Xylem IM244R04 User Manual
C
US
INSTRUCTION MANUAL
IM244R04
Models Covered:
SPD Plus
230V 1Ø Input 20-30 HP
230V 3Ø Input 40-60 HP
460V 40-100 HP
575V 40-100 HP
SPD Plus
VARIABLE SPEED PUMP CONTROL
INSTALLATION AND OPERATION MANUAL
U
L
®
1
3. Strip wires.
3. Check the contents against the order
ground wires to the drive terminals.
See “Power Supply and Wiring”
in the instruction manual.
4. Connect power, motor and
Frame Sizes R1…R4
and the shipping label to verify that all
parts have been received.
The drive requires a smooth,
vertical, solid surface, free from
heat and moisture, with free
Prepare the Mounting Location
WARNING! For oating networks
remove screws at EM1 and EM3 on
Frame Sizes R1…R4.
and PE for wiring.
* Single phase input power must use U1, W1
Frame Size R5
X0002
points.
1. Mark the mounting
2. Drill the mounting holes.
space for air ow – 200 mm (8
in.) above and below, and 25
mm (1 in.) around the sides of
the drive.
1. Remove the control panel
Remove the Front Cover
(display), if attached.
2. Loosen the
captive screw
at
the top.
top to remove
the cover.
3. Pull near the
SPD PLUS and use
1. Position the
screws or bolts to
securely tighten all
four corners.
Mount the Drive
Frame Size R6
WARNING!
sticker in the
appropriate lan-
guage on the inside
plastic shell.
2. Attach a warning
For oating net-
Install the Wiring (copper only)
F1 and F2
on Frame
works remove
screws at
Sizes R5 or R6.
supplied) in the conduit/gland box.
1. Install thin-wall conduit clamps (not
2. Install conduit/gland box.
1. Connect conduit runs to box.
Wiring Power
wiring through conduits.
2. Route input power and motor
_______________
___________________
______________________
_______________________
______________________________
WARNING! The Aquavar should ONLY
be installed by a qualied electrician.
Prepare for Installation
Check
frequency and voltage range must match drive
specifications (3 phase motor only).
• Motor Compatibility – Motor type, nominal current,
indoor controlled environment that is suitable for
• Suitable Environment – Drive requires heated,
the selected enclosure below 122º F (50º C).
requirements. Refer to NEC, Local, State or Munici-
pal codes.
Refer to the Installation Operation Manual and
• Wiring – Follow local codes for wiring and fusing
confirm that all preparations are complete.
Tools Required
Screwdrivers, wire stripper, tape measure, mount-
ing screws or bolts, and drill.
Use the following chart to interpret the type code
found on the drive label.
SPD 4 0600 N1
Single Pump Drive
Voltage
2 – 230 Volt 4 – 460 Volt 5 – 575 Volt
Task
Nominal Horsepower
0400 = 40 HP 0500 = 50 HP 0600 = 60 HP
0750 = 75 HP 1000 = 100 HP
Enclosure and Filter Options
Blank = NEMA 3R, no lter N1 = NEMA 1, no lter
F = NEMA 3R, with lter
NOTE: HP rating is for reference only, and is based on 3Ø input power.
• Voltage
• Nominal Motor Current
• Nominal Frequency
• Nominal Speed
Collect the following data from the motor nameplate
plate for later use in the Aquavar startup:
Collect Motor Data
• Nominal Power
NOTE: Lift the SPD PLUS by its chassis and not
by its cover.
Unpack the Drive
shipper immediately if damaged com-
ponents are found.
1. Unpack the drive.
2. Check for any damage and notify the
SPD PLUS
Quick Start Guide
The installation of the SPD PLUS adjust-able
Centrifugal Pump Controller
2
Overview
PREPARE for installation
UNPACK the drive
PREPARE mounting location
REMOVE the front cover
MOUNT the drive
INSTALL wiring
CHECK installation
REINSTALL the cover
APPLY power
speed drive follows the outline below.
START-UP Assistant
This guide provides a quick reference for
installing SPD PLUS drives having a standard
enclosure (NEMA 1).
NOTE: This guide does not provide detailed
installation, safety or operational instruc-
tions. See the Installation Operation Manual
for complete information.
Application
1. Align the cover
Reinstall the Cover
and slide
3
it on.
5
11.1%
40.2 PSI sp
0.0 PSI ac
0.0 HZ
DIR MENU
LOC
REM
WARNING! The SPD PLUS will start
up automatically at power up, if the
external run command is on.
