Grundfos RF2, RF4 Installation And Operating Instructions Manual

GRUNDFOS INSTRUCTIONS
Redi-Flo Variable Frequency Drive
USA Installation and operating instructions
SAFETY NOTICE
11
This equipment contains voltages that may be as great as 1000 volts! Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt the start–up procedure or troubleshoot this equipment.
PPRREECCAAUUTTIIOONNSS::
WWAARRNNIINNGG::
Do not touch any circuit board, power device or electrical connection before you first ensure that power has been disconnected and there is no high voltage present from this equipment or other equipment to which it is connected. Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt the start–up procedure or troubleshoot this equipment.
WWAARRNNIINNGG::
Be sure the system is properly grounded before applying power. Do not apply AC power before you ensure that grounds are connected. Electrical shock can cause serious or fatal injury.
WWAARRNNIINNGG::
Do not remove cover for at least five (5) minutes after AC power is disconnected to allow capacitors to discharge. Electrical shock can cause serious or fatal injury.
CCAAUUTTIIOONN::
Disconnect motor leads (T1, T2 and T3) from control before you perform a “Megger” test on the motor. Failure to disconnect motor from the control will result in extensive damage to the control. The control is tested at the factory for high voltage / leakage resistance as part of Underwriter Laboratory requirements.
CCAAUUTTIIOONN::
Do not connect AC power to the Motor terminals T1, T2 and T3. Connecting AC power to these terminals may result in damage to the control.
QUICK START GUIDE
21
QQUUIICCKK SSTTAARRTT GGUUIIDDEE
To operate the Redi-Flo VFD system, simply:
1. Submerge the RF2 or RF4 pump in the water to be pumped.
2. Connect the motor lead to the Redi-Flo VFD. (Note: With RF4 Variable Performance Pumps you must have an adapter cord to connect to Redi-Flo VFD.
##33 aanndd ##44 ffoorr ooppeerraattiioonn wwiitthh ggeenneerraattoorr oonnllyy.. WWAARRNNIINNGG:: DDoo nnoott lleett tthhee ggeenneerraattoorr rruunn oouutt ooff ggaass wwhhiillee ppoowweerriinngg tthhee VVFFDD.. IIff iitt ssuurrggeess aanndd ccrreeaatteess eexxcceessssiivvee vvoollttaaggee,, iinntteerrnnaall VVFFDD ddaammaaggee ccoouulldd rreessuulltt..
3. If using a generator, start the generator and allow it to warm up.
4. If the generator has a circuit breaker, close the breaker and check the output voltage from the generator. The output voltage must be within the specified ranges (refer to Technical Specifications, at the end of this manual) to ensure proper operation and prevent damage to the system. If the voltage is too high or too low, adjustments to the generator must be performed to allow the system to run.
5. Plug the Redi-Flo VFD into a generator or connect to utility power supply. The unit accepts 115V or 230V sources. Refer to the Input Power Terminals section for wiring instructions.
WWAARRNNIINNGG:: IInnccoorrrreecctt wwiirriinngg oonn tthhee 111155VV oorr 223300VV tteerrmmiinnaallss wwiillll ddaammaaggee tthhee ddrriivvee..
6. The VFD will initialize and be ready to drive the motor. After the initialization screen appears, the following will be displayed:
• STP means the drive is stopped
• V indicates motor volts
• REDIFL2 indicates Redi-Flo2 pump mode
• LOC means the drive is in Local Keypad Mode
• A indicates motor amps
• HZ indicates motor frequency
The VFD defaults to Redi-Flo2 operation. To change to Redi-Flo4 press the sequence SHIFT-▼-SHIFT keys. Use sequence SHIFT--SHIFT to return to Redi-Flo2.
7. Press the FWD key to start the motor and use the and arrow keys to increase
or decrease speed. Continuous holding of the arrow key will increase the rate of speed change. The STOP key is used to stop the motor.
8. Pressing the ENTER key allows the user to quickly set the speed to any given value
by using the and ▼ arrows to change speed and the SHIFT key to cursor between digits.
9. When powering down, unplug the Redi-Flo VFD from the generator BEFORE removing the motor lead from the Redi-Flo VFD or turning off the generator.
