Xylem 10 001 262R5 User Manual
INSTALLATION,
OPERATION AND
MAINTENANCE
INSTRUCTIONS
10-001-262
REV 5
AQUAFORCE
Pump Controller
VARIABLE SPEED PUMPING SYSTEMS
AQUAFORCE Installation, Operation, and Maintenance
Table of Contents
1. Introduction and safety.....................................................................................................................................................1
1.1 Introduction ....................................................................................................................................................................1
1.2 Safety ................................................................................................................................................................................1
1.3 Safety terminology and symbols ..................................................................................................................................1
1.4 Environmental safety .....................................................................................................................................................2
1.5 Recycling guidelines .......................................................................................................................................................2
1.6 User safety .......................................................................................................................................................................3
1.7 Product warranty ............................................................................................................................................................4
2. Transportation and storage .............................................................................................................................................5
2.1 Inspect the delivery ........................................................................................................................................................5
2.2 Transportation guidelines ..............................................................................................................................................5
2.3 Storage guidelines ...........................................................................................................................................................5
3. Product description ...........................................................................................................................................................6
3.1 General description ........................................................................................................................................................6
3.2 Operational limits ..........................................................................................................................................................6
3.3 Nameplate information .................................................................................................................................................6
3.4 Main parts and functions ...............................................................................................................................................7
3.5 Glossary of terms...........................................................................................................................................................8
Table of Contents
4. Installation ...........................................................................................................................................................................9
4.1 Field connections ............................................................................................................................................................9
4.2 Earth (ground) connections ..........................................................................................................................................9
4.3 Sensor and control wiring .............................................................................................................................................9
4.4 Pump package location guidelines ............................................................................................................................ 10
4.5 System piping and unit installation – nal checklist............................................................................................... 11
4.6 Electrical wiring and control setting – nal checklist ............................................................................................ 11
4.7 Operator interface ....................................................................................................................................................... 12
4.8 LEDs ............................................................................................................................................................................. 14
4.9 I/O................................................................................................................................................................................. 14
4.10 Set up and features .................................................................................................................................................... 15
4.10.0 Sensor Setup ................................................................................................................................................. 15
4.10.1 Pump Set Up ................................................................................................................................................ 16
4.10.2 System Setup ................................................................................................................................................ 17
4.10.3 Stage/Destage .............................................................................................................................................. 18
4.10.4 VFD ............................................................................................................................................................... 19
4.10.5 Exercise ......................................................................................................................................................... 21
4.10.6 Alternation .................................................................................................................................................... 21
4.10.7 Timed Auto Alternation ............................................................................................................................. 21
4.10.8 Alternation Basis .......................................................................................................................................... 22
4.10.9 PID ................................................................................................................................................................ 22
4.10.10 Reset Totals ................................................................................................................................................ 22
4.10.11 Date, Time Alternation............................................................................................................................. 23
4.10.12 Password ..................................................................................................................................................... 23
4.10.13 Input/Output (I/O) Setup ...................................................................................................................... 24
4.10.14 Communications ........................................................................................................................................ 24
4.10.15 Analog Input Override ............................................................................................................................. 25
4.10.16 Dynamic Flow Loss Compensation ....................................................................................................... 25
4.10.17 Save/Load ................................................................................................................................................... 25
4.10.18 Save to Flash............................................................................................................................................... 26
4.10.19 Load from Flash ........................................................................................................................................ 27
4.10.20 Load Default .............................................................................................................................................. 27
4.10.21 Display ......................................................................................................................................................... 27
AQUAFORCE Installation, Operation, and Maintenance
Table of Contents
4.10.22 Test Set Up ................................................................................................................................................. 28
4.10.23 Digital Input Test ...................................................................................................................................... 28
4.10.24 Digital Output Test ................................................................................................................................... 28
4.10.25 Analog Input Test ......................................................................................................................................29
4.10.26 Analog Output Test .................................................................................................................................. 29
4.10.27 LED Test .................................................................................................................................................... 29
4.10.28 Key Test ...................................................................................................................................................... 29
4.10.29 Display Test ................................................................................................................................................ 29
4.10.30 Communications Test ............................................................................................................................... 30
4.10.31 VFD Comm ............................................................................................................................................... 30
4.10.32 Alarms/Events Set Up ............................................................................................................................. 30
4.10.33 Low Discharge Pressure ........................................................................................................................... 31
