Xylem IM244R04 User Manual

C
US
INSTRUCTION MANUAL
IM244R04
Models Covered:
SPD Plus
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 qualied 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 congure 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 congure
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 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.
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 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.
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 sufx 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
specically for use in submersible or above ground
pump systems. The SPD Plus features an integrated Start-Up Assistant which simplies 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 qualied 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 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 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 sufx 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
SECTION 6: POWER SUPPLY AND WIRING (CONTINUED)
WARNING
Hazardous voltage
POWER CONNECTION DIAGRAMS
The following diagrams show the power connection layout for each frame size.
• For sizes R5 and N5 • For sizes R6 and N6
FIGURE 2
FIGURE 3
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 F1 and F2 for
frame sizes R5/N5 and R6/N6 to disable line to ground EMC lter and MOV protection.
NOTE
For single phase input power, use input power terminals U1, W1 and PE (ground).
12
SECTION 6: POWER SUPPLY AND WIRING (CONTINUED)
CONTROL TERMINAL CONNECTION DIAGRAM
The diagram below describes the control terminal connections.
NOTE
Pressure sensor cable must be wired during installation. All other connections are wired at the factory.
 Identication RELAY OUTPUTS R04 TO R06
1 RO4C
2 RO4A
3 RO4B
4 RO5C
5 RO5A
6 RO5B
7 RO6C
8 RO6A
9 RO6B
NOTE
A jumper wire is installed between DI1 and +24V at the factory. To remotely start and stop the drive while in REM mode, replace the jumper wire with a non-powered switch.
Relay output Default operation: Started
Relay output Default operation: Running
Relay output Default operation: Fault
FIGURE 4
13
WARNING
Hazardous voltage
WARNING
Hazardous voltage
SECTION 6: POWER SUPPLY AND WIRING
(CONTINUED)
INPUT POWER AND LINE TRANSFORMER REQUIREMENTS
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
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 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.
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 or F1 and F2 for frame sizes R5/N5 and R6/N6 to disable line to
ground EMC lter and MOV protection. Refer to
Figures 1, 2 and 3 for screw locations.
RESISTANCE GROUNDING AND GROUND FAULT PROTECTION
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.
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 or F1 and F2 for frame sizes R5/N5 and R6/N6 to disable line to
ground EMC lter and MOV protection. Refer to
Figures 1, 2 and 3 for screw locations.
14
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.
WARNING
Hazardous voltage
WARNING
Hazardous voltage
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.
SINGLE PHASE CONNECTION
For drives with a 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. Single phase
will not work with an SCR front end drive.
LINE TRANSFORMER
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 the SPD Plus installation. When in doubt contact the local power utility or the factory.
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 impedance is greater than 2%. A K Factor of 5 is sufcient if transformer impedance 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.
INPUT POWER SPECIFICATIONS
InputPower(mains)ConnectionSpecications
208/220/230/240 VAC 3-phase or 1-phase – 15% …+10% for SPD2XXXX Voltage (U1) 380/400/415/440/460/480 VAC 3-phase -15%...+10% for SPD4XXXX
500/525/575/600 VAC 3-phase -15%....+10% for SPD5XXXX
Prospective Short- Maximum allowed prospective short-circuit current in the supply is 100 kA Circuit Current providing that the input power cable of the drive is protected with (IEC 629) appropriate fuses. US: 100 000 AIC.
Frequency 48…63 Hz
Imbalance Maximum ±3% of nominal phase to phase input voltage
Fundamental Power
0.98 (at nominal load)
Factor (cos phi1)
15
SECTION 6: POWER SUPPLY AND WIRING
Hazardous voltage
DANGER
(CONTINUED)
CONDUIT, WIRE AND FUSE SIZING
When selecting the input power cable follow the rules
below:
• Do not use aluminum wires
• The cable must be able to carry the drive load
current
• The cable must be rated for at least 75ºC
• A four conductor cable (three phases and ground)
or four insulated conductors routed through conduit may be used. Shielding is not required. 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 wire sizing tables in Appendix B to determine the maximum length for the input and output cables. The maximum recommended total voltage drop on both input and output cable
combined is 5%. Standard wire sizing table provides
maximum cable lengths for 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 must then be adjusted to 75% of its value so that the maximum voltage drop of 5% is not
exceeded.