NNoottee:: TToo pprreevveenntt ttrriippppiinngg ppoowweerr ssoouurrccee cciirrccuuiitt bbrreeaakkeerrss pplleeaassee oobbsseerrvvee tthhee ffoolllloowwiinngg:: WWhheenn uussiinngg tthhee RReeddii-FFlloo44 ppuummpp aanndd aa VVFFDD ppoowweerr ssoouurrccee ooff 111155VVAACC,, mmoottoorr ssppeeeeddss ooff ggrreeaatteerr tthhaann 7700HHzz mmaayy ddrraaww oovveerr 1155 aammppss.. FFoorr 223300VVAACC ppoowweerr ssoouurrccee mmoottoorr ssppeeeeddss ggrreeaatteerr tthhaann 9900 HHzz mmaayy ddrraaww oovveerr 1155 aammppss.. IInn RReeddiiFFlloo44 mmooddee,, 110000 HHzz ccaannnnoott bbee eexxcceeeeddeedd wwiitthhoouutt cchhaannggiinngg ppaarraammeetteerrss..
STP 0V REDIFL2 LOC 0.0A 0.00HZ
PRE-INSTALLATION CHECKLIST
13
CCoommppoonneennttss ooff YYoouurr RReeddii-FFlloo VVFFDD SSyysstteemm
Your Redi-Flo Variable Performance Pump system should contain the following components:
1. Redi-Flo Variable Frequency Drive, (See Figure 1)
2. Either a Redi-Flo2® pump and motor with lead (Figure 2) or a Redi-Flo4™ Variable Performance pump, motor, lead, lead/plug and RF4 x VFD adapter cord (Figure 3).
Figure 1
Redi-Flo2®
Redi-Flo4®
Figure 2
Figure 3
TToo ooppeerraattee tthhee ssyysstteemm yyoouu wwiillll aallssoo nneeeedd::
1. A discharge hose or pipe to connect to the pump (See Figure 4).
2. An electrical plug to connect the Redi-Flo VFD power cord to your portable
generator may be needed if the supplied plug is not compatible with your generator (See Figure 5).
3. Safety cable and hardware for lowering and lifting the pump (See Figure 6).
Redi-Flo2®
Figure 6Figure 5
The exact type of plug used will depend upon your generator, The Redi-Flo VFD is supplied with a standard NEMA 5-15P, 115V, 3 prong plug.
Figure 4
Redi-Flo4®
ASSEMBLING THE REDI-FLO VFD SYSTEM
41
IINNPPUUTT PPOOWWEERR TTEERRMMIINNAALLSS
The input voltage can be changed between 115V and 230V by changing the line input connections as shown below:
WWaarrnniinngg - IIff tthhee RReeddii-FFlloo VVFFDD iiss mmiisswwiirreedd ffoorr tthhee iinnccoommiinngg vvoollttaaggee,, iinntteerrnnaall ddaammaaggee mmaayy ooccccuurr ttoo tthhee ddrriivvee..
AAttttaacchhiinngg tthhee PPuummpp ttoo tthhee ppiippee
When connecting the discharge pipe or tubing to the pump, a back-up wrench should be used. It is recommended that a safety cable be attached to the pump (using special brackets and cables, sold separately) anytime plastic pipe or flexible tubing is used (as shown if figure 6). A check valve may also be added to Redi-Flo2® pumps to prevent fluid from flowing back into the pump after it is turned off (backflow prevention). A check valve is standard on Redi-Flo4™ pumps. Always check to ensure joints are fastened securely. The use of a torque arrestor is not required when using the Redi-Flo VFD.
LLoowweerriinngg tthhee PPuummpp IInnttoo tthhee WWeellll
Make sure the electrical motor leads are not cut or damaged in any way when the pump is being lowered into the well. Do not use the motor leads to support the weight of the pump. To protect against surface water entering the well and contaminating the well, the well should be finished off utilizing a locally approved well seal.
The motor lead should be secured to the discharge pipe or tubing at frequent intervals to prevent sagging, looping and possible motor lead damage. Teflon® wire ties are recommended for environmental applications.
IIMMPPOORRTTAANNTT
Plastic pipe and tubing tend to stretch under load. This stretching must be taken into account when securing the motor lead to the riser pipe or tubing. Leave three to four inches of slack between clipped points. This tendency to stretch will also affect the calculation of the pump setting depth. When plastic pipe or tubing is used, it is recommended that a safety cable be attached to the pump to raise and lower it. Redi-Flo4™ pumps are designed to accommodate this cable and Redi-Flo2® pumps can be fitted with a safety cable bracket (part number 1A0019).
