Xylem IM098 User Manual
AQUA VAR
®
Model 56 Controller
Variable Speed
Pump Control
Installation Programming & Operation
Models Covered:
04168001
04168001WM
04168231
04168231WM
04168241
04168241WM
Software – CP-V00:004
IM098R02
AQUA V AR Model 56 Controller Owner’s Information Record
Aquavar Model 56 Controller Pump Code Number
S/N Transducer Model
Date Purchased Transducer Rating
Purchased From
Program Record
Parameter Range (Default) User Setting
Actual Pressure N/A Read-Only
Set Pressure 0-150 psi (45 psi)
Submenu Parameter N/A Read-Only
Password (66) Read-Only
Submenu Diagnostics N/A Read-Only
Motor Hours N/A Read-Only
S10 Address N/A Read-Only
Error N/A Read-Ony
Overload Error N/A Read-Only
OverVolt Error N/A Read-Only
Software Version N/A Read-Only
Change Pressure Disable (Enable)
Autostart Disable (Enable)
Mode Actuator, (Controller), Multicontroller
Regulation Mode (Normal), Inverse
Dimension Unit (psi), bar, %
Submenu Inverter N/A Read-Only
Maximum Frequency 6-60 Hz (60 hz)
Minimum Frequency 0-60 Hz (0 Hz)
Boost 0-25% (5%)
Configuration –
Minimum Frequency
Submenu Control N/A Read-Only
Window 0-100% (15%)
Hysterisis 0-100% (80%)
Acceleration High 1.0-999.9 (4 sec.)
Deceleration High 1.0-999.9 (4 sec.)
Acceleration Low 1.0-999.9 (70 sec.)
Deceleration Low 1.0-999.9 (70 sec.)
Lift Frequency 6-60 Hz (30 Hz)
Lift Intensity 0-100% (0%)
Fmin (F = 0)
AQUA V AR Model 56 Controller Owner’s Information Record
Program Record (continued)
Parameter Range (Default) User Setting
Submenu Multicontrol N/A Read-Only
Actual Value Increase 0-100% (6%)
Actual Value Decrease 0-100% (4%)
Enable Sequence Control 6-60 Hz (60 Hz)
Switch Interval 0-250 (12 Hrs)
Submenu Slave Pump
Slave Pump Configuration
Slave On 0-60 Hz (58 Hz)
Slave Off 0-60 Hz (0 Hz)
Submenu Sensor Read-Only
Sensor ZeroAdjust Press (INC) + (DEC)
Sensor Adjust Maximum 0.5-4.5 V
Submenu Test Run Read-Only
Test Run Start Press (INC) + (DEC)
Test Time 10-100 hrs (0 hrs)
Test Frequency 0-60 Hz (30 Hz)
Test Run Boost 0-25% (5%)
Submenu Error Read-Only
Conveyor Limit 0-100% (0%)
Error Delay 0-100 Secs (0 Secs)
Set Password 0-9999 (66)
Default Settings
Simple Multi Control,
Run Signaling or Error Signaling
INDEX
Index
System Design..................................................................................................................................1
Important Safety Instructions ...........................................................................................................2
Installation Procedures.....................................................................................................................4
1) Materials Checklist......................................................................................................................4
2) Mounting the Aquavar Model 56 Controller..................................................................................5
3) Electrical Connections..................................................................................................................7
4) Pump Priming...........................................................................................................................10
5) Run Test...................................................................................................................................10
▼
Programming .................................................................................................................................13
▼
1) Single Pump – Constant Pressure...............................................................................................13
2) Single Pump – Pump Protection.................................................................................................13
• To Set Run Out Protection ......................................................................................................14
3) Single Pump – System Curve Compensation ...............................................................................17
4) Circulator Applications ..............................................................................................................20
5) Multiple Pump – Constant Pressure or System Curve Compensation .............................................20
6) Slave Pump – Constant Pressure ................................................................................................23
Operator Custom Features and Displays ........................................................................................27
• Actual Pressure .............................................................................................................................27
• Set Pressure ..................................................................................................................................27
• Submenu Parameter......................................................................................................................27
• Password......................................................................................................................................27
• Change Pressure ...........................................................................................................................27
• Autostart ......................................................................................................................................27
• Mode ...........................................................................................................................................28
• Regulation Mode ..........................................................................................................................28
• Dimension Unit .............................................................................................................................28
• Submenu Inverter..........................................................................................................................28
• Max. Frequency.............................................................................................................................28
• Min. Frequency .............................................................................................................................28
• Boost............................................................................................................................................29
• Config. F Min. ...............................................................................................................................29
• F Min. Time...................................................................................................................................29
• Submenu Controller.......................................................................................................................29
• Window .......................................................................................................................................29
• Hysterisis ......................................................................................................................................30
• Acceleration High ..........................................................................................................................30
• Deceleration High..........................................................................................................................30
• Acceleration Low...........................................................................................................................30
