

EQUIPMENT HAZARD. The drive contains dangerous voltages when connected to line voltage. Installation, start-up, and maintenance must be performed only by qualiﬁed personnel. Failure to perform installation, start-up and maintenance by qualiﬁed personnel only could result in death or serious injury.

1. Perform pre-start procedure.

2. Ensure that all operator devices are in the OFF position.

3. Keep the built-in disconnect switch in the OFF position. Apply voltage to the unit. DO NOT operate drive now.

4. Conﬁrm input line voltage is balanced within 3%. If it is not, correct input voltage imbalance before proceeding. Repeat this procedure after voltage correction, when applicable.

5. Conﬁrm that the wiring matches the installation diagram that is supplied with the unit.

6. Ensure control wiring matches the installation application.

7. Turn the built-in disconnect to the ON position.

28 Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL

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Setup and commissioning

WARNING:

System commissioning must be performed by qualiﬁed personnel.

• Ensure that all piping connections are made before commissioning the drive.

• Follow all start-up procedures for the motor, pump, and controller as indicated in their respective manuals.

• Refer to the Technologic controller IOM for detailed information on controller programming and parameters.

• Some default parameters are controller. The default parameters that are listed in the Technologic controller IOM may be different.

• The motor parameters have been conﬁgured at the factory for the motor provided with the Integrated Technologic Controller. Do not modify the motor parameters. Modiﬁcation of the motor parameters can result in malfunction of the sensorless control algorithm.

Sensorless operation

This product has been equipped with sensorless control capability. This feature allows control of a process variable (pressure or ﬂow) without the need of installing an external transducer. Sensorless control is intended for use in closed loop systems such as hydronic circulating pump systems. Sensorless control is not intended for open loop systems. The sensorless control method uses the relationship between head (pressure), ﬂow, power and speed (frequency) to determine the appropriate speed for the pump that is required to maintain the process variable setpoint. Since these relationships change with the use of different pumps and motors, pump performance data for the pump used must be programmed in to the controller. This data has been pre-programmed in to the drive at the factory to give the most accurate control possible. The controller is pre-conﬁgured at the factory for sensorless pressure control (Set-up 3).

System Setup and Operation

conﬁgured specially for the Integrated Sensorless

Figure 15: Pump performance and power curves

The solid lines in the diagram above show typical pump performance curves at various speeds. The dotted lines show the pump power curve at various speeds. The dashed line shows the setpoint of the process variable, in this case pressure. If a wired pressure transducer was used, the transducer would provide feedback to the pressure control loop. The pressure control loop would then calculate the speed required to maintain the setpoint during various ﬂow conditions. In the case of sensorless pressure control, the drive calculates the pressure in the system based on the speed and power consumption of the pump and sends this value to the pressure control loop. The pressure control loop then calculates the speed command as with the wired transducer.

In either sensorless pressure or ﬂow control mode the manipulated variable can be monitored or displayed by accessing parameter 18-50 Sensorless Readout [Unit]. In

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System Setup and Operation

sensorless pressure control mode, the manipulated variable is ﬂow (ﬂow varies while the pressure setpoint is maintained). In sensorless ﬂow control mode, the manipulated variable is pressure. The units for the manipulated variable are set in parameter 20-60 Sensorless Unit. For sensorless pressure control (Set-up 3) Sensorless Unit is set to GPM. For sensorless ﬂow control (Set-up 4), Sensorless Unit is set to psi.

To change to sensorless ﬂow control, change the active set-up to Set-up 4 by changing parameter 0-10 Active Set-up to Set-up 4.

Flow compensation

As ﬂow in a pumping system increases, the system friction head losses will also increase. Friction head loss is higher in systems with increased pipe lengths or decreased pipe size. The impact of this head loss is that the pressure at different points in the system will vary depending on ﬂow rate and the distance from the pump. The loss will be most signiﬁcant in the zones farthest from the pump. The controller’s internal ﬂow compensation function is used to correct the effect of friction head loss in the system. The ﬂow compensation function calculates a control curve based on pump and system parameters. The controller actively adjusts the setpoint along the control curve based on the speed of the pump. In a pump system, change in speed is proportional to a change in ﬂow so the controller effectively adjusts the setpoint based on a change in speed. A change in pressure varies with the square of the change in speed or ﬂow so a quadratic compensation factor is used to adjust the setpoint. This is the ideal compensation curve. When the controller is conﬁgured for sensorless pressure operation, the Square-linear curve approximation (Parameter 22-81) is automatically conﬁgured. Parameter 22-81 can be modiﬁed to adjust the control curve between a linear (0%) and quadratic (100%) response if a wired sensor is used for feedback. The diagram below illustrates this concept.

Figure 16: Flow compensation with sensorless control enabled

The ﬂow compensation function requires some system parameters to be set in the controller to accurately model the control curve. Some parameters must be set based on the design of the system in order to properly conﬁgure this function. Set the parameters in the table below to properly conﬁgure the ﬂow compensation function when the controller is conﬁgured for sensorless control.

Table 10: Flow compensation parameters with sensorless control enabled

Parameter number Description Set to 22–80 Flow compensation Enabled 22–81 Square-Linear-Curve approximation Modify between 100% (square) and 0%

(linear) per system requirements.

22–87 Pressure at no ﬂow System pressure at no ﬂow and no ﬂow speed.

This is the minimum design head for the system.