223300VVAACC 111155VVAACC
RR22 BBtt//RR11 BB-TT11 TT22 TT33 GGNNDD
-----230VAC-----
-----------115VAC-----------
HHoott NNeeuuttrraall GGrreeeenn
ASSEMBLING THE REDI-FLO VFD SYSTEM
15
OOPPEERRAATTIINNGG CCOONNDDIITTIIOONNSS
To ensure the Redi-Flo Variable Performance Pumping system operates properly, follow these guidelines:
• The Redi-Flo2® or Redi-Flo4™ pump must be installed vertically with the discharge end pointed upwards.
• The electrical voltage supply to the Redi-Flo VFD must always be within + or - 10% of the specified power
supply ( 103.5 - 126.5 VAC at 115V connection or 207 - 253 VAC at 230V ).
• For best performance when operating on a generator, 115V generators should be set at 120V without load and
230V generators should be set at 240V without load. Use a separate meter to set voltage; do not rely on built­in meters found on generators. Verify generator voltage stays within tolerance at full load.
• The pump and motor must always be completely submerged in fluid to ensure
lubrication and cooling of the motor.
• The temperature of the fluid being pumped should be according to the technical
specifications shown in the motor specifications.
• The installation depth of the pump should always be at least three feet below the maximum drawdown level
of the well.
• Redi-Flo pumps are not recommended for well development or pumping fluid
containing abrasives.
• Redi-Flo2® pumps are not recommended for continuous operation applications.
• The warranty of the Redi-Flo pumps will be void if other than the Redi-Flo VFD is used or if corrosive fluids are
pumped.
• The service life of dedicated Redi-Flo pumps may be compromised if the ambient water quality exceeds one or
more of the following values:
pH<5 DO>2 ppm H2S>1 ppm CL->500 ppm TDS>1000 ppm
AAddhheerreennccee TToo EEnnvviirroonnmmeennttaall RReegguullaattiioonnss
When handling and operating the Redi-Flo Variable Performance Pump system, all environmental regulations concerning the handling of hazardous materials must be observed. When the pump is taken out of operation, great care should be taken to ensure that the pump contains no hazardous materials that might cause injury to human health or to the environment.
PPuurrggiinngg AA WWeellll
If the pump is used to purge a well, start the pump at minimum speed and gradually increase to desired speed. Redi-Flo products are not recommended for well development.
GGeenneerraattoorr UUssaaggee
MMiinniimmuumm ggeenneerraattoorr ssiizzee ((RReeddii-FFlloo22//RReeddii-FFlloo44)) For generators with voltage regulation 2500/3400 watts at 115/230VAC, single phase For generators without voltage regulation 5000/6700 watts at 115/230VAC, single phase Recommended for optimal performance 4000/5400 watts at 115/230 VAC, single phase
with voltage regulation
REDI-FLO VFD SPECIAL FEATURES
61
DDuuaall IInnppuutt CCaappaabbiilliittyy
Redi-Flo VFD can accept 115V or 230V single phase input voltage. Refer to the input power terminal section on page 4 for connection instructions.
EEnncclloossuurree
The Redi-Flo VFD NEMA 4 enclosure is designed for outdoor duty and is resistant to damage as a result of incidental exposure to rain.
UULL AApppprroovvaallss
The Redi-Flo VFD is UL Listed to U.S. and Canadian electrical safety standards.
DDuuaall FFuunnccttiioonnaalliittyy
The Redi-Flo VFD can change from operating Redi-Flo2® (MP1) to Redi-Flo4™ Variable Performance pumps with a few keystrokes.
OOppttiimmiizzeedd VVoollttss//FFrreeqquueennccyy ((VV//HHZZ)) PPaatttteerrnn
The Redi-Flo VFD V/Hz pattern is specially optimized to allow the most efficient operation of Redi-Flo2® and Redi-Flo4™ variable performance pumps.
REDI-FLO VFD KEYPAD OVERVIEW
17
OOvveerrvviieeww
The keypad is used to program the control parameters, to operate the motor and to monitor the status and outputs of the control by accessing the display options, diagnostic menus and the fault log.
IInnddiiccaattoorr LLiigghhttss
JOG - (Green) lights when Jog is active. FWD - (Green) lights when FWD direction is commanded. REV - (Green) lights when REV direction is commanded. STOP - (Red) lights when motor STOP is commanded.
JJOOGG -
Press JOG to select the preprogrammed jog speed. After the jog key has been pressed, use the FWD or REV keys to run the motor in the direction that is needed. The JOG key is only active in the local mode.
FFWWDD -
Press FWD to initiate forward rotation of the motor. (Active in Local and Jog modes).
RREEVV -
Press REV to initiate reverse rotation of the motor. (Active in Local and Jog modes).