When power is applied to the SPD PLUS,
the captive
screw.
control panel.
2. Tighten
3. Reinstall the
Always reinstall the front cover before turn-
ing power on.
Apply Power
1
the green LED comes on.
1. Apply input power.
NOTE! Before increasing motor speed,
check that the motor is running in the
desired direction.
Run the Start-Up Assistant
to congure the motor and
Start-Up
REM
system parameters. If this is
the rst time the drive has
been powered, the display
will prompt the user if they
would like to run the Start-
Up Assistant. Select Yes to
run the Start-Up Assistant.
If this is not the rst time the drive has been
powered, follow the steps below:
1. From the Main Screen press MENU to
enter the MENU screen.
2. Select QUICKSTART
3. Select Start-Up
4. Follow the menu prompts to congure
the drive.
NOTE! For common parameters and
menu items, use the Help Key to
display descriptions. If you encounter
Alarms or Faults, use the Help Key or
refer to the Diagnostic section of the
instruction manual.
transducer
cable
1. Route the
Wiring the Transducer
through
the conduit.
2. Strip the
transducer
cable
sheathing
and twist
the screen
wire.
wire of the
transducer to
terminal X1-1.
transducer (red or brown) to terminal
X1-10.
transducer (white or black) to X1-5. See
chart in next column.
screw).
3. Connect the screen
4. Connect the power supply wire of the
5. Connect analog output wire from the
6. Install the conduit/gland box cover (1
Digital input impedance 1.5 kΩ. Maximum voltage
1
for digital inputs is 30 V.
Before applying power, perform the follow-
Check Installation
ing checks.
√ Check
Environment conforms to specifications.
The drive is mounted securely.
Proper cooling space around the drive.
Motor and driven equipment are ready for start.
Floating networks: Internal RFI filter disconnected.
Drive is properly grounded, with pump/motor.
Input power (mains) voltage matches the drive
nominal input voltage.
The input power (mains) terminals, U1, V1, W1,
are connected and tightened as specified.
The input power (mains) fuses / mains switch installed.
The motor terminals, U2, V2, W2, are connected
and tightened as specified.
Motor cable is routed away from other cables.
NO power factor compensation capacitors are
connected to the motor cable.
Control terminals are wired and tightened as specified.
NO tools or foreign objects (such as drill shavings) are
inside the drive.
NO alternate power source for the motor is connected
– no input voltage is applied to the output of the drive.
3
INDEX
Important Safety Instructions................................................................................................................................................5
System Components .............................................................................................................................................................6
System Design ........................................................................................................................................................................ 8
Piping ....................................................................................................................................................................................10
Mounting the Controller .....................................................................................................................................................10
Power Supply and Wiring ...................................................................................................................................................11
Control Input and Output Functions .................................................................................................................................18
Starting the System ..............................................................................................................................................................19
Troubleshooting ...................................................................................................................................................................22
Appendix A - Input Power Requirements ........................................................................................................................27
Appendix B – Fuse and Wire Sizing ............................................................................................................................. 29-31
Appendix C - Weights and Dimensions ...........................................................................................................................31
Limited Warranty ..................................................................................................................................................................36
NOTE:
• Input and Output power connections require a minimum of 75ºC rated Copper wire only.
• In order to maintain the environmental rating integrity of the enclosure, all openings must be
closed by equipment rated Type 1 for Type 1 enclosures or Type 3R for Type 3R enclosures
• Maximum Ambient temperature range 5º F (-15º C) to 122º F (50º C).
• Maximum Humidity: 95% non-condensing.
4
Hazardous
voltage
DANGER
Hazardous
voltage
DANGER
Hazardous
Pressure
CAUTION
SECTION 1: SAFETY INSTRUCTIONS
DANGER
WARNING
CAUTION
Hazardous
voltage
DANGER
Hazardous
voltage
DANGER
Hazardous
voltage
DANGER
Hazardous
voltage
DANGER
Hazardous
voltage
DANGER
Hazardous
voltage
DANGER
Hazardous
Pressure
CAUTION
TO AVOID SERIOUS OR FATAL PERSONAL INJURY
OR MAJOR PROPERTY DAMAGE, READ AND
FOLLOW ALL SAFETY INSTRUCTIONS IN MANUAL
AND ON EQUIPMENT.
THIS MANUAL IS INTENDED TO ASSIST IN THE
INSTALLATION AND OPERATION OF THIS UNIT
AND MUST BE KEPT WITH THE UNIT.
This is a SAFETY ALERT SYMBOL.
