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IM213R04

Xylem IM213R04 User Manual [en, es, fr]

INSTRUCTION MANUAL
IM213R04
™
Aquavar SPD
Variable Speed Pump Control
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
INDEX
Starting the System (Input/Output Connections, Switch Settings, Motor Rotation) ................................14
Input and Output Functions (Control Terminals) ......................................................................................... 19
Troubleshooting ..............................................................................................................................................20
Controller Dimensions ....................................................................................................................................25
Appendix (Input Wire Sizing Chart) ...............................................................................................................26
Appendix (Output Wire Sizing Chart) ...........................................................................................................27
Limited Warranty ..............................................................................................................................................28
NOTE:
• Use Copper wire only.
• Suitable for use in a pollution degree 2 micro-environment.
• Motor overload protection provided at 100% of full load current.
• In order to maintain the environmental rating integrity of the enclosure, all openings must be closed
by equipment rated 3, 3R, 3S, 4, 4X, 6 or 6P.
• Maximum Ambient temperature range -22º F to 122º F.
• Maximum Humidity: 95% at 104º F non-condensing.
• Controller is rated TYPE 3R (Raintight) so it may be located outdoors
Page 2
DANGER
Hazardous voltage
DANGER
Hazardous Pressure
CAUTION
SAFETY INSTRUCTIONS
WARNING
CAUTION
CAUTION
Section 1
Important: Read all safety information prior to installation of the Controller.
NOTE
This is a SAFETY ALERT SYMBOL. When you see this symbol on the controller, pump or in this manual, look for one of the following signal words and be alert to the potential for personal
injury or property damage. Obey all messages that follow this symbol to avoid injury or death.
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
Used without a safety alert symbol indicates a potentially hazardous situation which, if not avoided, could result in property damage.
NOTE Indicates special instructions which are very important and must be followed.
NOTE
All operating instructions must be read, understood, and followed by the operating personnel. CentriPro
accepts no liability for damages or operating disorders which are the result of non-compliance with the
operating instructions.
1. This manual is intended to assist in the installation, operation and repair of the system and must be kept with the system.
2. Installation and maintenance MUST be performed by properly trained and qualied personnel.
3. Review all instructions and warnings prior to performing any work on the system.
4. Any safety decals MUST be left on the controller and/or pump system.
5. The system MUST be disconnected from the main power supply before attempting any operation
or maintenance on the electrical or mechanical part of the system. Failure to disconnect electrical power before attempting any operation or maintenance can result in electrical shock, burns or death.
6. When in operation, the motor and pump could start unexpectedly and cause serious injury.
Page 3
WARNING
Hazardous voltage
Hazardous Pressure
CAUTION
SYSTEM COMPONENTS
Section 2
Please review the SPD components and insure that you have all the parts and are familiar with their names. Be
sure to inspect all components CentriPro supplies for shipping damage.
SPD Variable Speed Controller:
1. SPD Controller
2. Pressure Transducer with Cable
3. Conduit Plate Caps
WARNING
DO NOT power the unit or run the pump until all electrical and plumbing connections,
especially the pressure sensor connection, are completed. The pump should not be run dry.
All electrical work must be performed by a qualied technician. Always follow the National Electrical Code (NEC), or the Canadian Electrical Code (CEC) as well as all local, state and provincial codes. Code questions should be directed to your local electrical inspector or code enforcement agency. Failure to follow electrical codes and OSHA safety standards
may result in personal injury or equipment damage. Failure to follow manufacturer's installation instructions
may result in electrical shock, re hazard, personal injury, death, damage to equipment, unsatisfactory performance and may void manufacturer's warranty.
Controller Product Code Information
SPD Y XXXX F
F = with Output Filter for Submersible Pump Applications
BLANK = without Filter for Above Ground/Centrifugal Pump Applications.
4 Digits for HP 5 HP = 0050
7.5 HP = 0075 10 HP = 0100 15 HP = 0150 20 HP = 0200 25 HP = 0250 30 HP = 0300
1 Digit for Input Voltage
230 volt = 2 460 volt = 4 575 volt = 5
SERIES
Page 4
SYSTEM DESIGN
Section 3
NOTE
Systems MUST be designed by qualied technicians only and meet all applicable state and local code requirements.
The following diagrams show a typical system using the SPD_ _ F with Filter, Constant Pressure Controller. Diagram #1 shows a typical set up for a submersible system.
1
2
SUPPLY POWER
L1 L2 L3
GND
6
T1 T2 T3
GND
4
5
8
3
FLOW
7
1 SPD_F CONTROLLER 2 FUSIBLE DISCONNECT
11
3 PRESSURE GAUGE 4 AIR DIAPHRAGM TANK 5 PRESSURE TRANSDUCER 6 3 PHASE OUTPUT (ALWAYS) 7 DISCHARGE CHECK VALVE 8 GATE VALVE (HIGHLY RECOMMENDED) 9 SUBMERSIBLE PUMP END
10 SUBMERSIBLE MOTOR (3 PHASE) 11 PRESSURE RELIEF VALVE
NOTE: FOR SINGLE PHASE INPUT, CONNECT L1 AND L3, THEN SET MOTOR OVERLOAD SWITCHES TO 50% OF CONTROLLER RATING OR LOWER.
9
10
Page 5
SYSTEM DESIGN
Section 3 (continued)
Diagram #2 shows a set-up for municipal water connection.
1
2
9
SUCTION
8
SUPPLY POWER
L1 L2 L3
GND
7
T1
T2
T3
3 PHASE OUTPUT
GND
TO MOTOR
4
5
9
10
FLOW
3
1 SPD CONTROLLER 6 AIR DIAPHRAGM TANK 2 FUSIBLE DISCONNECT 7 3 PHASE MOTOR 3 CENTRIFUGAL PUMP 8 GATE VALVE (BALL VALVE) 4 CHECK VALVE 9 PRESSURE GAUGE 5 PRESSURE TRANSDUCER (CABLE ASSEMBLY) 10 PRESSURE RELIEF VALVE
AIR
6
8
NOTES: For single phase input power, use L1 and L3 terminals and adjust motor overload switches
to 50% of controller rating or lower.