4.10.34 High Discharge Pressure .......................................................................................................................... 31
4.10.35 Low Suction Pressure ............................................................................................................................... 31
4.10.36 No Flow Shut Down ................................................................................................................................ 32
4.10.37 Low Water .................................................................................................................................................. 33
4.10.38 VFD/Comm Failure ................................................................................................................................. 33
4.11 Q-Start ......................................................................................................................................................................... 34
5. Operation ........................................................................................................................................................................... 35
5.1 Normal Scrolling Operation ..................................................................................................................................... 35
5.2 Auto Operation ........................................................................................................................................................... 36
5.2.0 Local Automatic Operation ........................................................................................................................... 36
5.2.1 Remote Automatic Operation ....................................................................................................................... 36
5.3 Pump Rotation ............................................................................................................................................................ 36
5.4 Hand Manual Operation ........................................................................................................................................... 37
5.5 SetPoint Modication ................................................................................................................................................ 37
5.6 Process Variable Monitoring .....................................................................................................................................38
5.7 Alarms/Events ........................................................................................................................................................... 38
5.8 Quick Access ............................................................................................................................................................... 39
6. Maintenance ..................................................................................................................................................................... 40
6.1 Preface .......................................................................................................................................................................... 40
6.2 Technical overview ..................................................................................................................................................... 40
6.3 Digital inputs .............................................................................................................................................................. 40
6.4 Digital outputs ............................................................................................................................................................ 40
6.5 Analog inputs .............................................................................................................................................................. 40
6.6 Memory ....................................................................................................................................................................... 40
6.7 CPU .............................................................................................................................................................................. 40
6.8 Power supply ............................................................................................................................................................... 41
6.9 Protection .................................................................................................................................................................... 41
6.10 Instruments and their use ....................................................................................................................................... 41
6.11 Field repair ................................................................................................................................................................ 42
6.12 Program updating .................................................................................................................................................... 42
6.13 Troubleshooting ....................................................................................................................................................... 43
6.14 Program Type and Version Number..................................................................................................................... 44
6.14.0 Log Menu ..................................................................................................................................................... 44
6.14.1 Alarm Log .................................................................................................................................................... 44
6.14.2 Pump log menu ........................................................................................................................................... 44
6.14.3 Pump log ...................................................................................................................................................... 45
6.14.4 Pump Run Time ......................................................................................................................................... 45
6.14.5 Pump On/Off Times ................................................................................................................................ 45
6.14.6 Data Log ...................................................................................................................................................... 45
6.14.7 Sensor ........................................................................................................................................................... 45
6.14.8 Totalized Value ............................................................................................................................................ 46
6.14.9 Operation ..................................................................................................................................................... 46
6.14.10 Operation Mode Change ......................................................................................................................... 46
6.14.11 Power Cycles ............................................................................................................................................. 46
AQUAFORCE Installation, Operation, and Maintenance
Table of Contents
6.13.12 Events ......................................................................................................................................................... 47
6.14.13 System On/Off ........................................................................................................................................ 47
6.14.14 Alternation ................................................................................................................................................. 47
6.14.15 System Reset .............................................................................................................................................. 47
6.14.16 Events ......................................................................................................................................................... 48
6.14.17 VFD ............................................................................................................................................................ 48
6.14.18 Exercise ...................................................................................................................................................... 48
6.14.19 Set Point ..................................................................................................................................................... 48
6.14.20 Service Log ................................................................................................................................................ 49
6.14.21 Error Log ................................................................................................................................................... 49
6.14.22 Operation Hours ...................................................................................................................................... 49
6.14.23 Destage Speed ........................................................................................................................................... 49
6.14.24 Run Time Setpoint ................................................................................................................................... 49
6.15 Maintenance (physical) ............................................................................................................................................ 50
7. Appendix ............................................................................................................................................................................ 51
7.1 Valid I/O Codes .......................................................................................................................................................... 51
7.2 AquaForce MODBUS Communication Points ...................................................................................................... 52
7.3 Quick Access Number Table ..................................................................................................................................... 53
7.4 Wiring Diagrams .......................................................................................................................................................... 54
8. Symbols .............................................................................................................................................................................. 55