Provide a dedicated fused disconnect rated for drives input current rating. (Fused disconnect included for NEMA3R enclosures.) No other equipment should be used for this disconnect. Use fast acting class T fuses. The recommended fuse sizes for each model are listed below.
INPUT POWER CONNECTIONS
Before making this connection, measure and verify the site voltage phase to phase and phase to ground. In the case of high line to ground voltage it may be necessary to disconnect the line to ground EMC and MOV protection. See Figures 1, 2 and 3 for details. Ensure the ground wire is connected back to the service entrance ground and that the service entrance ground is bonded to a proper ground rod.
Input
Voltage
230V
460V
575V
16
Model Number
SPD20400 114 150
SPD20400F 143 200
SPD20400N1 114 150
SPD20500 143 200
SPD20500F 178 250
SPD20500N1 143 200
SPD20600 178 250
SPD20600F 221 300
SPD20600N1 178 250
SPD40400 59 80
SPD40400F 72 90
SPD40400N1 59 80
SPD40500 72 90
SPD40500F 96 125
SPD40500N1 72 90
SPD40600 96 125
SPD40600F 96 125
SPD40600N1 96 125
SPD40750 124 175
SPD40750F 124 175
SPD40750N1 124 175
SPD41000 157 200
SPD41000F 157 200
SPD41000N1 157 200
SPD50400N1 52 60
SPD50500N1 77 100
SPD50600N1 77 100
SPD50750N1 99 150
SPD51000N1 144 200
Input Current
(Arms)
Mains Fuse Size
(UL Class T)
Ensure disconnect switches are locked in the OFF position before making this
connection. For models with an N1 (NEMA
1) sufx, connect conduit to the conduit
box supplied with the controller. For all other models (NEMA 3R), drill a hole that is properly sized for the conduit used in the bottom of the enclosure.
NOTE: Drilling in to the side or top of the enclosure will violate the NEMA 3R rating. Use metal conduit and metal conduit connectors. Size the conduits according to the NEC, CEC or local codes. Use the wire sizing chart in Appendix B to determine the size of the input power wires.
Connect the conduit and insert the wires into the controller or enclosure. Connect
wires to the “INPUT” terminal block. For
N1 models, this terminal block is on the controller and the terminal locations are as shown in Figures 1, 2 and 3. For all other models, this connection is made to the input side of the fused disconnect that is included in the enclosure. The connections from the output side of the disconnect to the controller are made at the factory. Connect the ground wire to the terminal labeled GND. For three phase input, connect the input phase wires to
U1, V1 and W1. For single phase input, connect the input wires to U1 and W1.
WARNING
Hazardous voltage
WARNING
Hazardous voltage
WARNING
Hazardous voltage
WARNING
Hazardous voltage
WARNING
Hazardous voltage
DANGER
Measure and verify site voltage phase to phase and phase to ground prior to connected power 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 on the controller labeled U2, V2, W2,
and GND. Connect the ground wire to the terminal labeled GND.
NOTE
Verify that there is at least 8” between input and
output connections or input connections and control wiring.
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
Do not use GFCI protection with this controller. Nuisance tripping will result.
NOTE
A single phase power input is designated only on
230 V specically, and the corresponding SPD Plus pump controllers are derated to 50%.
DANGER
Status Code Indicator Light and Control Panel Display are not voltage indicators! Always turn off disconnect switch and
wait 5 minutes before servicing.
If a reactor is used for a submersible motor, connect
drive output terminal block U2, V2, W2 and GND to
the corresponding input terminals of the load reactor. Connect the output terminals of the reactor to the
motor leads and GND. When wiring the load reactor
ensure all input connections from the controller are on the same side of the reactor terminal block.
NOTE
A load reactor or load lter is required in installations
where the output motor leads exceed 50 ft.
NOTE
It is recommended to use a load reactor with all 575V installations.
NOTE
Models with ‘F’ sufx include a load reactor prewired
to the controller.