Page 6
Hazardous Pressure
CAUTION
Hazardous Pressure
CAUTION
PIPING
Section 4
General
NOTE
All plumbing work must be performed by a qualied technician. Always follow all local, state and provincial
codes.
A proper installation requires a pressure relief valve, a ¼" female N.P.T. threaded tting for the pressure sensor,
and properly sized pipe. Piping should be no smaller than the pump discharge and/or suction connections.
Piping should be kept as short as possible. Avoid the use of unnecessary ttings to minimize friction losses.
Some pump and motor combinations supplied with this system can create dangerous pressure.
Select pipe and ttings accordingly per your pipe suppliers’ recommendation. Consult local codes
for piping requirements in your area.
All joints must be airtight. Use Teon tape or another type of pipe sealant to seal threaded connections. Please
be careful when using thread sealant as any excess that gets inside the pipe may plug the pressure sensor.
Galvanized ttings or pipe should never be connected directly to the stainless steel discharge head or casing as galvanic corrosion may occur. Barb type connectors should always be double clamped.
Pressure Tank, Pressure Relief Valve and Discharge Piping
Use only “pre-charged” tanks on this system. Do not use galvanized tanks. Select an area that is always above 34º F (1.1º C) in which to install the tank, pressure sensor and pressure relief valve. If this is an area where a water leak or pressure relief valve blow-off may damage property, connect a drain line to the pressure relief valve. Run
the drain line from the pressure relief valve to a suitable drain or to an area where water will not damage property.
Pressure Tank, System Pressure Sizing – A diaphragm tank (not included) is used to cushion the pressure system during start-up and shut-down.
It should be sized to at least 20% of the total capacity of your pump. Example: If your pump is sized for 100 GPM then size your tank for at least 20 gal. total volume, not draw down. Pre-charge your bladder tank to 10-15 PSI below your system pressure. The controller is pre-set for 50 PSI at the factory. Therefore a 35-40 PSI pre-charge in your tank would be required. Use the higher tank pre-charge setting if the system drifts over 5 PSI at a constant ow rate. NOTE: Pre-charge your tank before lling with water!
CAUTION
Maximum working pressure of HydroPro diaphragm tank is 125 psi.
Installing the Pressure Sensor
The pressure sensor requires a ¼" FNPT tting for installation. Install the pressure sensor with the electrical connector pointing up to avoid clogging the pressure port with debris. Install the pressure sensor in a straight
run of pipe away from elbows or turbulence. For optimum pressure control install the pressure sensor in the
same straight run of pipe as the pressure tank. Ensure the pressure sensor is within 10ft of the pressure tank.
Installing the pressure sensor far away from the pressure tank may result in pressure oscillations. Do not install the pressure sensor in a location where freezing can occur. A frozen pipe can cause damage to the pressure
sensor.
Page 7
WARNING
Hazardous voltage
PIPING
Section 4 (continued)
The pressure sensor cable is prewired to the controller. The cable can be shortened for a cleaner installation.
Longer cable lengths are available, consult factory. Maximum recommended pressure sensor cable length is 300ft. Avoid leaving a coil of pressure sensor cable as this can induce unwanted transient voltages and noise into
the system. Do not run the pressure sensor cable alongside the input or output wiring. Maintain a distance of at
least 8” between the pressure sensor cable and input or output wiring. Ensure the pressure sensor cable is connected as follows: Brown to terminal 7 (24VDC SUPPLY), White to
terminal 6 (TRANSDUCER INPUT), Drain to chassis. Connecting the Drain wire to the chassis electrically
connects the sensor case to the chassis of the controller. In some cases this drain wire must be disconnected from the controller chassis. In cases where the there is grounded metal piping which is continuous between the transducer and the motor or the transducer is installed in grounded metal piping, a ground loop can result so the drain wire must be disconnected from the chassis. In cases where there are sections of nonmetallic piping between the transducer and motor or the transducer is installed in ungrounded piping this drain wire should be connected to the controller chassis.
MOUNTING THE CONTROLLER
Section 5
General
Mount the controller in a well ventilated, shaded area using 4 screws. The controller must be mounted vertically. Be sure to leave 8 inches of free air space on every side of the unit. The controller must be in an area with an ambient between -22º F and 122º F. If installation is above 3300 feet above sea level, ambient temperatures are derated 1% per 330 feet above 3300 feet. The altitude limit for this controller is 6500 ft. Do not install above
6500 ft.
NOTE
Do not block the heat sink (ns) or fans and do not set anything on the units.
WARNING
The controller access cover should always be securely fastened to the control box due to the dangerous voltage/shock hazard inside the unit. A lock can be used to prevent unwanted entry.
Page 8
WARNING
Hazardous voltage
POWER SUPPLY AND WIRING
Section 6
Power Supply
NOTE
Installation and maintenance MUST be performed by properly trained and qualied personnel. Always follow the National Electrical Code (NEC) or Canadian Electric Code (CEC), as well as all state, local and provincial
codes when wiring the system.
The type of transformer and the connection conguration feeding a drive plays an important role in its performance and safety. The following is a brief description of some of the more common congurations and a discussion of their virtues and shortcomings. Always ask what type of power system the site has before sizing the drive.
Delta/Wye with grounded Wye neutral
This conguration is one of if not the most common. It provides rebalancing of unbalanced voltage with a 30 degree phase shift. Depending on the output connections from the drive to motor, the grounded neutral may be a path for common mode current caused by the drive output.
Delta/Delta with grounded leg
Another common conguration providing voltage rebalancing with no phase shift between input and output. Again, depending on the output connections from the drive to motor, the grounded neutral may be a path for common mode current caused by the drive output.
In this case the line to ground voltage on the phases that are not grounded will be equal to the phase to phase voltage. This voltage can exceed the voltage ratings of the EMC lter and input MOV protection devices. This can cause catastrophic controller failure if the line to ground EMC lter and input MOV protection devices are not disconnected. Refer to Disconnecting EMC Filter and MOVs for details on line to ground voltage limitations and disconnecting these devices.
WARNING
If the secondary of the transformer is a delta with a grounded leg (corner grounded delta), the
line to ground EMC lter components and line to ground MOV protection must be disconnected
or damage to the controller can result.
