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

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Programming .................................................................................................................................13

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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

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

Suction out of a well Direct connection

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

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.

! 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.

! 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.

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

Diagram 3

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

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

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.

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.

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

Diagram 6

U V W

GRD #2 #1

slave pump

10 9

motor thermistor

8 7

low water

6 5

external on/off R, 10 kohm, 5 volt DC

+5 V ub (red)

actual value signal 0.5-4.5 VDC, 50 ohm load resistance (white)

shield (black)

+ 5V

GND

RS-485

SIO +

SIO -

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

⁄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

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

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.

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