• Deceleration Low ..........................................................................................................................30
• Lift Frequency ...............................................................................................................................31
INDEX
Operator Custom Features and Displays (continued)
• Lift Intensity ..................................................................................................................................31
• Submenu Controller.......................................................................................................................31
• Actual Value Increase ....................................................................................................................32
• Actual Value Decrease ...................................................................................................................32
• Enable Sequence Control ...............................................................................................................33
• Switch Interval ..............................................................................................................................33
• Submenu Relay .............................................................................................................................33
• Relay Configuration .......................................................................................................................33
• Slave On Limit...............................................................................................................................33
• Slave Off Limit...............................................................................................................................33
• Submenu Sensor ...........................................................................................................................34
• Sensor Adjust................................................................................................................................34
• SensorMax – Adjust.......................................................................................................................34
• Submenu Test Run ........................................................................................................................34
• Start Test Run................................................................................................................................34
• Time Test Run ...............................................................................................................................34
• Test Frequency..............................................................................................................................34
• Boost Test Run ..............................................................................................................................34
• Submenu Error ..............................................................................................................................35
• Conveyor Limit..............................................................................................................................35
• Error Delay....................................................................................................................................35
• Set Password ................................................................................................................................35
• Default .........................................................................................................................................35
• Submenu Diagnosis.......................................................................................................................35
• Pump Runtime ..............................................................................................................................35
• Pump Address...............................................................................................................................35
• Last Error ......................................................................................................................................36
• Software Version...........................................................................................................................36
• Set Password ................................................................................................................................36
Repair of Faults and Errors .............................................................................................................37
• Low Water....................................................................................................................................37
• Overheating – Motor .....................................................................................................................37
• Overvoltage..................................................................................................................................37
• Undervoltage................................................................................................................................38
• Overheating – Heatsink .................................................................................................................38
• Overload ......................................................................................................................................38
• Pressure Sensor.............................................................................................................................38
• Conveyor Limit..............................................................................................................................38
• Error 1-8.......................................................................................................................................38
Appendix A – Pressure Transducer Data............................................................................................39
Appendix B – AQUAVAR Model 56 Controller Drive Head Technical Data ............................................41
System Design
System Design
Note
Systems MUST be designed by qualified technicians only.
The following diagrams show typical single pump and multi-pump systems using the AQUAVAR Model 56 Controller.
Connection can be made directly to a water supply or water can be drawn from a supply tank or well. In the case of
supply tanks and wells, level switches, (item 10) can be used to shut down the pumps when water is low. In the
direct connection, a pressure switch on the suction side (item 8) can be used.
Diagram 1
Multiple Pump Layout
Diagram 2
Single Pump Layout
Indirect connection
via supply tank
10
11
9
8
4
Suction out of a well Direct connection
3
8
4
9
8
4
10
6
2
14
1
5
9
4
8
4
1 Pump with AQUAVAR Model 56
Controller
2 Diaphragm tank
3 Distribution panel
4 Gate valves
5 Check valves
6 Foot valves
8 Incoming pressure control
9 Pressure gauges
10 Level switches
11 Supply tank
14 Pressure transmitter
2
14
4
1
5
9
14
4
1
5
14
4
1
5
A diaphragm pressure tank is used on the discharge side of the pump or pumps to maintain pressure in the line when
there is no demand. This will keep the pumps from continuing to run. With the AQUAVAR Model 56 Controller, it is not
necessary to have a large tank for supply purposes. In selecting a tank, make sure it can withstand system pressure.