Page 9
WARNING
Hazardous voltage
POWER SUPPLY AND WIRING
Section 6 (continued)
Ungrounded secondary
Grounding of the transformer secondary is essential to the safety of personnel as well as the safe operation of the drive. Leaving the secondary oating can permit dangerously high voltages between the chassis of the drive and the internal power structure components. In many cases this voltage could exceed the rating of the EMC lter and input MOV protection devices of the drive causing a catastrophic failure. In all cases, the input power to the drive should be referenced to ground. If the transformer can not be grounded, then an isolation transformer
must be installed with the secondary of the transformer grounded.
In this conguration the line to ground voltage from the incoming power supply may exceed the voltage rating of the line to ground EMC lter components and line to ground MOV protection. This can cause catastrophic controller failure if the line to ground EMC lter and input MOV protection devices are not disconnected. Refer to Disconnecting EMC Filter and MOVs for details on line to ground voltage limitations and disconnecting these devices.
WARNING
If a power system with an ungrounded secondary is used, the line to ground EMC lter components and line to ground MOV protection must be disconnected or damage to the controller can result.
Resistance grounding and ground fault protection
Connecting the Wye secondary neutral to ground through a resistor is an acceptable method of grounding.
Under a short circuit secondary condition, any of the output phases to ground will not exceed the normal line to line voltage. This is within the rating of the MOV input protection devices on the drive. The resistor is often used to detect ground current by monitoring the associated voltage drop. Since high frequency ground current can ow through this resistor, care should be taken to properly connect the drive motor leads using the recommended cables and methods. In some cases, multiple drives on one transformer can produce a cumulative ground current that can trigger the ground fault interrupt circuit.
Page 10
WARNING
Hazardous voltage
POWER SUPPLY AND WIRING
Section 6 (continued)
Open Delta (consult factory)
This type of conguration is common on 230 volt systems. From time to time it may be encountered where only single phase power is available and three-phase power is required. The technique uses two single phase transformers to derive a third phase. When used to power a drive this conguration must be derated to about 70% of the single phase rating of one transformer. This system provides poor regulation and it is possible that only the two line connected phases will provide power. In this case the drive must be derated to 50 % of its rating. (Ex. A 20 HP 230 volt drive now becomes a 10 HP 230 volt drive.)
WARNING
“Open Delta” power systems should be sized using the 50% derate factor. Consult factory.
Disconnecting EMC Filter and MOVs
For all controllers, if the line to ground voltage from the incoming power supply is greater than 300Vac then the line to ground EMC lter components must be disconnected as described below. For 230V controllers, if the line to ground voltage from the incoming power supply exceeds 300Vac then the line to ground MOVs must be disconnected as described below. For 460V controllers, if the line to ground voltage from the incoming power
supply exceeds 550Vac then the line to ground MOVs must be disconnected as described below.
To disconnect the line to ground EMC lter components, locate
the jumper shown below. The jumper is on the left hand side of the
controller on the main board. Move to the disconnected position
shown to the right.
To disconnect the line to ground MOV protection, locate the jumper shown below. The jumper is located
between the input and output terminal blocks on the main board. Move to the position shown.
For Frame Size 1 Controllers: For Frame Sizes 2 and 3 Controllers:
Page 11
POWER SUPPLY AND WIRING
Section 6 (continued)
For Frame Size 4 Controllers:
Single Phase Connection
For small drives with diode rectier front end it is possible to run a three phase output with a single phase input. Only part of the three phase input bridge is used. Ripple current becomes 120 Hz rather than 360. This places a greater demand on the DC lter components (capacitor bank and DC choke). The result is that the drive must be derated to 50% current.
The chart below shows the full load output current ratings of the controller when single phase or 3 phase power
is used. If single phase input power is used the Motor Overload switches must be set to 50% or lower.
Supply
Voltage
208/230
460
Frame Size Model Number
1
2
3
4
1
2
3
SPD20050
SPD20050F
SPD20075
SPD20075F
SPD20100
SPD20100F
SPD20150
SPD20150F
SPD20200
SPD20200F
SPD20250
SPD20250F
SPD20300
SPD20300F
SPD40050
SPD40050F
SPD40075
SPD40075F
SPD40100
SPD40100F
SPD40150
SPD40150F
SPD40200
SPD40200F
SPD40250
SPD40250F
SPD40300
SPD40300F
Nominal HP Rating
Controller Full Load
Output Current Rating
3 Phase Input 1 Phase Input 3 Phase Input 1 Phase Input
5.0 2.0 17.8 8.1
7.5 3.0 26.4 10.9
10.0 5.0 37.0 17.8
15.0 7.5 47.4 26.4
20.0 10.0 60.6 33.0
25.0 12.0 76.0 40.2
30.0 15.0 94.0 47.4
5.0 8.9
7.5 13.2
10.0 18.5
15.0 23.7
20.0 30.3
25.0 37.5
30.0 47.0
Page 12
POWER SUPPLY AND WIRING
Conduit, Wire and Fuse Sizing
The use of metal conduit with metal conduit connectors is recommended for all electrical connections. Use the NEC or CEC to determine the required conduit size for the application.
Refer to the chart below for the minimum allowable wire size for each controller. Note that these wire sizes are not adjusted for voltage drop due to long cable lengths. Refer to the wire sizing chart in the appendix to
determine the maximum length for the input cable. Refer to the motor manual for maximum output cable length.
The maximum recommended voltage drop on both input and output cable combined is 5%. Standard wire sizing charts give maximum cable lengths for only input or output cables. Because of this the lengths given in the table must be adjusted so the total voltage drop does not exceed 5%. For example, if the input wire sizing chart in the appendix gives the maximum length of 400' and only 100' is used then only 25% of the total voltage drop (1.25% drop) is used. The maximum output cable length read from the motor‘s wire sizing chart must then be adjusted to 75% of its value so that the maximum voltage drop of 5% is not exceeded.
Use only fast acting class T fuses. The wire used for the input power connections on models SPD20300 and SPD20300F must have a temperature rating of 90ºC minimum. All other wire must be rated 75 ºC minimum. The chart below shows the recommended sizes for wire and fuses for each controller. Note that the wire sizes were not adjusted for voltage drop due to long cable lengths.