NOTE
Ensure you have a three phase motor and verify the motor voltage matches input power supply voltage. Verify that the motor service factor amps do not exceed the drive output at rated ambient temperature. Ensure the ground is continuous between the controller and the motor. Ensure there
is at least 8" between the output wires and any other
wires.
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.
OUTPUT POWER CONNECTIONS
Ensure input power disconnect is locked in the off position before making the
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 bottom of the enclosure or controller conduit box extension. For frames N4, N5 and N6, it may be necessary to drill a hole in the bottom of the enclosure for conduit and wire entry.
For CentriPro motors, connecting U2 to Red, V2 to
Black and W2 to Yellow will give the correct rotation.
To change rotation, swap any two motor leads U2, V2
or W2.
Motor power and type are to be specied in Start-Up
Menu on drive keypad before running pump system.
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.
17
SECTION 7: CONTROL INPUT AND
WARNING
WARNING
OUTPUT FUNCTIONS
The control terminals allow for a variety of control functions. Some of the terminals are prewired by the factory. Removing prewired connections can disable some controller functions. Refer to the information below before removing prewired connections.
Turn off all power to the controller before wiring devices to the control
terminals.
All the DI inputs are switch inputs. Do
not connect external power to these inputs or damage to the controller will result. Only connect non-powered switch contacts to these inputs.
START/STOP (DI1,13): The DI1 input allows the pump/ motor to be turned on and off by an external switch while in REM mode. The input is pre-wired to +24V terminal 10.
For external control of this input, use only a non­powered external switch. Connect the contacts of the switch to terminals 10 (+24VDC Supply) and 13 (DI1-
START/STOP). When the switch is closed the controller is in START mode (output to motor is enabled). When
the switch is open the controller is in STOP mode (output to motor is disabled).
TRANSDUCER INPUT (AI2, 5) and +24VDC (10): These terminals are the transducer feedback and
transducer power supply. The controller is congured
with a 300 PSI 4-20mA output pressure transducer.
Connect the 3-wire pressure transducer cable with white wire of signal to terminal AI2/5, brown wire of +24 VDC transducer power supply to the drive terminal 10, and shield/drain wire to terminal 1/SCR. Refer to Section 4 for pressure transducer installation details.
RELAY OUTPUTS (RO1-R03, 19-27): Relay outputs RO1 through RO3 (terminals 19 to 27) are used to perform motor control and fault functions inside the controller. These functions are described below.
Start Ramp: Submersible motors require a start ramp function that ramps from 0Hz (stopped) to 30Hz in 1 second. DI3/15 ACC/DEC SEL and RO1/19-21 Ramp Select are used to implement this function.
No Water Restart Time: The No Water Restart Time
is used to automatically restart the controller after a
No Water/Loss of Prime (dry well) Fault is detected.
This function is implemented using DI2/14 Fault Reset, RO2/22-24 Fault Output and RO3/25-27 Under Load Output.
WARNING
Disabling the No Water Restart Time function by
removing the prewired connections will prevent the controller from automatically restarting after a
No Water/Loss of Prime Fault is detected.
ANALOG OUTPUTS (AO1, 7 and AO2, 8): These terminals provide 0-20mA output signals that can be used to control auxiliary equipment. These outputs
are congured in the application software. Analog Output 1 (AO1/7) is precongured to output a
0-20mA signal based on the output frequency of the
controller. Where 0Hz corresponds to 0mA and 60Hz corresponds to 20mA. Analog Output 2 (AO2/8) is precongured to output a 0-20mA signal based on the output current of the controller. Where 0A corresponds to 0mA and 100% of controller rated
output current corresponds to 20mA. The external device used with the Analog Outputs must have an
impedance less than 500Ω.
RELAY OUTPUTS (RO4-RO6, 1-9): The relay outputs
RO4-RO6 have been congured for Ready, Running
and Fault functions respectively. The operation of relay outputs RO4-RO6 is described below.
Controller Ready Relay (RO4, 1-3): This relay output
is congured to energize when the controller is
ready to function. The controller is ready when no faults exist and the input supply voltage is within range.