AQUAFORCE Installation, Operation, and Maintenance
AQUAFORCE Installation, Operation, and Maintenance
1. Introduction and Safety
1.1 Introduction
1.1.0 Purpose of the 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.
The information contained in this manual is intended to assist operating personnel by providing information on
the characteristics of the purchased equipment.
It does not relieve the user of the responsibility to adhere to local codes and ordinances and the use of accepted
practices in the installation, operation and maintenance of this equipment.
Further information pertaining to the installation, operation, and maintenance of your AquaForce pump
controller can be found in the IOMs for the associated equipment provided Maintenance section for a list of
relevant manuals.
Equipment cannot operate well without proper care. To keep this unit at top efciency, follow the recommended
installation and servicing procedures outlined in this manual.
Introduction and Safety
1.2 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 modication
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 an Xylem representative before proceeding.
• This manual clearly identies accepted methods of disassembling units. These methods must be
adhered to. Trapped liquid can rapidly expand and result in a violent explosion and injury. Never
apply heat to impellers, propellers, or their retaining devices to aid in their removal.
• Do not change the service application without the approval of an authorized Xylem
representative.
1.3 Safety terminology and symbols
1.3.0 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
AQUAFORCE Installation, Operation, and Maintenance
1
Introduction and Safety
1.3.1 Hazard levels
Hazard level Indication
DANGER: A hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING: A hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION: A hazardous situation which, if not avoided, could
result in minor or moderate injury.
NOTICE: • A potential situation which, if not avoided, could
result in undesirable conditions.
• A practice not related to personal injury.
1.3.2 Hazard categories
Hazard categories can either fall under hazard levels or let specic symbols replace the ordinary hazard level
symbols.
Electrical hazards are indicated by the following specic symbol.
Electrical Hazard:
These are examples of other categories that can occur. They fall under the ordinary hazard levels and may use
complementing symbols:
• Crush hazard
• Cutting hazard
• Arc ash hazard
1.4 Environmental safety
1.4.0 The work area
Always keep the station clean to avoid and/or discover emissions.
1.4.1 Waste and emissions regulation
Observe these safety regulations regarding waster 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.
1.4.2 Electrical installation
For electrical installation recycling requirements, consult your local electric utility.
1.5 Recycling guidelines
Always follow local laws and regulations regarding recycling.
2
AQUAFORCE Installation, Operation, and Maintenance
1.6 User safety
1.6.0 General safety rules
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 ash hazards.
• Always bear in mind the risk of drowning, electrical accidents, and burn injuries.
1.6.1 Safety equipment
Use safety equipment according to the company regulations. Use this safety equipment within the work area:
• Helmet
• Safety goggles
• 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 specic information about safety devices in other
chapters of this manual.
Introduction and Safety
1.6.2 Electrical connections
Electrical connections must be made by certied electricians in compliance with all international, national, state,
and local regulations. For more information about requirements, see sections dealing specically with electrical
connections.
1.6.3 Precautions during work
Observe these safety precautions when you work with the product or are in connection with the product:
• 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.
AQUAFORCE Installation, Operation, and Maintenance
3
1.6.4 Wash the skin and eyes
Do the following if chemicals or hazardous uids have come into contact with your eyes or your skin:
If you need to wash Then . . .
your . . .