22–89 Flow at design point System ﬂow at H

(pressure setpoint (20–

Design

21))

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System Setup and Operation

If the controller is conﬁgured to operate with a wired sensor or in sensorless ﬂow control mode, additional parameters must be set to properly conﬁgure the ﬂow compensation function because pump performance data is unknown by the controller. In a sensorless application the controller is preprogrammed with the pump performance data. This means that only 3 points (setpoint, pressure at no ﬂow and ﬂow at design point) are required to determine the control curve for a sensorless application. For a sensorless ﬂow or wired sensor application the pump data is not known so additional parameters must be conﬁgured for proper operation of the ﬂow compensation function. The parameters that are required to be conﬁgured will depend on whether the speed at the design point is known. If the speed at the design point is known, set Work Point Calculation (parameter 22-82) to disabled. Set the Speed at No Flow [Hz] and Pressure at No-Flow Speed (parameters 22-84 and 22-87 respectively), which correlate to point A on the diagram below. The intersection of the system setpoint and Speed at Design Point [Hz] (parameter 22-86) correlates with point B. With this information the controller can then calculate the control curve. Refer to the diagram below.

Figure 17: Flow compensation with sensorless control disabled and speed at system design working point is unknown

Table 11: Flow compensation parameters when speed at design point is known

Parameter number Description Set to 22–80 Flow compensation Enabled 22–81 Square-Linear-Curve approximation Modify between 100% (square) and 0%

(linear) per system requirements. 22–82 Work point calculation Disabled 22–84 Speed at no ﬂow (Hz) To ﬁnd this point, close all valves in the system

and run the pump at the minimum design

head. The speed corresponding to the

minimum head requirement at no ﬂow will be

entered here. 22–86 Speed at design point (Hz) These points correspond to the speed required

to maintain point B (design head (setpoint)

and ﬂow). 22–87 Pressure at no ﬂow System pressure at no ﬂow and no ﬂow speed.

This is the minimum design head.

If the speed at the design point is unknown, the Work Point Calculation (parameter 22-82) must be enabled. With the Work Point Calculation enabled the controller will calculate the speed at the design point based on settings of some additional parameters correlating to the points shown on the diagram below. The ﬁrst point determined is point A which is the minimum required head at minimum speed (parameters 22-84 and 22-87). Points C and D can be determined by consulting the pump performance curve. Point C is determined by extending the design setpoint line horizontally to intersect the rated curve which is the pump performance curve at rated speed (usually 50 or 60Hz). The ﬂow at this point (Q extending the design ﬂow point (Q

) is set in parameter 22-90 Flow at Rated Speed. Point D is determined by

Rated

) vertically to intersect the rated speed curve. The

Design

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System Setup and Operation

head generated at this ﬂow and speed is set at Pressure at Rated Speed (parameter 22-88). Knowing points A, C and D allow the controller to calculate point E along with the control curve which includes point B (speed, pressure and ﬂow at design speed). Refer to the diagram below.

Figure 18: Flow compensation with sensorless control disabled and speed at system design working point is unknown

Table 12: Flow compensation parameters when speed at design point is unknown

Parameter number Description Set to 22–80 Flow compensation Enabled 22–81 Square-Linear-Curve approximation Modify between 100% (square) and 0%

(linear) per system requirements. 22–82 Work point calculation Enabled 22–84 Speed at no ﬂow (Hz) To ﬁnd this point, close all valves in the system

and run the pump at the minimum design

head. The speed corresponding to the

minimum head requirement at no ﬂow will be

entered here. 22–87 Pressure at no ﬂow System pressure at no ﬂow and no ﬂow speed.

This is the minimum design head. 22–88 Pressure at rated speed This point corresponds to the head developed

at design ﬂow and rated speed. This value can

be deﬁned using the pump performance

curve. 22–89 Flow at design point This point corresponds to the system design

ﬂow.

22–90 Flow at rated speed This point corresponds to the ﬂow at rated

speed. This value can be deﬁned using the

pump performance curve.

Commissioning

NOTICE:

The factory default settings are

conﬁgured to require a start signal to be wired to DI18.

For fast and easy installation, the controller has been preprogrammed with 4 different setups. Each set-up is conﬁgured for a different application. The set-ups contain parameters that are preset for the given application.

Set-up 1

has been conﬁgured for constant pressure control with a wired pressure transducer. The pressure transducer input is conﬁgured for a transducer with a maximum output at 40psi. The setpoint is preset to 15psi. Connect transducer feedback to AI53. Be sure to properly set the analog input conﬁguration switch A53 to match the sensor output type (U = 0-10V output, I = 4-20mA output).

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System Setup and Operation

Set-up2has been conﬁgured for constant ﬂow control with a wired ﬂow transducer. The

ﬂow transducer input is conﬁgured for a transducer with a maximum output at 300 GPM. The setpoint is preset to 150 GPM. Connect transducer feedback to AI53. Be sure to properly set the analog input conﬁguration switch A53 to match the sensor output type (U = 0-10V output, I = 4-20mA output).

Set-up3has been conﬁgured for constant pressure control using sensorless pressure

control. No transducer connections are required. The setpoint has been preconﬁgured at the factory based on the order request. This is the default setup.

Set-up4has been conﬁgured for constant ﬂow control using sensorless ﬂow control. No

transducer connections are required. The setpoint has been preconﬁgured at the factory based on the order request.

The controller comes conﬁgured with Set-up 3 as the active set-up (sensorless pressure control). To select a different set-up:

1. From the status screen, press to enter the parameter list.

2. Use the up and down arrows to scroll to 0–** Operation/Display and press .

3. Under Operation/Display use the up and down arrows to select 0–1* Set-up

Operations and press

4. Under 0–1* Set-up Operations select 0–10 Active Set-up by pressing .

5. Press

to enable editing of the parameter.