The tank should have a capacity of about 10% of the maximum single pump flow rate in gpm. Pre-charge the tank to
the following:
PSI Set Pressure 15 30 45 60 75 90 105 120 135 150
PSI Tank Pre-charge 12 21 37 52 64 77 95 110 125 138
Note
Closed loop circulator systems may not require a pressure tank.
1
! Safety Instructions
Important: Read all safety information prior to installation of the
AQUA V AR Model 56 Controller.
Note
This is a SAFETY ALERT SYMBOL. When you see this symbol on the pump or in the manual, look
for one of the following signal words and be alert to the potential for personal injury or property
damage.
DANGER
WARNING
CAUTION
NOTICE Indicates special instructions which are very important and must be followed.
1. This manual is intended to assist in the installation, operation, and repair of the AQUAVAR Model 56
Controller and must be kept with the AQUAVAR Model 56 Controller.
Warns of hazards that WILL cause serious personal injury, death, or major property
damage.
Warns of hazards that CAN cause serious personal injury, death, or major property
damage.
Warns of hazards that CAN cause personal injury or property damage.
Note
All operating instructions must be read, understood, and followed by the operating personnel. Goulds
Pumps accepts no liability for damages or operating disorders which are the result ofnon-compliance
with the operating instructions.
2. To avoid serious or fatal personnel injury or major property damage, read and follow all safety instructions
in this manual.
2
! Safety Instructions
Safety Instructions
3. Installation and maintenance MUST be performed by properly trained and qualified personnel.
4. Review all instructions and warnings prior to performing any work on the AQUAVAR Model 56 Controller.
5. Any safety decals MUST be left on the AQUAVAR Model 56 Controller unit and pump.
Note
Inspect AQUA VAR Model 56 Controller for any damage after unpacking from shipping crates. Report
any damage immediately to the carrier or distributor/dealer immediately.
6. In addition to instructions contained in this manual, you must meet any local safety, electrical, or plumbing
codes and requirements. Installation, maintenance, or repair work must only be carried out by trained,
skilled, and qualified personnel.
7. The AQUAVAR Model 56 Controller drive head must be disconnected from the main power supply
before attempting any operation in the electrical or mechanical part of the system.
Note
When in operation, the motor can be stopped, but power remains at the drive head. The motor
and pump could start unexpectedly and produce serious injury. When the AQU AVAR Model 56
Controller drive head is connected to the main power supply, the inverter power supply and master
control unit are also connected to the power supply.
WARNING
Hazardous voltage
can shock, burn or
cause death.
WARNING!
FAILURE TO DISCONNECT ELECTRICAL POWER BEFORE ATTEMPTING ANY MAINTENANCE
CAN CAUSE SHOCK, BURNS, OR DEATH.
3
Installation Procedures
Electrical Connections continued
Step 1 - Identify Materials
The following materials are provided with the AQUA VAR Model 56 Controller. Please familiarize yourself with
each prior to installation.
PART QUANTITY P ART QUANTITY
1) AQUA VAR Model 56 Controller 1 6) 3/8" NPT Cord Grip 2
2) Washer (AV 1.1) 1 7) 3/8" NPT Plug 1
3) Mounting Bolt (AV 1.1) 1 8) Conduit Plate (two types) 1
4) Thermistor 1 9) Gasket 1
5) 1/2" NPT Liquid Tight Connector 3 10) Cover 1
11) Mounting Clamps (AV 1.15, 2.2) 4
2
8
3
9
4
5
6
10
Diagram 3
7
4
11
Installation Procedures
Step 2 – Mounting the AQUA V AR Model 56 Controller
1) The AQUA V AR Model 56 Controller drive
head is supplied with electrical connectors
and mounting hardware.