Eyes 1. Hold your eyelids apart forcibly with your ngers.
2. Rinse the eyes with eyewash or running water for at least 15 minutes.
3. Seek medical attention.
Skin 1. Remove contaminated clothing.
2. Wash the skin with soap and water for at least one minute.
3. Seek medical attentions, if required.
1.7 Product warranty
1.7.0 Coverage
Xylem undertakes to remedy faults in products from Xylem under these conditions:
• The faults are due to defects in design, materials, or workmanship.
• The faults are reported to an Xylem representative within the warranty period.
• The product is used only under the conditions described in this manual.
• The monitoring equipment incorporated in the product is correctly connected and in use.
• All service and repair work is done by Xylem-authorized personnel.
• Genuine Xylem parts are used.
• Only Ex-approved spare parts and accessories authorized by Xylem are used in Ex-approved products.
1.7.1 Limitations
The warranty does not cover faults caused by these situations:
• Decient maintenance
• Improper installation
• Modications or changes to the products and installation made without consulting Xylem
• Incorrectly executed repair work
• Normal wear and tear
Xylem assumes no liability for these situations:
• Bodily injuries
• Material damages
• Economic losses
1.7.2 Warranty claim
Xylem products are high-quality products with expected reliable operation and long life. However, should the need
arise for a warranty claim, then contact your Xylem representative.
Introduction and Safety
4
AQUAFORCE Installation, Operation, and Maintenance
2. Transportation and Storage
2.1 Inspect the delivery
2.1.0 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.
2.1.1 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 your sales representative if anything is out of order.
2.2 Transportation guidelines
2.2.0 Lifting methods
Transportation and Storage
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 specically identied 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.
• Care should be taken to prevent damage due to dropping or jolting when moving the controller.
Transportation damage should be brought to the carrier’s attention immediately upon receipt.
2.3 Storage guidelines
2.3.0 Storage location
The product must be stored in a covered and dry location protected from extreme cold, heat, dirt, and vibrations.
NOTICE:
• Protect the product against humidity, heat sources, and mechanical damage.
• Do not place heavy weights on the packed products.
2.3.1 Long-term storage
If the controller is stored for more than 6 months, these requirements apply:
• Store in a covered and dry location.
• Store the unit free from heat, dirt, and vibrations.
Extended storage of VFDs may require special attention prior to start-up. See manufacturer’s IOM for details.
AQUAFORCE Installation, Operation, and Maintenance
5
3. Product Description
3.1 General description
3.1.0 Description
The controller is a specic purpose programmable pump controller. This provides:
• Optimum pump control without the cost of general purpose control hardware.
• Software dedicated and established for the unit.
• Unique analog input protection of other members of the control family. In the event of a short
circuit condition, the current limit circuitry prevents failure of the analog input components.
NOTICE:
• Your controller should have a safety instruction decal. If the decal is missing or illegible, contact
your representative for a replacement.
3.2 Operational limits
3.2.0 Temperature and ventilation
All electrical equipment is susceptible to failure if operated in ambient temperatures outside of its rating. The
OPERATING temperature range for this unit is 0 to 40°C. The relative humidity should not exceed
90% non-condensing. The unit should not be operated outside these extremes.
Product Description
3.3 Nameplate information
3.3.0 Important information for ordering
Every pump station has a nameplate that provides information about the pump station. The pump station
nameplate is located on the inside of the control enclosure door.
When ordering spare parts, be prepared to identify the nameplate information when contacting the factory.
• Model
• Size
• Serial number
• Item numbers of the required parts
Model Number
Serial Number
Station Voltage
System FLA
SCCR
Largest Motor HP
Station Flow
Suction Pressure
Discharge Pressure
Pump Boost
Date Code
Residential & Commercial Water
Dallas, Texas, U.S.A
6
.