SSTTOOPP -
Press STOP to initiate a stop sequence. Depending on the setup of the control, the motor will either regen or coast to a stop. This key is operational in all modes of operation unless it has been disabled by the Keypad Stop parameter in the Keypad (programming) Setup Block.
LLOOCCAALL -
Press LOCAL to change between the local (keypad) and remote operation.
DDIISSPP -
Press DISP to return to display mode from programming mode. Provides operational status and advances to the next display menu item.
SSHHIIFFTT -
Press SHIFT in the program mode to control cursor movement. Pressing the SHIFT key once moves the blinking cursor one character position to the right. While in program mode, a parameter value may be reset to the factory preset value by pressing the SHIFT key until the arrow symbols at the far left of the keypad display are flashing, then press an arrow key. In the display mode the SHIFT key is used to adjust the keypad contrast.
RREESSEETT -
Press RESET to clear all fault messages (in local mode). Can also be used to return to the top of the block programming menu without saving any parameter value changes.
PPRROOGG -
Press PROG to enter the program mode. While in the program mode the PROG key is used to edit a parameter setting.
((UUPP AArrrrooww))..
Press
to change the value of the
parameter being displayed. Pressing
increments the value to the next greater value. Also, when the fault log or parameter list is displayed, the
key will scroll upward through the list. In the local mode pressing the
key
will increase motor speed to the next greater value.
EENNTTEERR -
Press ENTER to save parameter value changes and move back to the previous level in the programming menu. In the display mode the ENTER key is used to directly set the local speed reference. It is also used to select other operations when prompted by the keypad display.
((DDoowwnn AArrrrooww))
Press
to change the value of the
parameter being displayed. Pressing
decrements the value to the next lesser value. Also, when the fault log or parameter list is displayed, the
key
will scroll downward through the list. In the local mode pressing the
key
will decrease motor speed to the next lesser value.
KKeeyyppaadd DDiissppllaayy -
Displays status information during Local or Remote operation. It also displays information during parameter setup and fault or Diagnostic Information.
MMoottoorr SSeelleeccttiioonn -
The VFD defaults to Redi-Flo2 operation, to change to Redi-Flo 4, press the key sequence “Shift -
- Shift.” Use the sequence
“Shift -
- Shift” to return to Redi-Flo2.
MOTOR CONTROL VIA KEYPAD
81
The Redi-Flo VFD can operate the motor in three (3) different ways from the keypad.
1. Speed adjustment using the Keypad arrow keys
2. Speed adjustment with Keypad entered values
3. JOG Command
11)) KKeeyyppaadd aarrrrooww ssppeeeedd ccoonnttrrooll
Press FWD or REV to select desired direction of motor rotation, then press or hold the up arrow key to increase speed or use the down arrow key to reduce motor speed. Continuously holding the arrow key will cause the
speed to change in larger increments. The minimum speed increment produced by the arrow keys is defined in PROG/Keypad Setup/Keypad Speed INC. Default value of 0.10 Hz can be changed by the user.
22)) KKeeyyppaadd ssppeeeedd eenntteerreedd vvaalluuee
Press the ENTER key and use the and arrow keys to adjust digits and the SHIFT key to cursor to the desired
digit. Press ENTER when finished selecting desired motor speed to return to the display mode. Press the FWD or REV key to run the motor in the desired direction at the programmed speed.
33)) JJOOGG CCoommmmaanndd
The JOG key can be used to ramp the pump up to a predetermined speed in the forward or reverse direction. Press the JOG key then hold the FWD or REV key, and the pump will ramp to the speed set in PROG/Jog Settings/Jog Speed. Acceleration and deceleration times for Jog can also be set in this programming menu.
DDIISSPP KKeeyy
The DISP key can be used for accessing diagnostic and troubleshooting screens as shown below:
redifl2
Action
Apply Power Display mode showing mode,
voltage, current & frequency status.
Press DISP key Scroll to fault log block. Press ENTER to view the fault log
Press DISP key Scroll to diagnostic info block. Press ENTER to view diagnostic
Press DISP key Scroll to local speed ref. block. Press ENTER to change motor
Press DISP key Display mode showing output
frequency.
Press DISP key Display mode showing motor
speed (based on output frequency).
Press DISP key Display mode showing output
current.
Press DISP key Display mode showing output
voltage.
Description Display Comments
No faults present. Local keypad mode. If in remote mode, press local for this display.
if desired.
information if desired.
speed.
