Bell & Gossett P2001489 User Manual
INSTRUCTION MANUAL
Integrated Technologic
with Sensorless Control
®
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
Introduction and Safety
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
2 Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL
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.
Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL 3
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.
4 Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL
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
Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL 5
Transportation and Storage
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.
6 Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL
Transportation and Storage
NOTICE:
• Protect the product against humidity, heat sources, and mechanical damage.
• Do not place heavy weights on the packed product.
Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL 7
Product Description
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)
8 Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL
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
Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL 9
Electrical Installation
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.
10 Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL
*
91 (L1)
92 (L2)
93 (L3)
PE
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
03
0-10Vdc
+10Vdc
0-10Vdc
0/4-20 mA
240Vac, 2A
24Vdc
02
01
05
04
06
240Vac, 2A
24V (NPN)
0V (PNP)
0V (PNP)
24V (NPN)
19 (D IN)
24V (NPN)
0V (PNP)
27
24V
0V
(D IN/OUT)
0V (PNP)
24V (NPN)
(D IN/OUT)
0V
24V
29
24V (NPN)
0V (PNP)
0V (PNP)
24V (NPN)
33 (D IN)
32 (D IN)
1 2
ON
A53/S201
ON
21
A54/S202
ON=0-20mA
OFF=0-10V
95
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
0V
5V
S801
RS-485
RS-485
21
ON
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.
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
12 Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL
Removable control terminal connectors
1
4
2
3
130BA012.12
61
68
69
39
42
50
53
54
55
12
13
18
19
27
29
32
33
20
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.
Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL 13
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
14 Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL
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.
Integrated Technologic® with Sensorless Control INSTRUCTION MANUAL 15
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