6. Change parameter 0–10 Active Set-up to the desired set-up using the up and down buttons.

7. Press to save the changes.

8. Press to return to the status screen.

To complete commissioning of the controller it is recommended to use My Personal Menu. My Personal Menu has been conﬁgured with parameters commonly used in pump

applications. To access this menu press and select My Personal Menu by pressing

. Scroll through the My Personal Menu parameter list and adjust the parameters using

the navigation keys. The following parameters have been added to My Personal Menu for quick access:

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System Setup and Operation

Table 13: My personal menu parameters for set-ups 1 and 2

Setup 1 Setup 2

Constant Pressure

Wired Pressure Transducer

Constant Flow

Wired Flow Transducer

Parameter Number Parameter Name Default Value for Set-up 1 Default Value for Set-up 2 Parameter Description

20-21 Setpoint 1 15.0 150.0 Process setpoint. The

controller will adjust speed to maintain this value.

20-00 Feedback 1 Source Analog Input 53 Analog Input 53 Feedback source for the

PID controller, transducer

input source. 20-12 Reference/Feedback Unit psi GPM Transducer feedback units 20-13 Min Reference/Feedb. 0.0 0.0 Minimum feedback value

for the transducer. 20-14 Max Reference/Feedb. 40.0 300.0 Maximum feedback value

for the transducer. 3-41 Ramp 1 Ramp Up Time 10 s 10 s Ramp up time (0 to full

speed). Increasing this

time will produce a slower

ramp up. 3-42 Ramp 1 Ramp Down Time 10 s 10 s Ramp down time (full

speed to 0). Increasing this

time will produce a slower

ramp down. 20-93 PID Prop Gain 5 5 Proportional correction

gain for PID controller.

Increasing this value will

produce a faster system

response. CAUTION:

Increasing this value too

high can make the system

unstable and produce

severe oscillations. 20-94 PID Integration Time 3.3 s 3.3 s Integration time for the PID

controller. Increasing this

value will produce a slower

system response.

CAUTION: Decreasing this

value too low can make the

system unstable and

produce severe oscillations. 22-80 Flow Compensation Disabled Disabled Enables or disables ﬂow

compensation (head loss

compensation) function. 22-81 Square-Linear Curve

Approx.

100% 100% Adjusts shape of the ﬂow

compensation control

curve. 22-84 Speed at No Flow [Hz] 0.0 Hz 0.0 Hz Speed required to maintain

the minimum head at no

ﬂow. Use this parameter

when ﬂow compensation is

enabled. See ﬁgure 3,

point A.

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System Setup and Operation

Setup 1 Setup 2

Constant Pressure

Wired Pressure Transducer

Constant Flow

Wired Flow Transducer

Parameter Number Parameter Name Default Value for Set-up 1 Default Value for Set-up 2 Parameter Description

22-86 Speed at Design Point [Hz] 60.0 Hz 60.0 Hz Speed required to maintain

the design point. Use this

parameter when ﬂow

compensation is enabled.

See ﬁgure 3, point B. 22-87 Pressure at No Flow Speed 0.000 0.000 Pressure developed at no

ﬂow speed. Use this

parameter when ﬂow

compensation is enabled.

See ﬁgure 2, point A. 5-10 Terminal 18 Digital Input Start Start DI 18 function 5-11 Terminal 19 Digital Input No Function No Function DI 19 function 5-12 Terminal 27 Digital Input No Function No Function DI 27 function 6-50 Terminal 42 Output Speed 4-20mA Speed 4-20mA Analog output function 5-40 Function Relay Relay 1: No Alarm Relay 2:

Running

Relay 1: No Alarm Relay 2: Running

Relay 1 and 2 function. See

note below on how to

program this parameter.

Table 14: My personal menu parameters for set-ups 3 and 4

Setup 3 Setup 4

Sensorless Pressure

Sensorless Flow Control

Control

Parameter Number Parameter Name Default Value for Set-up 3 Default Value for Set-up 4 Parameter Description

20-21 Setpoint 1 15.0 150.0 Process setpoint. The

controller will adjust speed

to maintain this value. 20-00 Feedback 1 Source Sensorless Pressure Sensorless Flow Feedback source for the

PID controller, transducer

input source. 20-12 Reference/Feedback Unit psi GPM Transducer feedback units 20-13 Min Reference/Feedb. 0.0 0.0 Minimum feedback value

for the transducer. 20-14 Max Reference/Feedb. 40.0 300.0 Maximum feedback value

for the transducer. 3-41 Ramp 1 Ramp Up Time 10 s 10 s Ramp up time (0 to full

speed). Increasing this

time will produce a slower

ramp up. 3-42 Ramp 1 Ramp Down Time 10 s 10 s Ramp down time (full

speed to 0). Increasing this

time will produce a slower

ramp down.

Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL 35

Page 38

System Setup and Operation

Setup 3 Setup 4

Sensorless Pressure

Sensorless Flow Control

Control

Parameter Number Parameter Name Default Value for Set-up 3 Default Value for Set-up 4 Parameter Description

20-93 PID Prop Gain 5 5 Proportional correction

gain for PID controller.

Increasing this value will

produce a faster system

response. CAUTION:

Increasing this value too

high can make the system

unstable and produce

severe oscillations. 20-94 PID Integration Time 3.3 s 3.3 s Integration time for the PID

controller. Increasing this

value will produce a slower

system response.

CAUTION: Decreasing this

value too low can make the

system unstable and

produce severe oscillations. 22-80 Flow Compensation Disabled Disabled Enables or disables ﬂow

compensation (head loss

compensation) function. 22-81 Square-Linear Curve

Approx.