MOTOR CONTROL VIA KEYPAD
19
AAddjjuussttiinngg DDiissppllaayy CCoonnttrraasstt
When AC power is applied to the VFD, the keypad should display the status of the unit. If there is no display visible, or if it is difficult to read, use the following procedure to adjust the display. Contrast may be adjusted in the display mode when motor is stopped or running.
Action
Apply Power No visible display
Press DISP Key Places control in display mode Display mode.
Press SHIFT key 2 times Allows display contrast
Press Y or B Key
Press ENTER Saves level of contrast and exits
adjustment Adjusts display intensity
to display mode
Description Display Comments
PROG MENU
101
AAddvvaanncceedd PPrrooggrraammmmiinngg
A password is required for advanced programming features.
AAlltteerriinngg ssoommee ddeeffaauulltt sseettttiinnggss ffoorr RReeddii-FFlloo22 oorr
RReeddii-FFlloo44 ccoouulldd ppoossssiibbllyy ddaammaaggee tthhee mmoottoorr oorr VVFFDD..
For additional programming instructions, please refer to
the full programming guide found at the Baldor website: w
ww.Baldor.com The manual can be found under
Support — installation and operation manuals. It is Baldor manual number MN715, Series 15H Inverter.
LEVEL 1 BLOCKS LEVEL 2 BLOCKS
Preset Speeds Input Output Limits Brake Adjust
Preset Speed #1 Operating Mode Operating Zone Resistor Ohms Preset Speed #2 Command Select Min Output Frequency Resistor Watts Preset Speed #3 ANA CMD Inverse Max Output Frequency DC Brake Voltage Preset Speed #4 ANA CMD Offset PK Current Limit DC Brake Frequency Preset Speed #5 ANA CMD Gain REGEN Limit Brake on Stop Preset Speed #6 CMD SEL Filter REGEN Limit ADJ Brake on Reverse Preset Speed #7 Power Up Mode PWM Frequency Stop Brake Time Preset Speed #8 Brake on Start Preset Speed #9 Output Custom Units Start Brake Time Preset Speed #10 Digital Out #1 MAX Decimal Places Preset Speed #11 Digital Out #2 Value at Speed Process Control Preset Speed #12 Digital Out #3 Value DEC Places Process Feedback Preset Speed #13 Digital Out #4 Value Speed REF Process Inverse Preset Speed #14 Zero SPD Set PT Units of Measure Setpoint Source Preset Speed #15 At Speed Band Units of MEAS 2 Setpoint Command
Set Speed Point Set PT ADJ Limit Accel / Decel Rate Analog Out #1 Protection At Setpoint Band Accel Time #1 Analog Out #2 External Trip Process PROP Gain Decel Time #1 Analog Scale #1 Local Enable INP Process INT Gain S-Curve #1 Analog Scale #2 Process DIFF Gain Accel Time #2 Underload Set Point Miscellaneous Follow I:O Ratio Decel Time #2 Restart Auto/Man Follow I:O Out S-Curve #2 V/HZ and Boost Restart Fault/Hr Encoder Lines
Ctrl Base Frequency Restart Delay Integrator Clamp Jog Settings Torque Boost Factory Settings Minimum Speed Jog Speed Dynamic Boost Language Select Jog Accel Time Slip Comp Adj STABIL ADJ Limit Skip Frequency Jog Decel Time V/HZ Profile Stability Gain Skip Frequency #1 Jog S-Curve V/HZ 3-PT Volts Skip Band #1
V/HZ 3-PT Frequency Security Control Skip Frequency #2 Keypad Setup Max Output Volts Security State Skip Band #2 Keypad Stop Key Access Timeout Skip Frequency #3 Keypad Stop Mode Access Code Skip Band #3 Keypad Run Fwd Keypad Run Rev Motor Data Synchro Starts Keypad Jog Fwd Motor Voltage Synchro Starts Keypad Jog Rev Motor Rated Amps Sync Start Frequency 3 Speed Ramp Motor Rated Speed Sync Scan V/F Switch on Fly Motor Rated Frequency Sync Setup Time LOC. Hot Start Motor Mag Amps Sync Scan Time
Sync V/F Recover Sync Direction
Communications
Protocol Baud Rate
Drive Address
TROUBLESHOOTING GUIDE TO ERROR MESSAGES
111
INDICATION POSSIBLE CAUSE CORRECTIVE ACTION
Command Select Incorrect operating mode
Bus Overvoltage Trip or HW Overvoltage
programmed. Need expansion board. Install the correct expansion board for selected operating mode.
DECEL Rate set too low a value Lengthen DECEL time.
Change Operating Mode in the Level 1 Input block to one that does not require the expansion board.