When you see this symbol on the
pump, the controller or in the
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.
5. The system MUST be disconnected
from the main power supply before
attempting any operation or main-
tenance 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.
7. Even when the motor is stopped,
dangerous voltage is present at the
Power Circuit terminals U1, V1, W1
and U2, V2, W2 and, depending on the frame size,
UDC+ and UDC-, or BRK+ and BRK-.
8. WARNING! Dangerous voltage is
present when input power is con-
nected. After disconnecting the supply, wait at least 5 minutes (to let the intermediate
circuit capacitors discharge) before removing the
cover.
9. WARNING! Even when power is
removed from the input terminals of
the SPD Plus, there may be dangerous voltage (from external sources) on the power
disconnect or terminals of the relay outputs R01…R03.
CAUTION
Used without a safety alert symbol
indicates a potentially hazardous
situation which, if not avoided, could
result in property damage.
NOTICE: INDICATES SPECIAL INSTRUCTIONS
WHICH ARE VERY IMPORTANT AND
MUST BE FOLLOWED.
THOROUGHLY REVIEW ALL
INSTRUCTIONS AND WARNINGS
PRIOR TO PERFORMING ANY
WORK ON THIS CONTROLLER.
MAINTAIN ALL SAFETY DECALS.
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 qualied 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.
10. WARNING! When the control termi-
nals of two or more drive units are
connected in parallel, the auxiliary
voltage for these control connections must be
taken from a single source which can either be
one of the units or an external supply.
11. WARNING! The SPD Plus is not a
eld repairable unit. Never attempt to
repair a malfunctioning unit; contact
the factory or your local Authorized Service Center
for replacement.
12. WARNING! The SPD Plus will start up
automatically after an input voltage
interruption if the external run command is on.
13. WARNING! The heat sink may reach a high
temperature, in excess of 200º F. Severe
burns are possible.
14. WARNING! If the drive will be used
in a oating network, remove screws
at EM1 and EM3 (Frame size R4) or F1
and F2 (Frame size R5 or R6).
NOTE! For more technical information, contact the
factory or your local SPD Plus representative.
15. WARNING! Always consult your lo-
cal, state, municipal or NEC codes for
proper wiring, electrical installation of
inverter drives and AC motors.
5
SECTION 2: SYSTEM COMPONENTS
WARNING
Hazardous
voltage
Hazardous
Pressure
CAUTION
Please review the SPD Plus Variable Speed Pump Controller components and ensure that you have all the parts
and are familiar with their names. Be sure to inspect all components supplies for shipping damage.
SPD Plus Variable Speed Pump Controller Package:
• SPD Plus Variable Speed Controller
• Pressure Transducer with Cable
• Output Reactor (if ordered)
• Installation and Operation Manual
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 qualied 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.
SPD PLUS TYPE CODE AND PART NUMBER
Type Code:
SPD 4 0600 N1
Enclosure and Filter Options
Blank = NEMA 3R, no lter
F = NEMA 3R, with lter
N1 = NEMA 1, no lter
Nominal Horsepower
0400 = 40 HP
0500 = 50 HP
0600 = 60 HP
0750 = 75 HP
1000 = 100 HP
Voltage
2 = 230V
4 = 460V
5 = 575V
Single Pump Drive
NOTE: HP rating is for reference only, and is based on 3Ø input power.
6
PART NUMBERS
Nominal HP Rating
Supply
Voltage
208/230
460
575
NOTES
1) Refer to Appendix C for frame size details.
2) Drive supplied with pressure transducer and manual.
3) Controllers with an N1 sufx have a NEMA 1 enclosure and are rated for indoor use only.