Voltage Frame Size Model Number
SPD20050
SPD20050F
SPD20075
SPD20075F
SPD20100
SPD20100F
SPD20150
SPD20150F
SPD20200
SPD20200F
SPD20250
SPD20250F
SPD20300
SPD20300F
SPD40050
SPD40050F
SPD40075
SPD40075F
SPD40100
SPD40100F
SPD40150
SPD40150F
SPD40200
SPD40200F
SPD40250
SPD40250F
SPD40300
SPD40300F
208/230
460
1
2
3
4
1
2
3
Full Load
Output Current
17.8 5.0 30.0 7700
26.4 7.5 40.0 11400
37.0 10.0 50.0 16000
47.4 15.0 70.0 20500
60.6 20.0 80.0 26200
76.0 25.0 110.0 32800
94.0 30.0 135.0 40600
8.9 5.0 15.0 7700
13.2 7.5 20.0 11400
18.5 10.0 30.0 16000
23.7 15.0 40.0 20500
30.3 20.0 50.0 26200
37.5 25.0 60.0 32400
47.0 30.0 70.0 40600
Nominal HP Fuse Size
Generator
Size (VA)
Page 13
WARNING
Hazardous voltage
Hazardous voltage
DANGER
POWER SUPPLY AND WIRING
Section 6 (continued)
Input Power and Line Transformer Requirements The line input voltage and transformer power must meet certain phase and balance requirements. If you or
your installing electrical contractor is in doubt of the requirements, the following provide guidelines for installation. When in doubt contact the local power utility or the factory.
Before connecting power to the controller measure the line to line and line to ground voltage from the power source. The line to line voltage must be in the range of 195Vac to 265Vac (230V +/– 15%) for 230V models and 391Vac to 529Vac (460V +/– 15%) for 460V models. The maximum phase to phase imbalance is +/– 3%. If the phase to phase imbalance is greater than +/– 3% then an isolation transformer may be necessary. The line to ground voltage must be less than 110% of the nominal (230V or 460V) line to line voltage. If the line to ground voltage is not in this range the EMC lter and MOV components may need to be removed (see section on “Ungrounded secondary” transformers) or an isolation transformer with a grounded secondary may be
necessary.
If an isolation transformer is used, the best choice is ONE three phase, six winding transformer. A delta primary is best for third harmonic cancellation. A wye secondary avoids circulating current problems and provides the
very desirable option of grounding the secondary neutral for minimum voltage stress and ripple to ground. The transformer should have a KVA rating at least 1.1 times the maximum connected HP. A K factor of 6 is sufcient if transformer impedence is greater than 2%. A K Factor of 5 is sufcient if transformer impedence is greater than 3%. The transformer manufacturer may provide derating for non K Factor rated transformers to operate at the drive produced K Factor levels.
Other transformer congurations are acceptable. Three single phase transformers can be used if they are identical for phase to phase symmetry and balance. A wye connected primary neutral should never be grounded. Great care should be taken with delta primary delta secondary congurations. Any lack of phase to
phase symmetry could result in circulating currents and unacceptable transformer heating.
WARNING
Never use phase converters with drives as nuisance tripping and possible damage may occur. Instead, use single phase input power and 50% derate factor.
STARTING THE SYSTEM
Section 7
Output Power Connections
Run the motor lead wire from the motor or conduit box through metal conduit to the bottom of the
controller. Use metal conduit and metal conduit connectors. Size the conduits according to the NEC, CEC or local codes. Connect conduit and insert the wires through the second or third opening from the left. Choose the opening that ts or is larger than the conduit used. If the opening is larger than
the conduit, use conduit bushings to attach the conduit to the controller.
Consult motor manual to determine the wire size for the application. Ensure the ground connection to the motor is continuous. Connect wires to the output terminal block labeled T1/U, T2/V, T3/W, and GND/ . Connect the ground wire to the terminal labeled GND/ . Connect the other phase leads to T1/U, T2/V and T3/W.
For CentriPro Motors, connecting T1/U to Red, T2/V to Black and T3/W to Yellow will give the correct rotation.
Page 14
Hazardous voltage
DANGER
Hazardous voltage
DANGER
Hazardous voltage
DANGER
Hazardous voltage
DANGER
Hazardous voltage
DANGER
STARTING THE SYSTEM
Section 7 (continued)
DANGER
The controller has high leakage current to ground. The output terminals marked “GND” or “ ” must be directly connected to the motor ground. Failure to properly ground the controller
or motor will create an electrical shock hazard.
Input Power Connections
Make sure disconnect switches or circuit breakers are securely in the OFF position before making this connection. Run the input power wires from the fused disconnect through metal conduit to
the bottom of the controller. Use metal conduit and metal conduit connectors. Size the conduits according to the NEC, CEC or local codes. Use the wire sizing chart in the appendix to determine
the size of the input power wires. Connect the conduit and insert the wires into the far left opening on the
controller. Connect wires to the “INPUT” terminal block. Connect the ground wire to the terminal labeled GND.
For three phase input, connect the input phase wires to L1, L2 and L3. For single phase input, connect the input
wires to L1 and L3. If single phase input is used the motor overload switches must be set to 50% or lower.
CAUTION
The wire used for input power connections on models SPD20300 and SPD20300F must have a temperature
rating of 90ºC minimum.
DANGER
The controller has a high leakage current to ground. The input terminals marked “GND” must be directly connected to the service entrance ground. Failure to properly ground the controller or
motor will create an electrical shock hazard.
NOTE
If single phase input power is used the Motor Overload switches must be set to 50% or lower or nuisance
input phase loss errors can result.
NOTE
Do not use GFCI protection with this controller. Nuisance tripping will result.
DANGER
Status Code Indicator Light is not a voltage indicator! Always turn off disconnect switch and circuit breaker and wait 5 minutes before servicing.
DANGER
The controller will remain electrically charged for 5 minutes after power is turned off. Wait 5
minutes after disconnecting power before opening controller access cover as there is a severe
shock hazard.
Page 15
STARTING THE SYSTEM
Section 7 (continued)
Setting the Motor Overload Switches
The Motor Overload Setting Switches adjust the level of motor overload current protection necessary to protect the motor in case of an over current condition.