Add external dynamic braking resistors or module.
Input voltage too high. Verify proper AC line voltage.
Bus Undervoltage Input voltage too low. Verify proper AC line voltage.
External Trip
Hardware Protect Fault duration too short to be
Heatsink Temp Motor Overloaded. Correct motor loading.
Motor draws excessive current. Check motor for overloading.
External trip parameter incorrect. Verify connection of external trip circuit at J4-16.
identified.
Ambient temperature too high. Relocate control to cooler operating area.
Built-in fans are ineffective or inoperative.
Use step down transformer if needed. Use line reactor to minimize spikes.
Use step up transformer if needed. Check power line disturbances (sags caused by start up of
other equipment).
Monitor power line fluctuations with date and time imprint
to isolate power problem.
Verify proper sizing of control and motor.
Set external trip at J4-16.
Reset control. Check for proper grounding of power wiring and shielding of signal wiring. Replace control board.
Verify proper sizing of control and motor.
Add cooling fans or air conditioner to control cabinet. Verify fan operation.
Remove debris from fan and heatsink surfaces. Replace fan or check fan wiring.
parameter to “OFF” if no connection made
TROUBLE SHOOTING GUIDE (CONT.)
121
INDICATION POSSIBLE CAUSE CORRECTIVE ACTION
HW Desaturation Accel/Decel rate set too short.
HW Power Supply
HW Ground Fault Output current (motor current)
Torque Boost set too high. Electrical noise in logic circuits. Motor overloaded.
Power supply malfunctioned. Check internal connections.
leakage to ground.
Lengthen Accel/Decel rate. Reduce torque boost value. Check for proper grounding of power wiring and shielding of signal wiring. Verify proper sizing of control and motor or reduce motor load.
Replace logic power board. Disconnect wiring between control and motor. Retry test.
If GND FLT is cleared, reconnect motor leads and retry the test. Repair
motor if internally shorted. Replace motor lead wire with low capacitance cable. If GND FLT remains, contact your dealer.
Motor Will Not Start
Motor Will Not Reach Maximum Speed
Motor Will Not Stop Rotation
Motor runs rough Torque boost set too high. Adjust torque boost parameter value. at low speed
Motor overloaded. Check for proper motor loading.
Motor may be commanded to run below minimum frequency setting.
Incorrect Command Select parameter.
Incorrect frequency command. Verify control is receiving proper command signal at J4. Max Frequency Limit set too low. Adjust Max Frequency Limit parameter value. Motor overloaded. Check for mechanical overload. If unloaded motor shaft does not rotate
Improper speed command. Verify control is receiving proper command signal at input terminals.
MIN Output Speed parameter set too high.
Improper speed command. Verify control is receiving proper command signal at input terminals.
Misalignment of coupling. Faulty motor. Replace with a new motor.
Check couplings for binding. Verify proper sizing of control and motor.
Increase speed command or lower minimum frequency setting.
Change Command Select parameter to match wiring at J4.
freely, check motor bearings.
Verify control is set to proper operating mode to receive your speed command.
Adjust MIN Output Speed parameter value.
Verify control is set to receive your speed command.
Check motor/load coupling alignment.
TROUBLE SHOOTING GUIDE (CONT.)
113
INDICATION POSSIBLE CAUSE CORRECTIVE ACTION
New Base ID Replaced Control or circuit board. Restore parameters to factory settings.
No Display Lack of input voltage. Check input power for proper voltage.
Loose connections. Check input power termination.
Adjust display contrast. See Adjust Display Contrast.
NV Memory Fail Memory fault occurred. Press RESET key on keypad. Restore parameter values to factory
3 Sec Overload Peak output current exceeded 3 sec
1 Min Overload Peak output current exceeded 1
Over Speed Motor exceeded 110% of MAX
Param Checksum Memory fault occurred. Press RESET key on keypad. Restore parameter values to factory
Unknown Fault Code
Unstable Speed Oscillating load.
uP Reset A software watchdog timer has
FLT Log MEM Fail
Current SENS FLT
Bus Current SENS
rating.
minute rating.
Output Freq parameter value.
Microprocessor detected a fault that is not defined in the fault code table.
Unstable input power. Slip compensation too high.
reset the processor because a process has timed out.
Corrupt data in fault log (may occur on older systems only).
Failure to sense phase current. Press RESET key on keypad. If fault remains, call dealer.
Failure to sense bus current. Press RESET key on keypad. If fault remains, call dealer.
Reset control.