100% 100% Adjusts shape of the ﬂow

compensation control

curve. 22-84 Speed at No Flow [Hz] NA 0.0 Hz Speed required to maintain

the minimum head at no

ﬂow. Use this parameter

when ﬂow compensation is

enabled. See ﬁgure 3,

point A. 22-86 Speed at Design Point [Hz] NA 60.0 Hz Speed required to maintain

the design point. Use this

parameter when ﬂow

compensation is enabled.

See ﬁgure 3, point B. 22-87 Pressure at No Flow Speed 0.000 0.000 Pressure developed at no

ﬂow speed. Use this

parameter when ﬂow

compensation is enabled.

See ﬁgure 2, point A. 22-89 Flow at Design Point 0.000 NA System ﬂow at the setpoint

and rated speed. Use this

parameter when ﬂow

compensation is enabled.

See ﬁgure 2, point B. 5-10 Terminal 18 Digital Input Start Start DI 18 function 5-11 Terminal 19 Digital Input No Function No Function DI 19 function 5-12 Terminal 27 Digital Input No Function No Function DI 27 function 6-50 Terminal 42 Output Speed 4-20mA Speed 4-20mA Analog output function 5-40 Function Relay Relay 1: No Alarm Relay 2:

Running

Relay 1: No Alarm Relay 2: Running

Relay 1 and 2 function. See

note below on how to

program this parameter.

36 Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL

Page 39

System Setup and Operation

Parameter 5-40, Function Relay, in My Personal Menu is an array parameter. This parameter can be programmed using the following procedure.

1. Enter My Personal Menu as previously described.

2. Use the up and down arrows to scroll to parameter 5-40 Function Relay.

3. Press to enable editing.

4. Use the up and down arrows to select Relay 1 or Relay 2. Relay 1 is [0]. Relay 2 is [1].

5. Press to save the selection and enable editing of the relay

function.

6. Use the up and down arrows to select the desired relay function.

7. Press

to save the selection. This will also enable selection of Relay 1 or Relay 2. Repeat the steps above to change the function of the other relay.

8. To exit editing of the parameter press .

Once the parameters in My Personal Menu have been set, press to start the controller and complete the commissioning of the controller.

Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL 37

Page 40

Troubleshooting

Troubleshooting menus

The controller has various menus which display information used to troubleshoot the controller.

Changes Made

The Changes Made menu can be used to view changes made to parameters. To access

the Changes Made menu press and scroll to Changes Made. Press to enter the menu.

Loggings

During troubleshooting the Loggings menu can be used to monitor the parameters

shown on the LCP in graphical form. To access the Loggings menu press and scroll to

Data Log Settings

Loggings. Use the arrow keys to select the desired parameter to monitor. Press view the parameter in graphical form. The graphical window scrolls right to left, present state is on the right and past state is on the left. The window shows 1 minute of logged data and continuously updates from right to left.

Parameter group 15 Drive Information contains parameters that allow monitoring present and past state of the controller. The controller has been conﬁgured to log 4 parameters in the event of an alarm condition these settings are found in the Data Log Settings, parameter group 15-1*. The following parameters will be logged: Feedback [Unit], Frequency, Inverter Thermal and Motor Current. The controller is set to take 50 samples of data prior to the alarm event. This data can be viewed by accessing the controller using the MCT 10 tool. Contact the factory for details.

Reset the frequency converter

Parameter group 15 Drive Information contains parameters that allow monitoring present and past state of the controller. The controller has been the even of an alarm condition. The following parameters will be logged: Feedback [Unit], Frequency, Inverter Thermal and Motor Current. The controller is set to take 50 samples of data prior to the alarm event. The data can be viewed by accessing the Quick Menu mode

by pressing . Scroll to sub-menu Q6 Loggings and press A warning or alarm is signalled by the relevant LED on the front of the frequency

converter and indicated by a code on the display.

38 Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL

conﬁgured to log 4 parameters in

Page 41

Trip-locked alarm

Troubleshooting

A warning remains active until its cause is no longer present. Under certain circumstances operation of the motor may still be continued. Warning messages may be critical, but are not necessarily so.

In the event of an alarm, the frequency converter will have tripped. Alarms must be reset to restart operation once their cause has been rectiﬁed. This may be done in four ways:

1. By using the [RESET] control button on the LCP.

2. Via a digital input with the “Reset” function.

3. Via serial communication/optional ﬁeldbus.

4. By resetting automatically using [Auto Reset] function. After a manual reset using the [RESET] control button on the LCP, the [AUTO ON] or

[HAND ON] button must be pressed to restart the motor.

If an alarm cannot be reset, the reason may be that its cause has not been rectiﬁed, or the alarm is trip-locked (see also table on following page).

NOTICE:

Disconnect and lock out electrical power before installing or servicing the unit.

• Alarms that are trip-locked offer additional protection, means that the mains supply must be switched off before the alarm can be reset.

• After being switched back on, the frequency converter is no longer blocked and may be reset as described above once the casue has been rectiﬁed.

• Alarms that are not trip-locked can also be reset using the automatic reset function in 14–20 Reset Mode. Warning: Automatic wake-up is possible.)

If a warning and alarm is marked against a code in the table on the following page, this means that either a warning occurs before an alarm, or it can be speciﬁed whether it is a warning or an alarm that is to be displayed for a given fault. This is possible, for instance, in 1–90 Motor Thermal Protection. After an alarm or trip, the motor carries on coasting, and the alarm and warning ﬂash on the frequency converter. Once the problem has been rectiﬁed, only the alarm continues ﬂashing.