Bank 1 switches 1, 2 and 3 allow adjustment of the motor overload setting. These switches adjust the motor overload protection as a percentage of the full load output current rating of the controller. Choose a motor overload setting that meets or is less than the motor’s SFA rating. For example, if the full load output current rating of the controller is 37A and the motor SFA rating is 33A, the motor overload setting should be set to 85% (33A/37A = 89%, next lowest setting is 85%).
In applications where the pump and motor are not used to the full capacity the
system may not draw current close to the motor’s SFA rating. In this case choose a motor overload setting that is close to the actual full load running current.
NOTE
If single phase input power is used the motor overload switches must be set to 50% or lower or nuisance input phase loss errors can result.
The chart below shows the motor overload setting for each model.
Supply
Voltage
208/230
460
Frame
Size
1
2
3
4
1
2
3
Model
Number
SPD20050
SPD20050F
SPD20075
SPD20075F
SPD20100
SPD20100F
SPD20150
SPD20150F
SPD20200
SPD20200F
SPD20250
SPD20250F
SPD20300
SPD20300F
SPD40050
SPD40050F
SPD40075
SPD40075F
SPD40100
SPD40100F
SPD40150
SPD40150F
SPD40200
SPD40200F
SPD40250
SPD40250F
SPD40300
SPD40300F
100% 95% 90% 85% 80% 70% 50% 40%
17.8 16.9 16.0 15.1 14.2 12.5 8.9 7.1
26.4 25.1 23.8 22.4 21.1 18.5 13.2 10.6
37.0 35.2 33.3 31.5 29.6 25.9 18.5 14.8
47.4 45.0 42.7 40.3 37.9 33.2 23.7 19.0
60.6 57.6 54.5 51.5 48.5 42.4 30.3 24.2
76.0 72.2 68.4 64.6 60.8 53.2 38.0 30.4
94.0 89.3 84.6 79.9 75.2 65.8 47.0 37.6
8.9 8.5 8.0 7.6 7.1 6.2 4.5 3.6
13.2 12.5 11.9 11.2 10.6 9.2 6.6 5.3
18.5 17.6 16.7 15.7 14.8 13.0 9.3 7.4
23.7 22.5 21.3 20.1 19.0 16.6 11.9 9.5
30.3 28.8 27.3 25.8 24.2 21.2 15.2 12.1
37.5 35.6 33.8 31.9 30.0 26.3 18.8 15.0
47.0 44.7 42.3 40.0 37.6 32.9 23.5 18.8
Motor Overload Setting
Page 16
STARTING THE SYSTEM
Section 7 (continued)
CAUTION
Failure to properly set the Motor Overload Setting switches can result in loss of motor overload protection and will void the motor warranty. Nuisance tripping or motor damage can occur if these switches are not set
properly.
Setting the Acceleration/Deceleration Switches
Switch 4 from bank 1 and switches 1 and 2 from bank 2 control the acceleration/deceleration ramp times. The
acceleration/deceleration switches (ACCEL/DECEL RAMP SETTINGS) control how fast the controller will change
the speed of the motor. The ramp setting is the time it takes the motor to change from minimum speed to
maximum speed. For example, if the ramp setting is set to 1 second and the minimum speed is set to 30Hz, the motor will ramp up from 30Hz to 60Hz in 1 second. A faster ramp setting should be used in systems where the ow rate can change quickly. This means that the motor can react faster to maintain the set pressure. A slower ramp setting should be used in systems where the ow rate changes slowly or where fast changes in speed can
cause water hammer or pressure surges.
Setting the No Water Restart Time Switches
Switches 3 and 4 from bank 2 control the no water restart time. The no water (dry well) restart time switches control the time between a no water (dry well) error and the restart of the system. For example, if the no water restart time switches are set to 30 minutes, the system will restart 30 minutes after a no water (dry well) error has been detected. For the 10 minute restart time, the controller will not restart if 5 faults are detected within 60 minutes. All other settings will continue to restart after the chosen restart time.
NOTE
Failure to properly set the motor overload switches can result in nuisance no water (dry well) faults.
Setting the Minimum Frequency Switch
Switch 1 from bank 3 controls the minimum frequency. The minimum frequency switch controls the slowest speed that the motor will run. For submersible pump/motor applications these switches must always be set to
30Hz minimum speed. For above ground applications with high suction pressure, the 15Hz setting can be used to prevent pressure oscillation at low speeds. In some cases the suction pressure may be high enough that the pump exceeds the pressure setting at 30Hz. In this case the 15Hz setting can be used.
CAUTION
Failure to properly set the minimum frequency switch can result in motor damage and will void the motor warranty. The minimum frequency must be set to 30Hz for submersible applications.
Setting the Carrier Frequency Switch
Switch 2 from bank 3 controls the carrier frequency. For model numbers without the F sufx, the switch can be used to change the output carrier frequency to avoid audible noise issues in above ground applications. For model numbers with the F sufx, this switch is disabled and the carrier frequency is always set to 2 kHz.
Setting the Pressure
When power is applied the pump will start and the system pressure will increase to the factory preset pressure (50 PSI if SP1 is enabled and a 300 PSI sensor is used or 75PSI if SP2 is enabled and a 300 PSI sensor is used).
After the pressure has stabilized, use the increase (INC) or decrease (DEC) pressure adjust pushbuttons to
adjust the pressure setting. Push and Hold the increase or decrease pushbutton until the desired pressure
setting is reached. The new pressure setting will save when the system goes into standby mode (solid green
light/pump off). Pressure set point 1 will be adjusted and stored when the SP2/SP1 switch input is open. Pressure set point 1 is preset to 50 PSI when used with a 300 PSI transducer. Pressure set point 2 will be adjusted and stored when the SP2/SP1 switch input is closed. Pressure set point 2 is preset to 75 PSI when used with a 300 PSI transducer.
Page 17
Hazardous voltage
DANGER
STARTING THE SYSTEM
Section 7 (continued)
Motor Rotation Direction
If the pressure/ow seems low or the system is indicating Motor Overload error check the motor rotation
direction. Turn the breaker/disconnect switch to the off position and wait 5 minutes. Switch any two leads on the
controller output (T1/U, T2/V or T3/W). Turn the breaker/disconnect switch to the on position. Observe pressure and ow. If the pressure or ow still seems low check plumbing.