Model Number
SPD20400 40 20 103 51 114 57 N6
SPD20400F 40 20 129 64 143 72 N6
SPD20400N1 40 20 103 51 114 57 R4
SPD20500 50 25 129 64 143 72 N6
SPD20500F 50 25 160 80 178 89 N6
SPD20500N1 50 25 129 64 143 72 R6
SPD20600 60 30 160 80 178 89 N6
SPD20600F 60 30 199 99 221 111 N6
SPD20600N1 60 30 160 80 178 89 R6
SPD40400 40 — 53 — 59 — N4
SPD40400F 40 — 65 — 72 — N4
SPD40400N1 40 — 53 — 59 — R4
SPD40500 50 — 65 — 72 — N4
SPD40500F 50 — 87 — 97 — N5
SPD40500N1 50 — 65 — 72 — R4
SPD40600 60 — 87 — 97 — N5
SPD40600F 60 — 87 — 97 — N5
SPD40600N1 60 — 87 — 97 — R4
SPD40750 75 — 113 — 125 — N6
SPD40750F 75 — 113 — 125 — N6
SPD40750N1 75 — 113 — 125 — R5
SPD41000 100 — 141 — 157 — N6
SPD41000F 100 — 141 — 157 — N6
SPD41000N1 100 — 141 — 157 — R6
SPD50400N1 40 — 47 — 52 — R4
SPD50500N1 50 — 69 — 77 — R6
SPD50600N1 60 — 69 — 77 — R6
SPD50750N1 75 — 89 — 99 — R6
SPD51000N1 100 — 130 — 144 — R6
3 Phase
Input
1 Phase
Input
Full Load Output
Current (50C)
3 Phase
Input
1 Phase
Input
Full Load Output
Current (40C)
3 Phase
Input
1 Phase
Input
Frame
Size
7
SECTION 3: SYSTEM DESIGN
SPD PLUS CENTRIFUGAL PUMP CONTROL SYSTEM
The SPD Plus pump controller is a simple, easy to use
and commission Variable Speed Drive (VSD) designed
specically for use in submersible or above ground
pump systems. The SPD Plus features an integrated
Start-Up Assistant which simplies system commissioning and setup.
NOTE
The SPD Plus is not recommended for the residential
well applications. Consult CentriPro for suitable
Variable Speed Controllers designed for residential
well pumps.
The following diagrams show some typical system
designs using the SPD Plus.
NOTE
Systems MUST be designed by qualied technicians
only and meet all applicable state and local code
requirements.
DIAGRAM #1 shows a typical set up for a submersible pump and control system.
1
2
SUPPLY POWER
U1
V1
W1
GND
6
U2
V2
W2
GND
8
1 DRIVE CONTROLLER
2 FUSIBLE DISCONNECT
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
3
4
5
7
FLOW
11
9
10
8
SECTION 3: SYSTEM DESIGN
1
Hazardous
Pressure
CAUTION
DIAGRAM #2 shows a set-up for an Above Ground booster pump and control system.
2
9
SUCTION
8
SUPPLY POWER
U1
V1
W1
GND
7
U2
V2
W2
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
SECTION 4: PIPING
GENERAL
NOTE
All plumbing work must be performed by a qualied
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
controlled by the SPD Plus can create
dangerous pressure. Select pipe
and ttings according to your pipe suppliers’
recommendation. Consult local codes for piping
requirements in your area.
All joints must be airtight. Use PTFE thread seal 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 pump discharge 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.
9
SECTION 4: PIPING (CONTINUED)
Hazardous
Pressure
CAUTION
WARNING
Hazardous
voltage
PRESSURE TANK, SYSTEM PRESSURE
Sizing – A bladder 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 15-20 PSI below your system pressure. 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
bladder tank is 125 psi.
INSTALLING THE PRESSURE SENSOR
The pressure sensor requires a ¼" NPT 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 10 feet 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.
The pressure sensor cable must be wired to the
controller control terminals. The pressure sensor
cable wiring diagram is shown in Section 6. The cable
can be shortened for a cleaner installation. Longer
cable lengths are available, consult factory. Maximum
recommended pressure sensor cable length is 300
feet. 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 for more than 1
foot. 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 10 (24VDC SUPPLY), White
to terminal 5 (AI2, TRANSDUCER FEEDBACK), Drain to
SCR Terminal 1. Connecting the Drain wire to the SCR
Terminal 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 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.
SECTION 5: MOUNTING THE
CONTROLLER
GENERAL
Mount the controller in a ventilated, shaded area.
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 5 ºF (-15 ºC) and 122 ºF (50 ºC).
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
6600 ft. Do not install above 6600 ft.
NOTE
Do not block the heat sink (ns) and 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.
NOTE
Controllers with an N1 sufx have a NEMA 1 enclosure and are rated for indoor use only.
10
SECTION 6: POWER SUPPLY AND WIRING
WARNING
Hazardous
voltage
POWER CONNECTION DIAGRAMS
The following diagrams show the power connection layout for each frame size.
• For sizes R4 and N4
WARNING
If the secondary of the transformer is a delta with a grounded leg (corner grounded delta) or
oating network, the line to ground EMC lter components and line to ground MOV protection
must be disconnected or damage to the controller can result. Remove screws EM1 and EM3 for
frame sizes R4/N4 to disable line to ground EMC lter and MOV protection.
FIGURE 1
11
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