AQUAFORCE Installation, Operation, and Maintenance
Nameplate Data Explanation
Model Number The manufacturer’s number to indicate the particular type of product which
has been acquired.
Serial Number A set of characters that uniquely identies a single unit and can be used for
traceability and warranty purposes.
Station Voltage The rated voltage at which the station has been designed for. Should match the
application site supply voltage.
System FLA The full-load-amperage at which the station can operate.
SCCR “Short-Circuit Current Rating”. Represents the maximum level of short-circuit
current that a component or assembly can withstand.
Largest Motor HP The rated HP for the largest Pump in the system.
Station Flow The designed duty point, in GPM, LPH, etc.
Suction Pressure The line pressure on the input side of the pump station.
Discharge Pressure The line pressure on the output side of the pump station.
Pump Boost The difference between the input side of the pump station and the output side
of the pump station.
Date Code Marking of products to indicate their date of manufacture.
3.4 Main parts and functions
3.4.0 Input voltage
The VFD and AquaForce Pump Controller can be set up to operate across a broad range of voltages. It was
factory set to operate on the voltage shown on the nameplate. Check the VFD nameplate for the proper input
and output voltages before wiring the VFD.
The voltage tolerance is +10/-5% and phase to phase voltage must not have an imbalance greater than 5 VAC.
3.4.1 Ground connections
A grounding terminal is provided for a dedicated ground wire connection. All provisions of the National Electrical
Code and local codes must be followed.
WARNING:
• Conduit grounds are not adequate. A separate ground wire must be attached to the ground lug provided in
the enclosure to avoid potential safety hazards.
Product Description
3.4.2 Power wiring
Power wire types and sizes must be selected based upon conformance with the National Electrical Code and all
local codes and restrictions. In addition, only copper (Cu) wire rated for 75°C (minimum) may be used for the
power connections. Refer to the input current as listed on the nameplate afxed to the enclosure door when
sizing wire.
3.4.3 Output/motor disconnect
It is necessary that any device which can disconnect the motor from the output of the VFD be interlocked to the
emergency shutdown circuits of the VFD. This will provide an orderly shutdown if the disconnecting device is
open circuited while the VFD is in operation. Failure to provide this interlock may result in damaged components
due to improper installation.
CAUTION:
• Metal lings can create electrical short circuits. Do not drill, saw, le or perform any operation
on the VFD conduit entry plate while attached to the VFD.
AQUAFORCE Installation, Operation, and Maintenance
7
Product Description
3.4.4 Analog signals
Shielded cable (#22 AWG, Belden type 8762, Alpha #2411, or equal) should be installed for all D.C. control
wiring. The shield must be terminated in the Controller panel. Do not connect the shield at the other end of the
cable! Insulate the shield so that no electrical connection is made at the other end of the cable. A twisted pair of
#22 AWG conductors (Belden 8442, or equal) can be used in place of shielded cable. The cable length must be
limited to 5,000 feet for #22 AWG wire.
3.4.5 Field connection diagrams
Refer to the pump Installation, Operation, and Maintenance Manual for specic details unique to the pump.
Refer to the ow sensor/transmitter Installation, Operation, and Maintenance manual for specic details unique to the
ow sensor/transmitter.
Job specic wiring and dimensional drawings and typical eld connection diagram should be reviewed prior to unit
installation and operation.
3.5 Glossary of terms
VFD Variable Frequency drive; converts a constant power input into a variable power output for the motor;
a device for controlling motor speed.
Alternation Process of determining which pump will serve as lead pump and which pump will serve as lag pump.
Destage To turn off a lag pump.
Lag pump Standby pump which activates only when lead pump alone cannot efciently provide sufcient
pressure or ow rate.
Lead pump Duty pump which runs continuously until a standby pump is required.
LED Light emitting diode, located on OIP and controller.
OIP Operator Interface Panel.
PID Proportional Integral Derivative; 3 variables required for error control.
PV (Process Signal generated by a sensor which is set up to control the system.