For CentriPro Motors, connecting T1/U to Red, T2/V to Black and T3/W to Yellow will give the correct rotation.
NOTE
It is possible for the pump to maintain constant pressure with a low ow or a high suction head even if the
pump is rotating backwards. While the pump is running use an amp probe on one of the output power leads connected to the motor and compare the current draw between the two rotation directions. The lowest current reading indicates the pump is running in the correct direction.
System Status
The status indicator light displays the status of the controller. A constant green status code indicates that the pump is in standby mode (pump not running). A blinking green status code indicates that the pump is running. A
constant orange light indicates the input voltage is low. A blinking or constant red light indicates a problem with the controller or system. Refer to the access cover side panel for a list of status codes. See Section 9 for more
details.
DANGER
The status code indicator light is not a voltage indicator! Always turn off disconnect switch and circuit breaker and wait 5 minutes before servicing.
Page 18
INPUT AND OUTPUT FUNCTIONS
Section 8
The control terminal strips allow for a variety of input and output functions.
Warning: Turn off all power to the controller before wiring devices to the
control terminals.
Warning: Inputs RUN/STOP, HAND/AUTO, SP2/SP1 and PRESSURE DROP
are switch inputs. Do not connect power to these inputs or damage to the
controller will result. Only connect non-powered switch contacts to these
inputs.
RUN/STOP: This input allows the pump/motor to be turned on and off by
an external switch. Connect the contacts of a non-powered external switch to terminals 1 (COM) and 2 (RUN/STOP). When the switch is closed the controller is in RUN mode (output to motor is enabled). When the switch is
open the controller is in STOP mode (output to motor is disabled).
HAND/AUTO: This input allows the controller to run the motor at full speed without the use of a pressure transducer. This input can be
controlled by an external non-powered switch. Connect the contacts of a non-powered external switch to terminals 3 (COM) and 4 (HAND/AUTO). When the switch is closed the controller is in HAND mode. While in HAND mode the RUN/STOP input is used to start and stop the motor and the pressure transducer input is ignored. When the switch is open the controller is in AUTO mode. While in AUTO mode the controller uses the pressure transducer feedback to control the speed of the motor.
INPUT and +24V: These terminals are the transducer feedback and transducer power supply. Connect the
white lead from the transducer cable to terminal 6 (INPUT). Connect the brown lead from the transducer cable to terminal 7 (+24V). Connecting the drain (bare) wire to the chassis allows grounding of the case of the pressure transducer. The controller is congured with a 300 PSI 4-20mA output pressure transducer.
ANALOG OUTPUT: This output is a 4-20mA signal based on motor speed (4mA = 0Hz, 20mA = 60Hz) and can be connected to external monitoring or external control devices. Connect terminal 10 (ANALOG OUTPUT) to the 4-20mA input of the external device. Connect terminal 9 (COM) to the negative side of the current loop on the external device. The external device must have an input resistance (impedance) in the range of 45Ω to 250Ω. The maximum output voltage is 24V.
SP2/SP1: This input allows the system to operate at one of 2 pressure settings. This input can be controlled by
an external non-powered switch. Connect the contacts of a non-powered external switch to terminals 5 (COM)
and 11 (SP2/SP1). When the switch is closed pressure set point 2 is enabled (preset to 75 PSI when used with a 300 PSI transducer). When the switch is open pressure set point 1 is enabled (preset to 50 PSI when used with a 300 PSI transducer).
PRESSURE DROP: This input allows the user to select the amount of pressure drop in the system before the
pump starts. This input can be controlled by an external non-powered switch. Connect the contacts of a non­powered external switch to terminals 5 or 9 (COM) and 12 (PRESSURE DROP). When the switch is closed the
system pressure will drop 20 PSI (when used with a 300 PSI transducer) before restarting the pump. When the switch is open the system pressure will drop 5 PSI (when used with a 300 PSI transducer) before restarting the pump.
RUN RELAY: This output indicates when the pump/motor is running. This output can be used to control power
to a light, an alarm or other external device. When the pump/motor is off terminal 13 (RELAY1 – NO) will be open and terminal 14 (RELAY 1 – NC) will be connected to terminal 15 (RELAY1 – COM). When the pump/motor is on terminal 13 (RELAY1 – NO) will be connected to terminal 15 (RELAY1 – COM) and terminal 14 (RELAY 1 – NC) will
be open. The relay rating is 250Vac, 5 amps maximum.
FAULT RELAY: This output indicates when the system is faulted. This output can be used to control power to a
light, an alarm or other external device. When the system is not faulted terminal 16 (RELAY2 – NO) will be open and terminal 17 (RELAY 2 – NC) will be connected to terminal 18 (RELAY2 – COM). When the system is faulted terminal 16 (RELAY2 – NO) will be connected to terminal 18 (RELAY2 – COM) and terminal 17 (RELAY 2 – NC) will
be open. The relay rating is 250Vac, 5 amps maximum.
Page 19
Hazardous voltage
DANGER
TROUBLESHOOTING
Section 9
General
The Aquavar SPD drives are self-diagnosing controllers. If a problem occurs, observe the Status Code Indicator Light on the front of the unit. No Status Code Indicator Light means either no or low input voltage (less than
140Vac).
DANGER
Status Code Indicator Light is not a voltage indicator! Always turn off disconnect switch and circuit breaker and wait 5 minutes before servicing. High voltage may still remain on controller.
Refer to the status code label on the side of the controller access cover to diagnose system errors.
See the following diagram.
Use the following table to help troubleshoot problems.
Red Flashes Fault Code Restart Action
Constant Replace Controller Controller will not restart. Power must be reset to clear the fault.
2 Blinks No Water / Loss of Prime
3 Blinks Sensor Fault
4 Blinks Pump or Motor Bound
5 Blinks Short Circuit / Ground Fault Controller will not restart. Power must be reset to clear the fault.
6 Blinks Input Phase Loss
7 Blinks Temperature
8 Blinks Over Voltage
9 Blinks Motor Overload Controller will restart automatically.
Page 20
Controller will restart automatically according to the No Water Restart
Time switches (switches 3&4 of bank 2).
Controller will restart automatically when the sensor signal is within the
valid operating range.
Controller will restart automatically 5 times. After 5 faults the power must be reset to clear the fault.