Table 15: Alarm/Warning code list

Number Description Warning Alarm/Trip Alarm / Trip Lock Parameter Reference 1 10 volts low X 2 Live zero error (X) (X) 6–01 3 No motor (X) 1–80 4 Mains phase loss (X) (X) (X) 14–12 5 DC link voltage high X 6 DC link voltage low X 7 DC over voltage X X 8 DC under voltage X X 9 Inverter overloaded X X 10 Motor ETR over

(X) (X) 1–90

temperature

11 Motor thermistor over

(X) (X) 1–90

temperature 12 Torque limit X X 13 Over current X X X 14 Earth fault X X X 15 Hardware mismatch X X

Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL 39

Page 42

Troubleshooting

Number Description Warning Alarm/Trip Alarm / Trip Lock Parameter Reference 16 Short circuit X X 17 Control word timeout (X) (X) 8–04 18 Start failed X 23 Internal fan fault X 24 External fan fault X 14–53 25 Brake resistor short-

circuited 26 Brake resistor power

(X) (X) 2–13

limit 27 Brake chopper short-

X X

circuited 28 Brake check (X) (X) 2–15 29 Drive over temperature X X X 30 Motor phase U missing (X) (X) (X) 4–58 31 Motor phase V missing (X) (X) (X) 4–58 32 Motor phase W missing (X) (X) (X) 4–58 33 Inrush fault X X 34 Fieldbus communication

X X

fault 35 Out of frequency range X X 36 Mains failure X X 37 Phase imbalance X X 38 Internal fault X X 39 Heatsink sensor X X 40 Overload of digital

(X) 5–00, 5–01

output terminal 27 41 Overload of digital

(X) 5–00, 5–02

output terminal 29 42 Overload of digital

(X) 5–32

output on X30/6 42 Overload of digital

(X) 5–33

output on X30/7 46 Pwr. card supply X X 47 24 V supply low X X X 48 1.8 V supply low X X 49 Speed limit X (X) 1–86 50 AMA calibration failed X 51 AMA check Unom and

Inom 52 AMA low Inom X 53 AMA motor too big X 54 AMA motor too small X 55 AMA parameter out of

range 56 AMA interrupted by user X 57 AMA timeout X 58 AMA internal fault X X

40 Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL

Page 43

Troubleshooting

Number Description Warning Alarm/Trip Alarm / Trip Lock Parameter Reference 59 Current limit X 60 External interlock X 62 Output frequency at

maximum limit 64 Voltage limit X 65 Control board over-

X X X

temperature 66 Heat sink temperature

low 67 Option conﬁguration has

changed 69 Pwr. card temp X X 70 Illegal FC conﬁguration X 71 PTC 1 safe stop X X 72 Dangerous failure X

73 Safe stop auto restart 76 Power unit setup X 79 Illegal PS conﬁg X X 80 Drive initialized to

default value 91 Analog input 54 wrong

settings 92 NoFLow X X 22–2* 93 Dry pump X X 22–2* 94 End of curve X X 22–5* 95 Broken belt X X 22–6* 96 Start delayed X 22–7* 97 Stop delayed X 22–7* 98 Clock fault X 0–7* 201 Fire M was active

Warnings and alarms

Warning/Alarm Description Cause Remedy 1 — 10 V low The control card voltage is

below 10 V from terminal

50.

Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL 41

A short in a connected potentiometer or improper wiring of the potentiometer.

Remove the wiring from terminal 50. If the warning clears, the problem is with the customer wiring.

Page 44

Troubleshooting

Warning/Alarm Description Cause Remedy 2 — Live zero error This warning or alarm will

only appear if programmed by the user in 6–01 Live Zero Timeout Function. The signal on one of the analog inputs is less than 50% of the minimum value that is programmed for that input.

Broken wiring or faulty device sending the signal.

Check the connections on all the analog input terminals. Control card terminals 53 and 54 for signals, terminal 55 common. MCB 101 terminals 11 and 12 for signals, terminal 10 common. MCB 109 terminals 1, 3, 5 for signals, terminals 2, 4, 6 common.

Check that the frequency converter programming and switch settings match the analog signal type.

Perform Input Terminal Signal Test

4 — Mains phase loss A phase is missing on the

supply side, or the mains voltage imbalance is too

Check the supply voltage and supply currents to the

frequency converter. high. This message also appears for a fault in the input rectiﬁer on the frequency converter. Options are programmed at 14–12 Function at Mains Imbalance.

5 — DC link voltage high The intermediate circuit

voltage (DC) is higher than the high voltage warning limit.

The limit is dependent on the frequency converter voltage rating. The frequency converter is still active.

6 — DC link voltage low The intermediate circuit

voltage (DC) is lower than the low voltage warning limit.

The limit is dependent on the frequency converter voltage rating. The frequency converter is still active.

7 — DC overvoltage If the intermediate circuit

voltage exceeds the limit, the frequency converter trips after a time.

Connect a brake resistor

Extend a ramp time

Change the ramp type

Activate functions in 2–10

Brake Function

Increase 14–26 Trip Delay at

Inverter Fault

8 — DC under voltage If the intermediate circuit

voltage (DC) drops below the under voltage limit, the frequency converter checks if a 24 VDC backup supply is connected.

If no 24 VDC backup supply is connected, the frequency converter trips after a ﬁxed time delay. The time delay varies with unit size.

Check that the supply

voltage matches the

frequency converter

voltage.

Perform input voltage test

Perform soft charge and

rectiﬁer circuit test.

42 Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL

Page 45

Warning/Alarm Description Cause Remedy 9 — Inverter overloaded The frequency converter 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 frequency converter cannot be reset

The fault is that the frequency converter is overloaded by more than 100% for too long.

Compare the output current

shown on the LCP with the

frequency converter rated

current.

Compare the output current

shown on the LCP with the

measured motor current.

Display the Thermal Drive

Load on the LCP and until the counter is below

90%.