Variable)
Proof timer Minimum time period before controller acknowledges an input; time period for which a signal must
be stable before it is accepted by the controller as a sustained and valid signal.
RTC Real time clock.
Stage To start a lag pump.
SP Set point.
HD Hard Deck.
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AQUAFORCE Installation, Operation, and Maintenance
4. Installation
4.1 Field connections
4.1.0 Diagrams
Review the wiring diagrams and dimensional drawings before you install and operate the unit.
4.1.1 Electrical precautions
WARNING:
• Prevent electrical shocks. Disconnect the power supply before beginning installation. FAILURE
TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN SERIOUS PERSONAL INJURY,
DEATH AND/OR PROPERTY DAMAGE.
• Each motor must have a properly sized drive. Ground fault protection should be sized properly.
Refer to local electrical codes for sizing and selection.
• Refer to the motor manufacturer’s IOM for specic installation information.
• Motor can start automatically. Keep hands away from output shaft until motor is completely
stopped and input power is removed from the motor control panel. Lockout main power switch
while working near motor shaft.
• The use of motor disconnect switches is acceptable. Consult the factory for proper interlocking
with variable frequency drives.
• Motor control equipment and electronic controls are connected to hazardous line voltages.
When servicing electronic controls, there will be exposed components at or above line potential.
Extreme care should be taken to protect against shock. Stand on an insulating pad and make
it a habit to use only one hand when checking components. Always use accurate test meters
when checking electrical components. Always work with another person in case of an emergency.
Disconnect power when performing maintenance. Be sure equipment is properly grounded. Wear
safety glasses whenever working on electronic control or rotating equipment.
Installation
DANGER:
• Troubleshooting live control panels exposes personnel to hazardous voltages. Electrical
troubleshooting must only be done by a qualied electrician. FAILURE TO FOLLOW THESE
INSTRUCTIONS COULD RESULT IN SERIOUS PERSONAL INJURY, DEATH, AND/OR
PROPERTY DAMAGE.
4.2 Earth (ground connections)
WARNING:
• Conduit grounds are not adequate. A separate ground wire must be attached to the ground lug
provided in the enclosure to avoid potential safety hazards. Failure to follow these instructions
could result in serious personal injury or death, property damage.
A grounding terminal is provided for a dedicated earth (ground) wire connection. You must follow all provisions
of the National Electrical Codes and local codes.
4.3 Sensor and control wiring
The following sections are based on the installation of standard AquaForce product. Because of customized
software and hardware, the installing contractor should base all wiring connections on the wiring diagrams that
accompany each controller. These sections are meant to complement, not replace, those wiring diagrams.
AQUAFORCE Installation, Operation, and Maintenance
9
To control variable frequency drives it is necessary to wire RS485 with each VFD.
With certain bypass and control methods it is necessary to disable the adjustable frequency drive from running.
This is accomplished by wiring from the terminals to each VFD’s interlock terminals. Should this wiring be
required, any jumpers which may be found on the VFD’s interlock terminals should be removed.
The control family may be provided with the capability to accept many analog inputs. Typically all analog inputs
must be 4-20mA and powered by the 24VDC power supply in the controller. All shields must be grounded in the
controller only to prevent ground loops and improper signals.
Hardwire communications refers to the capability of the Controller to communicate with an energy management
system. Standard communication features are listed below:
Remote Start/Stop – Remove the jumper from Terminal 200 and install a switch as indicated on the wiring
diagram. CLOSED CONTACT of this switch will provide the start signal.
Remote Alarm Indication – A digital output rated 2.5 AMPs at 240V is supplied. This output closes to indicate
an alarm condition exists.
User Congurable I/O – The Controller comes equipped with the capability to dene the operation of any
unused input or output signal. Refer to System Set Up I/O menus.
4.4 Pump package location guidelines
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 specically identied
lifting points. Lifting devices such as eyebolts, slings, and spreaders must be rated, selected, and used for the
entire load being lifted.