Run Relay (RO5, 4-6): This relay output is
congured to energize when the controller is
running the motor. The relay is de-energized when the controller stops the motor.
Fault Relay (RO6, 7-9): This relay output is
congured to energize when the controller is
faulted. The relay is de-energized when there is no system fault or after a fault clears.
WARNING
Disabling the Start Ramp function by removing the prewired connections can result in damage to the submersible motor and will void the motor and controller warranty.
18
SECTION 8: STARTING THE SYSTEM
APPLY POWER
When power is applied to the SPD Plus Controller, the status LED turns green.
SPD Plus Drive keypad functionality and Main Screen display is described below:
Status LED Motor State Reference Value
Control Mode
Motor Speed
Soft Key 1
LOC/REM
Stop
REM
40.2 PSI sp
0.0 PSI ac
0.0 HZ
DIRMENU
LOC REM
11.1%
Pressure Setpoint
Actual System Pressure
Soft Key 2
Up/Down Buttons
Help Function
Start
Name Function
Displays Drive Status: Green Constant = Not Faulted/No Alarm
Status LED
Motor State
Control Mode
Reference Value
Pressure Setpoint Displays the system pressure setpoint in PSI.
Actual System Pressure
Motor Speed Actual motor speed in Hz.
Soft Key 1 Function of this button changes according to the state of the display panel.
Soft Key 2 Function of this button changes according to the state of the display panel.
LOC/REM Toggles the drive control mode between local (LOC) and remote (REM). See Control Mode above.
Up/Down Buttons
Help Button Displays information about the parameter or screen shown on the display.
Start
Stop
Green Flashing = Alarm Red Constant = Faulted (Auto-restart fault) Red Flashing = Faulted (Locked Out)
Rotating = Drive is Running the Motor Stationary = Drive has Stopped the Motor
Displays the current control mode of the drive. In local mode (LOC) the drive ignores the pressure sensor feedback and speed is set with the up and down buttons. In remote mode (REM) the drive uses the pressure sensor feedback signal to control the system pressure.
In REM: Displays the pressure setting in %.
In LOC: Displays the speed reference in Hz.
Displays the actual system pressure in PSI as indicated by the pressure transducer.
In REM: Changes the pressure setting. In LOC: Changes the speed reference. In sub menus: changes parameters
In REM: Button is disabled In LOC: Initiates operation of the drive.
In REM: Button is disabled In LOC: Stops operation of the drive.
19
SECTION 8: STARTING THE SYSTEM
(CONTINUED)
START-UP ASSISTANT
Do you want to use the start-up assistant?
YES
NO
EXIT
NOTE
If this is the rst time
that the drive has been powered or the Start­Up Assistant has not been run, the display will prompt the user if they would like to run the Start-Up Assistant. Select Yes using the up and down arrows then press OK to run the Start-Up Assistant.
The Start-Up Assistant will prompt the user for information about the application, motor information and fault response. The prompt screens are shown below:
MOTOR TYPE SETTING: Select the
motor type used in the application using the up and down arrows and press OK.
The minimum frequency is set to 30Hz for the Submersible setting and 15Hz for the Above Ground setting.
The next prompt will be for either to enter
the motor horsepower rating or the motor nominal current rating. The prompt displayed will depend on the controller size.
The Start-Up Assistant can be entered at any time by following the procedure below:
QUICKSTART: From the Main Screen press MENU key to enter MENU as shown below and choose QUICKSTART.
MOTOR
HORSEPOWER
SETTING: Select the
motor HP used in
the application. The
controller lists only
the valid HP selections
based on the
controller size. If there
is only 1 valid selection
based on the drive
size and motor type,
this screen is skipped.
Note that the prompt
will also change based
on the controller
voltage rating.
20
START-UP: Select Start­Up with the up and down arrows and press SEL.
MOTOR NOMINAL
CURRENT SETTING:
The display will initially
show a default current
based on the previous
selections. Enter the
nominal motor current
rating using the up
and down arrows on
the keypad. This is the
full load current rating
for the motor.