Verify connection of operator keypad.
settings. If fault remains, call dealer. Check PK Current Limit parameter in the Level 2
Output Limits block. Check motor for overloading. Increase ACCEL time. Reduce motor load. Verify proper sizing of control and motor.
Check PK Current Limit parameter in the Level 2
Output Limits block. Check motor for overloading. Increase ACCEL/DECEL times. Reduce motor load. Verify proper sizing of control and motor.
Check Max Output Freq in the Level 2 Output Limits block.
settings. If fault remains, call dealer. Press RESET key on keypad. Restore parameter values to factory
settings. If fault remains, call dealer. Correct motor load.
Correct input power. Adjust slip compensation.
Press RESET key on keypad. If fault remains, call dealer.
Press RESET key on keypad. If fault remains, call dealer.
HOW TO ACCESS DIAGNOSTIC INFORMATION
141
redifl2
Action Description Display Comments
Apply Power Logo display for 5 seconds.
Display mode showing Local mode voltage, current & frequency status.
Press DISP key Scroll to fault log block. Press ENTER to view the fault log
Press DISP key Scroll to diagnostic info block. Press ENTER to view diagnostic
Press ENTER key Access diagnostic information. .
Press DISP key Display mode showing control
temperature.
Press DISP key Display mode showing bus
voltage.
Press DISP key Display mode showing bus
Current.
Press DISP key Display mode showing PWM
Frequency.
Press DISP key Display mode showing %
overload current remaining.
Press DISP key Display mode showing real time
opto inputs & outputs states. (0=Open, 1=Closed)
Press DISP key Display mode showing actual
drive running time since the Fault log was cleared.
Press DISP key Display operating zone with rated
hp and input voltage (for the operating zone) and control type.
Press DISP key Display mode showing continuous
amps; PK amps rating; amps/volt scale of feedback, power base ID.
Press DISP key Display mode showing which
Group1 or 2 expansion boards are installed.
Press DISP key Display mode showing software
version and revision installed in the control.
Press DISP key Displays exit choice. Press
ENTER to exit.
25.0
2497
No faults present. Local keypad mode. If in remote/serial mode, press local for this display.
if desired.
information if desired.
Displays operating temperature in degrees C.
Opto Inputs states (Left); Opto Outputs states (Right).
HR.MIN.SEC format.
Press ENTER to exit diagnostic information.
HOW TO ACCESS THE FAULT LOG
115
When a fault condition occurs, motor operation stops and a fault code is displayed on the Keypad display. The control keeps a log of the last 31 faults. If more than 31 faults have occurred, the oldest fault will be deleted from the fault log. To access the fault log, perform the following procedure:
redifl2
redifl2
Action
Apply Power Logo display for 5 seconds.
Display mode showing Local mode voltage, current & frequency status.
Press DISP key Press DISP to scroll to the Fault
Press ENTER key Display first fault type and time
Press Y key
Press RESET key Return to display mode. Display mode stop key LED is on.
Log entry point.
fault occurred. Scroll through fault messages.
Description Display Comments
No faults present. Local keypad mode. If in remote/serial mode, press local for this display.
Typical display.
If no messages, the fault log exit choice is displayed.
How to Clear the Fault Log Use the following procedure to clear the fault log.
Action
Apply Power Logo display for 5 seconds.
Display mode showing Local mode voltage, current & frequency status.
Press DISP key Press DISP to scroll to the Fault
Log entry point.
Description Display Comments
Display mode.
Press ENTER key Displays most recent message.
Press SHIFT key
Press RESET key
Press SHIFT key
Press ENTER key Fault log is cleared. No faults in fault log.
Press Y or B key
Press ENTER key Return to display mode.
Scroll Fault Log Exit.