Installation
Guideline Explanation
Make sure that the space around the pump This facilitates ventilation, inspection,
package is sufcient. maintenance, and service.
If you require lifting equipment such as hoist or This makes it easier to properly use the lifting
tackle, make sure that there is enough space above equipment and safely remove and relocate the
the pump package. components to a safe location.
Protect the unit from weather and water damage This is applicable if nothing else is specied.
due to rain, ooding, and freezing temperatures.
Do not install and operate the equipment in closed Acceptable devices:
systems unless the system is constructed with • Pressure relief valves
properly-sized safety devices and control devices. • Compression tanks
• Pressure controls
• Temperature controls
• Flow controls
If the system does not include these devices,
consult the engineer or architect in charge before
you operate the pump.
Take into consideration the occurrence of The best pump location for noise and vibration
unwanted noise and vibration. absorption is on a concrete oor with subsoil
underneath.
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AQUAFORCE Installation, Operation, and Maintenance
4.5 System piping and unit installation – nal checklist
1. Check that the unit base is properly leveled, grouted and secured.
2. Check that all lubrication points are properly lubricated per motor manufacturer’s instructions.
3. Check that the shut-off valves to the transmitters open.
4. Check that the shut-off valves to the pump suction open.
5. Check that the shut-off valves to the discharge line open.
6. Check that the piping is properly supported to prevent strains on the unit.
7. Check that the system, including pumps and valving, are purged of debris and air.
CAUTION:
• Seal damage may occur. Do not run pumps dry. Fill and vent the pump volute prior to operation.
FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN PROPERTY DAMAGE
AND/OR MODERATE PERSONAL INJURY.
4.6 Electrical wiring and control settings – nal checklist
1. Check the unit nameplate or motor terminal connection to ensure the feeder line voltage
corresponds to the unit voltage
WARNING:
• Electrical shock hazard. Inspect all electrical connections prior to powering the unit. Wiring connections
must be made by a qualied electrician in accordance with all applicable codes, ordinances, and
good practices. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN SERIOUS
PERSONAL INJURY, DEATH, AND/OR PROPERTY DAMAGE.
Installation
2. Check that feeder wires are correctly sized for the load.
3. Check that the fuses are correctly sized. They must not exceed 1.75 times the full load current of
the motor. Usual sizing is 1.15 to 1.5 times the full load current.
DANGER:
• High voltage 3 phase power can kill. Disconnect and lockout power prior to servicing. FAILURE TO
FOLLOW THESE INSTRUCTIONS COULD RESULT IN SERIOUS PERSONAL INJURY, DEATH,
AND/OR PROPERTY DAMAGE.
WARNING:
• Conduit grounds are not adequate. A separate ground wire must be attached to the ground lug provided in
the enclosure to avoid potential safety hazards. FAILURE TO FOLLOW THESE INSTRUCTIONS
COULD RESULT IN SERIOUS PERSONAL INJURY, DEATH, AND/OR PROPERTY DAMAGE.
4. Check that the unit is properly grounded.
5. Make sure all the power terminals in the control panel have been tightened.
AQUAFORCE Installation, Operation, and Maintenance
11
4.7 Operator interface panel
4.7.0 Diagrams
The OIP consists of a 4 x 20 character LCD screen and a 26 button keypad with LEDs which display system
status. The OIP communicates through a CAN bus to the CPU
Installation
4.7.1 Key functionality
The names of the keys on the Operator Interface Panel (OIP) are shown as CAPITAL LETTERS in this
manual. Table 1 shows the functionality of the keys on the OIP.
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AQUAFORCE Installation, Operation, and Maintenance
4.7.2 Table 1 Key Functionality
Key Name Functionality
START/STOP Starts or stops the system.
AUTO/ MANUAL Toggles the operation mode. The system must be stopped to change the
operation mode.