10 — Motor overload temperature

According to the electronic thermal protection (ETR), the motor is too hot. Select whether the frequency converter gives a warning or an alarm when the counter reaches 100% in 1– 90 Motor Thermal

The fault occurs when the motor is overloaded by more than 100% for too long.

Check for motor

overheating.

Check if the motor is

mechanically overloaded.

Check that the motor

current set in 1–24 Motor

Current is correct. Protection.

11 — Motor thermistor over temp

The thermistor might be disconnected. Select whether the frequency converter gives a warning or an alarm in 1–90 Motor Thermal Protection.

Check for motor

overheating.

Check if the motor is

mechanically overloaded.

When using terminal 53 or

54, check that the

thermistor is connected

correctly between either

terminal 53 or 54 (analog

voltage input) and terminal

50 (+10 V supply) and that

the terminal switch for 53

or 54 is set for voltage.

Check 1–93 Thermistor

Source selects terminal 53

or 54.

When using digital inputs

18 or 19, check that the

thermistor is connected

correctly between either

terminal 18 or 19 (digital

input PNP only) and

terminal 50. Check 1–93

Thermistor Source selects

terminal 18 or 19.

Troubleshooting

Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL 43

Page 46

Troubleshooting

Warning/Alarm Description Cause Remedy 12 — Torque limit The torque has exceeded

the value in 4–16 Torque Limit Motor Mode or the value in 4–17 Torque Limit Generator Mode. 14–25 Trip Delay at Torque Limit can change this from a warning only condition to a warning followed by an alarm.

If the motor torque limit is

exceeded during ramp up,

extend the ramp up time.

If the generator torque limit

is exceeded during ramp

down, extend the ramp

down time.

If torque limit occurs while

running, possibly increase

the torque limit. Be sure the

system can operate safely at

a higher torque.

Check the application for

excessive current draw on

the motor.

13 — Over current The inverter peak current

limit (approx. 200% of the rated current) is exceeded. The warning lasts about 1.5 seconds, then the frequency converter trips and issues an alarm. This fault may be caused by shock loading or fast

Remove power and check if

the motor can be turned.

Check that the motor size

matches the frequency

converter.

Check parameters 1–20

through 1–25 for correct

motor data. acceleration with high

inertia loads. If extended mechanical brake control is selected, trip can be reset externally.

14 — Ground (earth) fault There is current from the

output phases to ground, either in the cable between the frequency converter and the motor or in the motor itself.

Remove power to the

frequency converter and

repair the earth fault.

Check for ground faults in

the motor by measuring the

resistance to ground of the

motor leads and the motor

megohmmeter.

15 — Hardware mismatch A ﬁtted option is not

operational with the present control board hardware or software.

Record the value of the

following parameters and

contact your Xylem

supplier:

• 15–40 FC Type

• 15–41 Power Section

• 15–42 Voltage

• 15–43 Software Version

• 15–45 Actual Typecode String

• 15–49 SW ID Control Card

• 15–50 SW ID Power Cord

• 15–60 Option Mounted

• 15–61 Option SW Version

44 Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL

Page 47

Warning/Alarm Description Cause Remedy 16 — Short circuit There is a short circuit in the

motor or motor wiring.

Remove power to the frequency converter and repair the short circuit.

17 — Control word timeout There is no communication

to the frequency converter. The warning will only be

active when 8–04 Control Timeout Function is NOT set to [0] OFF.

If 8–04 Control Timeout Function is set to Stop and Trip, a warning appears and the frequency converter ramps down until it stops then displays an alarm.

Check connections on the series communication cable.

Increase 8–03 Control Timeout Time

Check operation of the communication equipment

Verify proper installation based on EMC requirements.

18 — Start failed The speed has not been

able to exceed 1–77

This may be caused by a

blocked motor. Compressor Start Max Speed [RPM] during start within the allowed time. (set in 1–79 Compressor Start Max Time to Trip).

23 — Internal fan fault The fan warning function

checks if the fan is running. The fan warning can be disabled on 14–53 Fan Monitor.

Check for proper fan operation.

Cycle power to the frequency converter and check that the fan operates brieﬂy at start up.

Check the sensors on the heatsink and control card.

24 — External fan fault The fan warning function

checks if the fan is running. The fan warning can be disabled on 14–53 Fan Monitor.

Check for proper fan operation.

Cycle power to the frequency converter and check that the fan operates brieﬂy at start up.

Check the sensors on the heatsink and control card.

25 — Brake resistor short circuit

The brake resistor is monitored during operation. If a short circuit occurs, the brake function is

Remove power to the frequency converter and replace the brake resistor

(see 2–15 Brake Check). disabled and the warning appears. The frequency converter is still operational but without the brake function.

26 — Brake resistor power limit

The power transmitted to the brake resistor is calculated as a mean value over the last 120 seconds of run time. The calculation is based on the intermediate circuit voltage and the brake resistance value set in 2–16 brake Max. Current.

The warning is active when the dissipated braking is higher than 90% of the brake resistance power.

If Trip [2] is selected in 2–13 Brake Power Monitoring, the frequency converter will trip when the dissipated braking power reaches 100%.

Troubleshooting

Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL 45

Page 48

Troubleshooting

Warning/Alarm Description Cause Remedy 27 — Brake chopper fault The brake transistor is

monitored during operation and if a short circuit occurs, the brake function is disabled and a warning is issued.

The frequency converter is still operational but, since the brake transistor has short-circuited, substantial power is transmitted to the brake resistor, even if it is

Remove power to the

frequency converter and

remove the brake resistor.

inactive.

28 — Brake check failed The brake resistor is not

Check 2–15 Brake Check. connected or not working.