FAULT MESSAGES
161
FAULT MESSAGE DESCRIPTION
Invalid Base ID Failure to determine control horsepower and input voltage configuration from the Power
Base ID value in software. NV Memory Fail Failure to read or write to non-volatile memory. Param Checksum Parameter Checksum error detected. Low INIT Bus V Low bus voltage detected on startup. HW Desaturation High output current condition detected (greater than 400% of rated output current). On B2
size controls, a desat error can indicate any of the following: low line impedance, brake
transistor failure or internal output transistor overtemperature. HW Surge Current High output current condition detected (greater than 250% of rated output current). HW Ground Fault Ground Fault detected (output current leakage to ground). HW Power Supply Control Board power supply failure detected. Hardware Protect A general hardware fault was detected but cannot be isolated. 1 MIN Overload Peak output current exceeded the 1 minute rating value. 3 SEC Overload Peak output current exceeded the 3 second rating value. Overcurrent Continuous current limit exceeded. BUS Overvoltage High DC Bus voltage. Bus Undervoltage Low DC Bus voltage condition detected. Heat Sink Temp Control heatsink exceeded upper temperature limit. For size B2 controls, this fault may
indicate the main heatsink or the gate drive circuit board is too hot. External Trip Connection between J4-16 and J4-17 is open. New Base ID Control board detected a change in the Power Base ID value in software. REGEN RES Power Excessive power dissipation required by Dynamic Brake Hardware. Line REGEN Fault in Line REGEN converter unit - Series 21H Line REGEN Inverter control. EXB Selection Expansion board not installed to support the selected Level 1 Input Block, Command
Select parameter. Torque Proving Unbalanced current in the three phase motor leads. Unknown FLT Code Microprocessor detected a fault that is not identified in the fault code table. µP RESET A software watchdog timer has reset the processor because a process has timed out. FLT Log MEM Fail Corrupt data in fault log (may occur on older systems only). Current SENS FLT Failure to sense phase current. Bus Current SENS Failure to sense bus current.
TECHNICAL SPECIFICATIONS
117
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Input Voltage
Output Voltage 3 X 220V 3 X 230V
Continuous Output Current (230V input) 6.05A 8.25A
Continuous Output Current (115V input) 6.05A 6.50A
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Control System PWM Output Voltage Clamp @ 220V Clamp @ 230V
Carrier Freq. Selectable: 1-5 KHz
Freq. Resolution 0.1Hz*
Input Freq. Range 48 – 62 Hz
Maximum Output Frequency(230V input) 400 Hz 100 Hz
Maximum Output Frequency(115V input) 400 Hz 80 Hz
Base Frequency 400 Hz 100 Hz
Torque Boost 0 – 15% Nominal Voltage
V/F Pattern Selectable Linear/Square Law
Accel Time 0.5 – 3600 Seconds
Decel Time 0.5 – 3600 seconds
Accel/Decel Pattern Linear
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Ground Fault Ground Fault detection for Equipment Protection
Overcurrent
Over Voltage 400VDC
Under Voltage 200VDC
Motor Overload I2 x T Characteristic
Line Start Lock Out VFD will not start upon input power application
Line Transient Rating
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Operating Temp. -10 to 40 degree C
Storage Temp. -30 to 65 degree C
Vibration 0.5G, Max / 57-150 Hz Elevation 3300 ft. without derating
Max source fault current 5 Kamps
Enclosure rating UL Type 4, No Direct Sunlight
1 X 115V +/- 10% or 1 X 230V +/- 10%
Single Phase Input
Output Short Circuit
Locked Rotor
860 VAV, 810J MOV Between any power
input terminal & Ground
360 VAC, 380 J MOV Between any two
power input terminals
WARRANTY SERVICE
119
The Redi-Flo VFD is covered by the original equipment manufacturers warranty for a period of 24 months. To obtain warranty services, contact the distributor or dealer from which it was purchased to obtain instructions. UUnnddeerr nnoo cciirrccuummssttaanncceess sshhoouulldd ddeeffeeccttiivvee pprroodduucctt bbee rreettuurrnneedd ttoo tthhee ddiissttrriibbuuttoorr,, ddeeaalleerr,, oorr GGRRUUNNDDFFOOSS wwiitthhoouutt aa rreettuurrnn mmaatteerriiaallss aauutthhoorriizzaattiioonn ((RRMMAA))..
SSEERRVVIICCEE PPAARRTTSS
Only four repair parts are available, the carrying case, the keypad, power cord and Harting motor connection. Contact the dealer from which the unit was purchased for these parts.
Being responsible is our foundation
Thinking ahead makes it possible
Innovation is the essence
L-RF-IO-009 Rev. 06/02
Printed in the U.S.A.
North American Regional Headquarters
Grundfos Pumps Corporation 17100 W. 118th Terrace Olathe, KS 66061 Telephone (913) 227-3400 Fax: (913) 227-3500
www.grundfos.com
Grundfos Canada, Inc.
2941 Brighton Road Oakville, Ontario L6H 6C9, Canada Telephone: (905) 829-9533 Fax: (905) 829-9512
Bombas Grundfos de Mexico, S.A. de C.V.
Boulevard TLC #15 Parque Stiva Aeropuerto Apodaca, N.L. Mexico C.P. 66600 Telephone: 52-81-8144-4000 Fax: 52-81-8144-4010
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