PUMP 1-4 ENABLE Enables or disables the corresponding pump. Pumps cannot be disabled
while they are failed.
RESET/ SILENCE This key is used to reset alarms and events. When the A/V Alarm relay
output is set. Pressing of this key resets the alarms and events.
HELP Press the HELP button, from the status screens, to view alarms or events
while the HELP LED is ashing. While in the Alarm screen, press the HELP
button again to view help messages for active alarms. Press HELP any other
time to view screen specic help messages.
PV/1 Press PV from the status screens, to bring up the process variable screen
SETPT/2 Press SET PT from the status screens, to bring up the set point menu shown in
section 5.5
SETUP/3 Press SETUP, from the status screens, to bring up the Setup Menu shown in
section 4.10
ALT/4 Press ALT, from the status screens, to manually alternate the pump staging
sequence.
LOG/5 Press LOG, from the status screens, to bring up the Log Menu, shown in
section 6.14.0
YES/7 Press YES at OK prompts to accept values and proceed
INFO/8 Press INFO, from the status screens, to bring up the program type and version
number shown in section 6.14
NO/0 Press NO at OK prompts to edit the parameters
ENTER Conrms entries
CLEAR Clears entries or used to exit some screens
PREV/( ) Navigates to neighboring screens
NEXT/( ) Navigates to neighboring screens
UP (▲) Used to modify values and navigate to neighboring screens
DOWN (▼) Used to modify values and navigate to neighboring screens
Note: Setting the display contrast.
The Contrast on the display is set at the factory. However, the user can make a different
contrast setting as desired. To do this press “Enter”. while holding down this key, the “UP” and
“DOWN” key can be used to set contrast.
ENTER + UP... increase contrast
ENTER + DOWN... reduce contrast
▲
Installation
▲
AQUAFORCE Installation, Operation, and Maintenance
13
4.8 LEDs
4.9 I/O
4.9.0 Analog Inputs
4.9.1 Digital Inputs
Installation
Table 2 gives the meaning of the LED states.
LED Description
START/STOP On = Start
Off = Stop
AUTO/ MANUAL On = Auto
Off = Manual
PUMP 1-4 On = Pump On
Off = Pump Disabled
Blink = Pump Ready, Blink Fast = Pump Failed
RESET/ SILENCE Off = OK
Blink = Reset Required
HELP Off = OK
Blink = Event/Alarm(press HELP from the status screens to view)
The AquaForce Pump Controller is equipped with 2 analog input channels. The analog inputs must provide a
4-20mA signal. Typically, analog inputs will be powered by the 24V power supply within the panel. For analog
inputs which source their own power, consult factory.
Shielded 22 AWG cable should be installed for all analog input wiring. The shield must be terminated in the
AquaForce Pump Controller. Do not connect the shield at the other end of the cable! Insulate the shield so that
no electrical connection is made at the other end of the cable. A twisted pair of #22 AWG conductors can be
used in place of shielded cable. The cable length must be limited to 2,500 feet for #22 AWG wire.
The AquaForce Pump Controller is equipped with (3) 24VDC digital input channels. This signal voltage must
be obtained from the 24VDC power supply mounted to the subpanel. It is not recommended that other power
sources be used without factory approval. All digital inputs are automatically assigned based on Table 3. See the
typical wiring diagram in Appendix.
Table 3: Digital Inputs Functionalities
Functionality DI # Description
Start/Stop Sw 1 Remote contact can be used to start/stop the system.
Optional DI 2 This digital input can be used as a optional low water switch.
Optional DI 3 This digital input can be used as a push to silence switch.
# 22 AWG cable should be installed for all eld wiring to digital inputs.
4.9.2 Digital Output Module
The digital output consists of 1 normally open and 1 normally closed contact for each output rated at 2.5A at
240V. Customer connections are made directly to the terminals mounted on the digital output module. Refer to
section 4.10.13 for relay output setup.
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AQUAFORCE Installation, Operation, and Maintenance
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