29 — Heatsink temp The maximum temperature

of the heatsink has been exceeded. The temperature fault will not reset until the temperature falls below the reset heatsink temperature. The trip and reset points are based on the frequency converter power size.

Check for the following

conditions:

• Ambient temperature too high.

• Motor cable too long.

• Incorrect airﬂow clearance above and below the frequency converter.

• Blocked airﬂow around the frequency converter.

• Damaged heatsink fan.

• Dirty heatsink.

30 — Motor phase U missing

31 — Motor phase V missing Motor phase V between the

32 — Motor phase W missing

33 — Inrush fault Too many power-ups have

Motor phase U between the frequency converter and the motor is missing.

frequency converter and the motor is missing.

Motor phase W between the frequency converter and the motor is missing.

occurred within a short time

Remove power from the frequency converter and check motor phase U.

Remove power from the frequency converter and check motor phase V.

Remove power from the frequency converter and check motor phase W.

Let the unit cool to operating temperature.

period.

34 — Fieldbus communication fault

Communication between the ﬁeldbus and the communication option card is not operating.

36 — Mains failure This warning/alarm is only

active if the supply voltage to the frequency converter is lost and 14–10 Mains

Check the fuses to the frequency converter and mains power supply to the

unit. Failure is NOT set to [0] No Function.

46 Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL

Page 49

Warning/Alarm Description Cause Remedy 38 — Internal fault When an internal fault

occurs, a code number deﬁned in the table below is displayed.

Cycle power to the

frequency converter.

Check that the option is

properly installed.

Check for loose or missing

wiring.

It may be necessary to

contact your Xylem supplier

or service department. Note

the code number for further

troubleshooting directions.

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.

40 — Overload of digital output terminal 27

Check the load connected

to terminal 27 or remove

short-circuit connection.

Check 5–00 Digital I/O

Mode and 5–01 Terminal

27 Mode.

41 — Overload of digital output terminal 29

Check the load connected

to terminal 29 or remove

short-circuit connection.

Check 5–00 Digital I/O

Mode and 5–02 Terminal

29 Mode.

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 short-circuit

connection. Check 5–32

Term X30/6 Digi Out (MCB

101).

For X30/7, check the load

connected to X30/7 or

remove short-circuit

connection. Check 5–33

Term X30/7 Digi Out (MCB

101).

45 — Ground fault 2 Ground (earth) fault on

startup.

Check for proper grounding

(earthing) and loose

connections.

Check for proper wire size.

Check motor cables for

short-circuits or leakage

currents.

Troubleshooting

Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL 47

Page 50

Troubleshooting

Warning/Alarm Description Cause Remedy 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: 24 V, 5 V, +/- 18 V. When powered with 24 VDC with the MCB 107 option, only the 24 V and 5 V supplies are monitored. When powered with three-phase

Check for a defective power

cord.

Check for a defective control

card.

Check for a defective option

card.

If a 24 VDC power supply is

used, verify proper supply

power.

mains voltage, all three supplied are monitored.

47 — 24 V supply low The 24 V DC is measured on

the control card.

The external 24 V DC backup power supply may

Contact your Xylem

supplier.

be overloaded.

48 — 1.8 V supply low The power supply is

measured on the control card.

The 1.8 V DC supply used on the control card is outside of allowable limits.

Check for a defective control

card.

If an option card is present,

check for an overvoltage

condition.

49 — Speed limit When the speed is not

within the speciﬁed range in 4–11 Motor Speed Low Limit [RPM] and 4–13 Motor Speed High Limit [RPM], the frequency

When the speed is below the speciﬁed limit in 1–86 Trip Speed Low [RPM] (except when starting or stopping) the frequency

converter will trip. converter will show a warning.

50 — AMA calibration failed Contact your Xylem supplier

or Xylem Service Department.

51 — AMA check Unom and Inom

The settings for motor voltage, motor current, and

Check the settings in parameters 1–20 to 1–25.

motor power are wrong.

52 — AMA low Inom The motor current is too

low.

Check the setting in 4–18 Current Limit.

53 — AMA motor too big The motor is too big for the

AMA to operate.

54 — AMA motor too small The motor is too small for

the AMA to operate.

55 — AMA Parameter out of range

The parameter values of the motor are outside of the acceptable range. AMA will not run.

56 — AMA interrupted by the user

The AMA has been interrupted by the user.

57 — AMA timeout Try to restart AMA again.

Repeated restarts may overheat the motor.

58 — AMA internal fault Contact your Xylem

supplier.

48 Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL

Page 51

Warning/Alarm Description Cause Remedy 59 — Current limit The current is higher than

the value in 4–18 Current Limit.

Ensure that motor data in parameters 1–20 through 1–25 are set correctly.

Possibly increase the current limit. Be sure that the system can operate safely at a higher limit.

60 — External interlock A digital input signal is

indicating a fault condition external to the frequency controller.

62 — Output frequency at maximum limit

The output frequency has reached the value set in 4– 19 Max Output Frequency.

Check the application to determine the cause. Possibly increase the output frequency. Be sure the system can operate safely at a higher output frequency. The warning will clear wieh the output drops below the maximum limit.

65 — Control card over temperature

The cut-out temperature of the control card is 80°C.

Check that the ambient operating temperature is within limits.

Check for clogged ﬁlters. Check fan operation. Check the control card.

66 — Heatsink temperature low

The frequency converter is too cold to operate. This warning is based on the temperature sensor in the IGBT module.

Increase the ambient temperature of the unit.

A trickle amount of current can be supplied to the frequency controller whenever the motor is stopped by setting 2–00 DC Hold/Preheat Current at 5% and 1–80 Function at Stop.