RAMP SPEED
WARNING
SETTING: Select the ramp speed based on the system requirements. The ramp speed sets the acceleration and deceleration time for the motor. The acceleration time is the time for the motor to transition from 0Hz (stopped) to 60Hz (full speed). The deceleration time is the time for the
motor to transition from 60Hz (full speed) to 0Hz (full stopped). The FAST ramp selection sets the acceleration ramp to 5
seconds and the deceleration ramp to 8 seconds. The
MEDIUM ramp selection sets both the acceleration
and the deceleration ramp to 25 seconds. The SLOW
ramp selection sets both the acceleration and the deceleration ramp to 60 seconds.
RESTART PRESSURE DROP SETTING: The
Restart Pressure Drop Setting allows the user to select the amount of pressure drop allowed in the system before the pump restarts after
a No Water Demand
condition is detected.
A No Water Demand
condition exists when the pump has
satised the desired
system pressure and reached the minimum frequency. If the
Restart Pressure Drop is set to 5 PSI and the pump has
satised the desired system pressure and turned off
on no demand, the controller will turn the pump back on after the system pressure has dropped 5 PSI below the system pressure setting.
Setting the Ramp Speed too fast can result in unstable operation and can damage pump, motor and piping.
NO WATER RESTART
TIME SETTING: The
No Water Restart
Setting sets the time
between detection
of a No Water/Loss
of Prime fault and the
restart of the system.
For example, if the No
Water Restart Time
is set to 10 MIN, the
system will restart 10
minutes after a Water/
Loss of Prime fault has
been detected. This
parameter is typically
set according to the recovery rate of the water source. The restart time can be set to 10 minutes, 30 minutes or 1 hour using the Start-Up Assistant.
START REMINDER SCREEN: This is a
reminder screen. This screen is shown only if the controller is set to local mode (LOC). To change to remote mode (REM) and enable pressure control, press the LOC/ REM button.
CAUTION
The controller ignores the pressure sensor feedback signal and Start Signal on DI1 when operated in local (LOC) mode. Hazardous pressure can result.
The controller is now set up and is ready to be started.
SETTING THE CONTROL MODE
The Control Mode can be set to either local (LOC) or remote (REM). The Control Mode is indicated in the upper left hand corner of the display screen. Use REM for pressure control mode. This mode uses the pressure transducer feedback on AI2 to control the system pressure. Note that the start and stop buttons on the display are disabled in REM mode. The start enable on DI1 can be used to remotely start and stop
the motor. Use LOC for xed speed mode. The speed
can be set with the up and down buttons on the keypad. The motor can be started and stopped using the start and stop buttons on the keypad. The in LOC mode the start enable on DI1 is disabled.
21
WARNING
WARNING
SETTING PRESSURE SETPOINT
Hazardous voltage
DANGER
Hazardous voltage
DANGER
When in REM mode, set the desired pressure setpoint
by pressing the Up or Down arrow keys on keypad. Push and hold the Up or Down arrow keys until the desired pressure setting is obtained. The pressure
setpoint is displayed on the rst row of the Main Screen display with units of ‘PSI SP’. The actual
system pressure reported by the pressure transducer is displayed on the second row of the Main Screen
display with units of ‘PSI AC’.
DRIVE STATUS LED
The status code indicator light or LED displays the status of the controller. The status indicator is located in the upper left hand corner of the display keypad. A constant green status indicates that the pump is in normal operation. A blinking green status code indicates the unit has an alarm. A constant red status code indicates the unit is faulted and will attempt to automatically restart. A blinking red status code indicates the unit is faulted and will not attempt to restart. See Section 9 for Troubleshooting.
DANGER
The status code indicator light is not a voltage indicator! Always turn off disconnect switch and wait 5 minutes
before servicing.
MOTOR ROTATION DIRECTION
NOTE
Before increasing motor speed, check that the motor is running in the desired direction.
If the pressure/ow seems low or the system is
indicating Motor Overload error check the motor rotation direction. Turn the disconnect switch to the off position and wait 5 minutes. Switch any two
output leads on the controller, U2, V2 or W2. Turn
the disconnect switch to the on position. Observe
pressure and ow. If the pressure or ow still seems
low check plumbing. For CentriPro Motors, connecting
U2 to Red, V2 to Black and W2 to Yellow will give the
correct rotation.