Controller will restart automatically 5 times. After 5 faults the power must be reset to clear the fault.
Controller will restart automatically when temperature is within the operating range of the controller.
Controller will restart automatically when the input voltage is within the
operating range of the controller.
TROUBLESHOOTING
NO LIGHT
Controller Status Description
Check the input voltage to the controller. Measure the input voltage be-
Low/No Input Voltage
tween phases using an AC Voltmeter. This voltage should be greater than
140Vac for the status indicator light to turn on.
GREEN LIGHT CODES
Flashes Controller Status Description
Constant Green Light indicates the pump is off. The system is in Standby
Constant Standby
Blinking Pump Running Flashing Green Light indicates the pump is running.
mode when there is no ow in the system and the pressure setting has been reached or the RUN/STOP input is set to STOP (open switch).
ORANGE LIGHT CODES
Flashes Controller Status Description
Constant Orange Light indicates the system input voltage is low. For 230V
Constant Low Input Voltage
Blinking
No Water/Loss of Prime
Fault Disabled
units, the orange light will be indicated when the input voltage is between
140Vac and 170Vac. For 460V units, the orange light will be displayed
when the input voltage is between 140Vac and 310Vac. Blinking Orange Light indicates the No Water/Loss of Prime Fault is dis-
abled and the pump/motor is running. For details see 2 Blinks under Red
Light Codes.
Number of
Flashes
Constant Controller Error
2 Blinks No Water/Loss of Prime
Controller Status Description
RED LIGHT CODES
Internal controller fault. The controller may be internally damaged. Verify the error by turning power off, waiting 5 minutes then apply power. If the error persists, replace controller.
This fault can be caused by:
• Water supply level in well falls below suction inlet of pump.
• Plugged suction screen.
• Restriction in pipe between pump and pressure sensor.
• Air bound pump.
• Deadheaded pump, pump running against a closed valve.
• Filling long irrigation lines on start-up**
• Incorrect setting of Motor Overload Setting switches.
In systems where the motor operates at less than Service Factor Amps the controller may show a false No Water/Loss of Prime fault. Reduc­ing the motor overload setting will eliminate the false readings.
If problem persists, please verify supply capacity.
The controller will automatically restart according to the No Water Restart
Time switches.
** Controllers with software revision A3 or later allow the user to disable
this function by holding down both push buttons for 5 seconds while the pump/motor is running. While the no water/loss of prime function is dis-
abled, the status LED will blink orange while the pump/motor is running. To re-enable the function, hold down both push buttons for 5 seconds
while fault is disabled and the pump/motor is running.
It is not recommended to keep the No Water/Loss of Prime fault disabled
after the system has been primed. Doing so can result in damage to the pump.
Page 21
TROUBLESHOOTING
Number of
Flashes
3 Blinks Sensor Fault
Controller Status Description
RED LIGHT CODES
This fault can be caused by:
• Disconnected sensor. Disconnect sensor from sensor cable connector
and reconnect to ensure a good connection.
• Disconnected sensor cable lead inside the controller. Check for loose
wires where the sensor cable connects to the circuit board by tugging on each wire.
• Broken wire in the sensor cable.
• Miswired sensor cable. Check that the wires are connected to the cor-
rect terminals on the control terminal block. Connect terminal 7 (24VDC
SUPPLY) to the Brown wire. Connect terminal 6 (TRANSDUCER INPUT)
to the White wire. Connect the Drain wire to the chassis.
• Vacuum in the system. A vacuum condition may exist in the system pip­ing. Remove the sensor from the piping to release the vacuum.
• Failed sensor. To diagnose this failure a meter capable of reading mil­liamperes (mA) and DC voltage (VDC) is required.
- Set the meter to read DC voltage (VDC)
- Place the black lead on terminal 5 (COM) and the red lead on terminal
7 (24VDC SUPPLY)
- If functioning properly, the DC voltage will be 24VDC +/- 15%. If this
voltage is not present, disconnect all control terminals and repeat the measurement. If voltage does not recover, replace controller.
- Disconnect the White wire in the sensor cable from terminal 6.
- Set the meter to read DC current (mA)
- Connect the black lead from the meter to terminal 6 (TRANSDUCER
INPUT)
- Connect the red lead from the meter to the White wire in the sensor
cable.
- The meter will display the output of the sensor. If functioning properly,
the output of the sensor will be between 4mA and 20mA depending on the pressure in the system. Refer to the chart below to determine
the sensor feedback at various pressures.
Page 22
The following formula gives the transducer output based on applied pressure:
Output Current = Pressure Range
Output Current Range
[ ] ( )
x System Pressure + 4mA
TROUBLESHOOTING
Number of
Flashes
3 Blinks
(continued)
4 Blinks Pump or Motor Bound
5 Blinks Short Circuit/Ground Fault
6 Blinks Input Phase Loss
7 Blinks Temperature
Controller Status Description
Sensor Fault
(continued)
RED LIGHT CODES
Where:
• Output Current is the transducer output
• Output Current Range is the maximum output signal of the transducer
minus the minimum output signal of the transducer. In this case: Output Current Range = 20mA – 4mA, or 16mA
• Pressure Range is the pressure that corresponds to the maximum out-
put signal. For a 300 PSI transducer the Pressure Range = 300 PSI – 0 PSI = 300 PSI
• System Pressure is the system pressure as read on the pressure gauge.
This fault can be caused by:
• Mechanical binding from debris in pump.
• Electrical failure of the motor.
• Incorrect setting of Motor Overload Setting switches.
• Incorrect rotation.
• Motor phase loss.
This fault will be displayed if the output current exceeds 125% of the
controller rating. The controller will attempt to restart 5 times. If the condi­tion persists the controller will lock out and will need to be reset. Verify the error by turning power to controller off for 5 minutes and then on. Pump/ Motor/Wiring must be checked if fault persists.
This fault can be caused by:
• Electrical failure of the motor
• Electrical failure of wiring between controller and motor.
This fault will be displayed if the output current exceeds 150% of the
controller rating. Verify the error by turning power to controller off for 1 minute and then on. If error persists, motor and wiring between controller
and motor must be checked. Turn power off for 5 minutes. Remove the
three motor wires from the terminal block. Check output wiring and motor for shorting phase to phase and phase to ground. Refer to motor's manual for information on resistance readings and megger readings.
