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.
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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 [phone]
Fax: [phone]

www.grundfos.com

Grundfos Canada, Inc.

2941 Brighton Road
Oakville, Ontario L6H 6C9, Canada
Telephone: [phone]
Fax: [phone]

Bombas Grundfos de Mexico, S.A. de C.V.

Boulevard TLC #15
Parque Stiva Aeropuerto
Apodaca, N.L. Mexico
C.P. 66600
Telephone: [phone]
Fax: [phone]