67 — Option module conﬁguration has changed

68 — Safe stop activated Loss of the 24 VDC signal

69 — Power card temperature

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

on terminal 37 has caused the frequency controller to trip.

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

Check that the conﬁguration change is intentional and reset the frequency controller.

To resume normal operation, apply 24 VDC to terminal 37 and reset the frequency controller.

Check that the ambient operating temperature is within limits.

Check for clogged ﬁlters. Check fan operation. Check the power card.

70 — Illegal FC

conﬁguration

The control card and power card are incompatible.

Contact your supplier with the typecode of the unit from the

Troubleshooting

Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL 49

Page 52

Troubleshooting

Warning/Alarm Description Cause Remedy 80 — Drive initialized to

default value

Parameter settings are initialized to default

Reset the unit to clear the

alarm. settings after a manual reset.

92 — No ﬂow A no-ﬂow condition has

been detected in the system.

22–23 No-Flow Function is set for alarm.

Troubleshoot the system

and reset the frequency

converter after the fault has

been cleared.

93 — Dry pump A no-ﬂow condition in the

system with the frequency converter operating at high speed may indicate a dry

22–26 Dry Pump Function is set for alarm.

Troubleshoot the system

and reset the frequency

converter after the fault has

been cleared. pump.

94 — End of curve Feedback is lower than the

set point.

95 — Broken belt Torque is below the torque

level set for no load, indicating a broken belt.

This may indicate leakage in the system. 22–50 End Of Curve Function is set for alarm.

22–60 Broken Belt Function is set for alarm.

Troubleshoot the system,

and reset the frequency

converter after the fault has

been cleared.

Troubleshoot the system

and reset the frequency

converter after the fault has

been cleared.

96 — Start delayed Motor start has been

delayed due to short-cycle protection.

22–76 Interval between Starts is enabled.

Troubleshoot the system

and reset the frequency

converter after the fault has

been cleared.

97 — Stop delayed Stopping the motor has

been delayed due to short cycle protection.

22–76 Interval between Starts us enabled.

Troubleshoot the system

and reset the frequency

converter after the fault has

been cleared.

98 — Clock fault Time is not set or the RTC

clock has failed.

200 — Fire mode This indicates the frequency

controller is operating in ﬁre mode.

Reset the clock in 0–70 Date

and Time.

Cycle power to the unit to

remove the warning. See

the ﬁre mode data in the

alarm log.

201 — Fire mode was active This indicates the frequency

controller had entered ﬁre mode.

Cycle power to the unit to

remove the warning. See

the ﬁre mode data in the

alarm log.

202 — Fire mode limits exceeded

While operating in ﬁre mode one or more alarm conditions has been ignored which would

Operating in this condition voids unit warranty.

Cycle power to the unit to

remove the warning. See

the ﬁre mode data in the

alarm log. normally trip the unit.

203 — Missing motor With a frequency converter

operating multi-motors, an

This could indicate a missing motor.

Inspect the system for

proper operation. under-load condition was detected.

204 — Locked rotor With a frequency converter

operating multi-motors, an

This could indicate a locked rotor.

Inspect the motor for proper

operation. overload condition was detected.

250 — New spare part A component in the

frequency converter has been replaced.

Reset the frequency

converter for normal

operation.

50 Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL

Page 53

Troubleshooting

Warning/Alarm Description Cause Remedy 251 — New typecode A component in the

frequency converter has been replaced and the

Reset the frequency

converter for normal

operation. typecode changed.

Table 16: Internal fault codes

Number Deﬁnition 0 Serial port cannot be initialized. Contact your Xylem

supplier or Xylem service department. 256–258 Power EEPROM data is defective or too old. 512–519 Internal fault. Contact your Xylem supplier or Xylem

Service department. 783 Parameter value outside of min/max limits 1024–1284 Internal fault. Contact your Xylem supplier or Xylem

Service department. 1299 Option SW in slot A is too old 1300 Option SW in slot B is too old 1302 Option SW in slot C is too old 1315 Option SW in slot A is not supported (not allowed) 1316 Option SW in slot B is not supported (not allowed) 1318 Option SW in slot C1 is not supported (not allowed) 1379–2819 Internal fault. Contact your Xylem supplier or Xylem

Service department. 2820 LCP Stack overﬂow 2821 Serial port overﬂow 2822 USB port overﬂow 3072–5122 Parameter value is outside its limits 5123 Option in slot A: Hardware incompatible with control

board hardware 5124 Option in slot B: Hardware incompatible with control

board hardware 5125 Option in slot C: Hardware incompatible with control

board hardware 5126 Option in slot C1: Hardware incompatible with control

board hardware 5376–6231 Internal fault. Contact your Xylem supplier or Xylem

Service department.

Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL 51

Page 54

Page 55

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Xylem |’zīləm|

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 xyleminc.com

Visit our Web site for the latest version of this document and more information

The original instruction is in English. All non-English instructions are translations of the original instruction.

2013 Xylem Inc

Bell & Gossett is a trademark of Xylem Inc or one of its subsidiaries.

P2001489

Bell & Gossett P2001489 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction and Safety

Introduction

Safety

Safety message levels

User safety

Environmental safety

Transportation and Storage

Inspect the delivery

Inspect the package

Inspect the unit

System lifting

Transportation guidelines

Storage guidelines

Product Description

System description

Electrical Installation

Preinstallation

Line input (mains) connection

Control terminal connections

Local control panel

Menu keys

Navigation keys

Operation keys

Programming the controller

System Setup and Operation

Pre-start procedure

Pre-startup inspections

Start-up procedure

Setup and commissioning

Troubleshooting

Troubleshooting menus

Reset the frequency converter

Warnings and alarms