This fault can be caused by:
• Disconnected input power phase.
• Incorrect Motor Overload Setting switches. When using single phase input power the Motor Overload Setting switches must be set to 50% or
lower.
For three phase input operation; this fault will be displayed if input volt­age imbalance is more than 3%. The controller will attempt to restart 5
times. If the condition persists the controller will lock out and will need to be reset.
This fault can be caused by:
• High ambient temperature. The maximum ambient temperature rating is 122ºF (50ºC).
• Low ambient temperature. The minimum ambient temperature rating is
-22ºF (-30ºC).
This fault will be displayed if the ambient temperature is greater than
122ºF (50ºC) or less than -22ºF (-30ºC). Do not install the controller where
it will be exposed to direct sunlight. Check for a fan failure. The fans on the back of the controller will turn on only when needed. The fans will turn on
when the motor is running and the heatsink temperature reaches 104ºF (40ºC).
Page 23
TROUBLESHOOTING
Number of
Flashes
8 Blinks Over Voltage
9 Blinks Motor Overload
Controller Status Description
RED LIGHT CODES
This fault can be caused by:
• High input voltage.
This fault will be displayed if the phase to phase input voltage is greater
than 275V for 230V units and 560V for 460V units.
This fault can be caused by:
• Mechanical binding from debris in pump.
• Electrical failure of the motor.
• Incorrect setting of Motor Overload Setting switches.
• Incorrect rotation.
The controller will protect the motor from over current by limiting the cur-
rent applied to the motor. The current limit is set according to the Motor
Overload Setting switches. This fault is displayed if the output frequency is reduced to limit the current to the motor by more than 10Hz for 5 minutes.
Page 24
CONTROLLER DIMENSIONS
Page 25
APPENDIX: INPUT WIRE SIZING CHARTS
Maximum Allowable Conductor Length in Feet (40˚C Ambient, 5% drop)
Ratings Conductor Size for 75˚C Rated Wire (Lengths in Bold Require 90˚C Rated Wire)
14 12 10 8 6 4 3 2 1 1/0 2/0 3/0 4/0 250 300 350 400 500 600 750 1000
Input
Current
SFA
Motor
HP
Motor
Input
Controller
2 7.6 17.6 112 185 306 495 776 1243 1566 1980 2496 3152 3979
3 10.1 23.3 224 367 579 931 1174 1485 1874 2368 2991 3778
5 17.5 40.4 321 524 666 846 1071 1356 1717 2171 2740 3238 3889
230V,
1Ø Input
7 1/2 26.4 61.0 333 428 548 697 886 1127 1427 1805 2136 2568 3005 3440
10 33.0 76.2 331 427 547 698 891 1132 1434 1700 2045 2395 2744 3421
15 46.0 106.2 373 482 622 794 1012 1204 1451 1702 1954 2440 2942 3696
2 7.6 8.9 276 444 715 1138 1774 2832 3561
3 10.1 11.9 203 329 534 853 1332 2128 2677 3383
5 17.5 20.6 177 297 484 761 1221 1539 1946 2454 3101 3915
7 1/2 26.4 31.1 310 494 800 1011 1282 1619 2048 2588 3271
10 33.0 38.8 240 387 632 802 1019 1289 1632 2065 2611 3294 3893
230V,
3Ø Input
15 46.0 54.1 264 440 563 719 912 1159 1471 1862 2353 2784 3345 3914
20 60.0 70.6 418 538 687 876 1116 1416 1793 2124 2554 2990 3425
25 76.0 89.4 410 528 677 868 1104 1402 1665 2004 2349 2693 3359
30 94.0 110.6 531 687 878 1119 1333 1606 1885 2165 2705 3260
2 3.8 4.5 1130 1561 2495 3956
3 5.3 6.2 804 1114 1785 2833
5 8.5 10.0 489 684 1104 1760 2745
7 1/2 13.5 15.9 252 414 682 1098 1719 2751 3464
10 17.2 20.2 313 524 853 1341 2152 2712 3430
460V
15 23.0 27.1 377 625 991 1598 2018 2555 3225
20 30.0 35.3 464 745 1211 1535 1947 2461 3115 3940
25 37.0 43.5 590 968 1232 1566 1984 2514 3184
30 47.0 55.3 744 952 1217 1545 1963 2492 3155 3988
Lengths in BOLD require 90ºC wire Input connections for models SPD20300 and SPD20300F always require 90ºC wire
Page 26
APPENDIX: OUTPUT WIRE SIZING CHARTS
Maximum Allowable Conductor Length in Feet (40˚C Ambient, 5% drop)
Ratings Conductor Size for 75˚C Rated Wire
14 12 10 8 6 4 3 2 1 1/0 2/0 3/0 4/0 250 300 350 400 500 600 750 1000
SFA
Motor
HP
Motor
Input
Controller
2 7.6 327 525 843 1340 2089 3333
3 10.1 242 391 631 1006 1569 2505 3152 3981
5 17.5 129 214 355 573 899 1440 1813 2293 2890 3651
7 1/2 26.4 224 371 587 946 1195 1513 1909 2413 3049 3852
10 33.0 171 289 463 751 950 1205 1522 1925 2435 3077 3880
230V
15 46.0 320 526 670 854 1081 1371 1737 2198 2775 3281 3941
20 60.0 233 391 502 643 818 1040 1322 1675 2118 2507 3013 3526
25 76.0 295 384 495 633 808 1032 1310 1661 1969 2368 2773 3177 3961
30 94.0 386 498 639 821 1046 1330 1580 1902 2231 2558 3192 3848
2 3.8 1332 2123 3391
3 5.3 950 1517 2427 3851
5 8.5 582 935 1505 2395 3733
7 1/2 13.0 366 597 972 1556 2432 3888
10 16.5 277 458 756 1218 1909 3056 3848
460V
15 23.0 309 525 860 1356 2180 2750 3480
20 30.0 384 644 1025 1658 2096 2656 3354
25 37.0 507 817 1331 1687 2141 2708 3428
30 47.0 624 1028 1311 1669 2115 2682 3399
Lengths in BOLD require 90ºC wire
Page 27
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