• Remove the motor fan cover from your
three phase TEFC motor by removing the
fan cover screws.
•Obtain the fan cover (5) and the AQUAV AR
Model 56 Controller (1) and attach them
together with the mounting bolt (4) and
washer (3).
•Use the fan cover screws to mount the fan
cover/AQUA V AR Model 56 Controller
combination to the motor.
Diagram 4
(AV 1.1 style)
AQUAVAR Model 56 Controller Dimensions
(Weight = 4.3 lbs.)
155 mm
120 mm
Diagram 5
65 mm
5
Installation Procedures
Step 2 – Mounting the AQUA VAR Model 56 Controller
2) Mounting:
• Remove the 3 screws from the AQUA VAR
cover.
•Place the center bit in the AQUAV AR heat
sink.
•Place the AQUAV AR on the motor.
• Hang the 4 clamps by the motor fan cover
and mount with the 4 screws to the
AQUA V AR.
• Replace the AQUA VAR cover with the
3 screws.
Type Weight (kg)
AV 1.15 4.70
AV 1.2 4.70
4 screw
M5x50
continued
Gasket
Center bit
(AV 1.15, AV 2.2 style)
Closing cap
Transducer
4 mounting
clamps
Connection
motor
conduit box
Thermistor
70
155
Cable entries
Don't forget the gaskets for the 3 screws.
Ensure that there is no water on the unit
before you open the cover.
6
Installation Procedures
Electrical Connections
WARNING
WARNING!
FAILURE TO DISCONNECT AND LOCKOUT ELECTRICAL POWER AND WAIT FIVE MINUTESFOR
CAPACITOR DISCHARGE BEFORE SERVICING AQUAVAR MODEL 56 CONTROLLER CAN CAUSE
Hazardous voltage
can shock, burn or
cause death.
SHOCK, BURNS, OR DEATH.
Note
Installation and maintenance must only be performed by properly trained and qualified personnel
equipped with the proper tools.
WARNING
Hazardous voltage
can shock, burn or
cause death.
WARNING!
INSTALL, GROUND, AND WIRE ACCORDING TO LOCAL AND NATIONAL ELECTRICAL
CODE REQUIREMENTS.
INSTALL AN ALL LEG DISCONNECT SWITCH NEAR THE MOTOR.
DISCONNECT AND LOCKOUT ELECTRICAL POWER BEFORE INSTALLING OR SERVICING.
ELECTRICAL SUPPLY MUST MATCH PUMP’S AND AQUAVAR MODEL 56 CONTROLLER NAMEPLATE
SPECIFICATIONS. INCORRECT VOLTAGE OR WIRING CAN CAUSE FIRE DAMAGE, AND VOIDS
WARRANTY.
MOTORS WITH AUTOMATIC THERMAL PROTECTION MAY OPEN THEIR ELECTRICAL CIRCUIT
WHEN A THERMAL OVERLOAD EXISTS. THIS CAN CAUSE THE MOTOR TO START UNEXPECTEDLY
AND WITHOUT WARNING.
7
Installation Procedures
Step 3 – Wiring the AQUA V AR Model 56 Controller to the motor
(Parts in the electrical fittings package will be
required for this procedure). Refer to diagrams 6 and
7 before proceeding.
1) Remove the 3 screws holding the top of the
AQUA V AR Model 56 Controller. Carefully lift
off the top, disconnect the groundwire and set
aside.
2) Motor Lead Connections: Locate the
terminals U, V, W and GRD #1 inside the
AQUA V AR Model 56 Controller. Connect
wires to the terminals and route the cable as
shown on diagram 7.
3) Connections in Conduit Box: The free end of
the motor cable should now be routed
through the strain relief on the conduit box.
Connect the motor leads using the motor
nameplate as reference.
TERMINALS
FOR RS485
MOTOR CONNECTIONS
X2
X3
Diagram 6
U V W
GRD #2 #1
NO
12
slave pump
CC
11
NC
10
9
motor thermistor
8
7
low water
6
5
external on/off R, 10 kohm, 5 volt DC
4
+5 V ub (red)
3
actual value signal 0.5-4.5 VDC, 50 ohm load resistance (white)
2
shield (black)
1
+ 5V
4
GND
3
RS-485
SIO +
2
SIO -
1
CONTROL TERMINALS
MAIN SUPPLY
L2
L1
Place the thermistor terminal in the conduit
box and fasten so that the sensor will contact
the motor shell. Connect the thermistor with
2 wires routed to locations X2 #9 and X2 #8.
4) Pressure Transducer Installation and
Wiring: Locate the pressure transducer and
cable. The threaded end of the transducer is
1
⁄4" NPT. Install the transducer in the
a
discharge pipe on the downstream side of
the check valve and connect the cable.
Now select one of the remaining holes in
the plate on the AQUA V AR Model 56
Controller heat sink. Route the cable through
the o-ring and fasten. Cut to length and
connect to locations X2 #1, X2 #2, X2 #3.
See diagram 6 for reference.
Diagram 7
8
Installation Procedures
Electrical Connections continued
5) Input Power Cable Installation: The main
power cable is connected to GRD #2, L1, L2
for 230 V olt single phase.
•Route the cable through the strain relief per
diagram #7, cut to length and connect.
•See Appendix B for protection requirements.
6) For Multi-Pump Systems: Use a three core
shielded cable to connect terminals X3/1,
X3/2 and X3/3 between the AQUA VAR Model 56
Controller units. These are the RS-485 interface
connections. (See diagram 6 and 8). Shielding
may be grounded on terminal X3/3.
7) Low W ater Switch: Used to indicate low
water, connect to terminals X2/6 and X2/7.
Refer to diagram 6. Jump terminals if not used.
8) External On/Off: Used to turn the AQUA VAR
Model 56 Controller on/off from an external panel
or controller, connect to X2/5 and X2/4. Refer
to diagram 6. Jump terminals if not used.
9) Relay: This connection may be used to turn
on/off a full speed slave pump or an external
run or error indicator. Wire the relay to the
switch controlling the device selected.
(X2/10, X2/11, and X2/12)
Motor
connections
Terminals of
the RS485
interface
Main supply
connections
Motor
connections
Control
terminals
AV 1.1 AV 1.15, 1.2
9
Installation Procedures
Pump Priming
Refer to your pump operation manual for instructions on pump priming.
Run Test
WARNING
DO NOT APPL Y POWER TO THE AQU AVAR MODEL 56 CONTROLLER OR PUMP UNTIL
ELECTRICAL CONNECTIONS HAVE BEEN REVIEWED BY A QUALIFIED ELECTRICIAN AND MEET
ALL APPLICABLE STATE AND LOCAL REQUIREMENTS.
Instructions
1) Check all wiring. All motors used with the
AQUA V AR Model 56 Controller are three
phase TEFC (a wall mounted version permits
the use of other enclosures). Y ou will need to
check the direction of rotation of the motor
shaft. If you have followed all of the previous
steps carefully, you should now be ready to
apply power to the AQUA V AR Model 56
Controller unit.
2) Close discharge valve. Make sure the
discharge valve is closed. Apply power to the
AQUA V AR Model 56 Controller.
3) The next step is to apply power to the AQUA V AR
Model 56 Controller and check for proper rotation
of the motor. The first start up of the AQUAV AR
Model 56 Controller should be done with the
external programming device. If you operate the
AQUA V AR Model 56 Controller without the
programming device, the following parameters
have to be set in the submenu (see operation in
the main menu).
Screen
—
—
NO AUTOSTART – DISABLE INVERTER
◆ Change pressure: ENABLED
◆ Autostart: ENABLED
The AQUA V AR Model 56 Controller is
delivered with these settings as standard.
Change Pressure without Remote Control
1) Start the pump with the push button on
the front plate of the AQUA V AR Model 56
Controller.
2) Then press the and buttons together
for more than 3 seconds.
▼
▼
▼
10
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