NOTE
SECTION 9: TROUBLESHOOTING
DANGER
Disconnect power, lock-out all switch disconnects then wait 5 minutes before attempting to service the unit. Use
caution as there may still be hazardous voltage on the input side of the switch disconnect powering the unit.
Do not attempt any measurement, parts replacement or other service procedure not described in this manual. Such action will void the warranty, may endanger correct operation and increase downtime and expense.
All electrical installation and maintenance work described in this chapter should only be undertaken
by qualied service personnel. The Safety instructions on the rst pages of this manual must be followed.
GENERAL
The SPD Plus is a self-diagnosing controller. If a prob­lem occurs, observe the Fault or Alarm messages on the control panel display as well as the Status LED on the keypad.
STATUS INDICATOR
The Status Indicator is located in the upper left hand corner of the keypad display. The chart below de­scribes the possible states of the Status Indicator.
Drive State LED Color
Flashing
Not Faulted/ No Alarm
Green Constant
Alarm Green Flashing
Faulted (Auto-restart fault)
Red Constant
Faulted (Locked Out) Red Flashing
Constant/
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 typically indicates the pump is running in the correct direction.
22
RED – FAULTS:
The drive signals that it has detected a severe error, or fault, by:
• Enabling the red LED on the drive according to
the table above.
• Overriding the control panel display with the
display of a fault code.
• Stopping the motor (if it was on).
SECTION 9: TROUBLESHOOTING
(CONTINUED)
The fault code on the control panel display is tempo­rary. Pressing any of the following buttons removes the fault message: MENU, ENTER, UP button, or
DOWN button. The message reappears after a few
seconds if the control panel is not touched and the fault is still active.
FLASHING GREEN – ALARMS:
For less severe errors, called alarms, the diagnostic display is advisory. For these situations, the drive is simply reporting that it had detected something
“unusual.” In these situations, the drive:
• Flashes the green LED on the drive (does not
apply to alarms that arise from control panel operation errors).
• Overrides the control panel display with the
display of an alarm code and/or name.
FAULT LISTING
Fault
Code
1 OVERCURRENT
2 DC OVERVOLT
3 DEV OVERTEMP
4 SHORT CIRC
6 DC UNDERVOLT
7 AI1 LOSS Fault not enabled
Fault Name In Panel Description and Recommended Corrective Action
Output current is excessive. Check for and correct:
• Excessive motor load, pump overload
• Insufcient acceleration time
• Faulty motor, motor cables or connections
• Bound pump or locked rotor
Intermediate circuit DC voltage is excessive. Check for and correct:
• Static or transient overvoltages in the power supply.
• Deceleration time is too fast
• Power wires routed too close to each other. Ensure at least 8" between
power wires and all other wiring.
Controller heatsink is overheated. Temperature is at or above 115ºC (239ºF). Check for and correct:
• Fan failure
• Obstructions in the air ow
• Dirt or dust coating on the heatsink
• Excessive ambient temperature
• Excessive motor load
• Ambient temperature
• Altitude
Fault current. Check for and correct:
• A short-circuit in the motor cable(s) or motor.
• Supply disturbances
Intermediate circuit DC voltage is not sufcient. Check for and correct:
• Missing phase in the input power supply.
• Blown fuse
• Undervoltage on mains
The alarm messages disappear from the control panel display if/when any of the following are pressed on
the control panel: MENU, ENTER, UP button or DOWN
button. The message returns periodically as long as the alarm condition exists.
CORRECTING FAULTS
The recommended corrective action for faults is:
• Use the "Fault Listing" table below to nd and
address the root cause of the problem.
• Reset the drive by pressing RESET on keypad.
•NOTE:Itmaybenecessarytoremoveand
reapply the Start Signal on DI1 to start the drive after a fault is reset by pressing RESET on the keypad.
• Turn the power off for 5 minutes then turn on.
23
SECTION 9: TROUBLESHOOTING (CONTINUED)
FAULT LISTING
Fault
Code
Fault Name In Panel Description and Recommended Corrective Action
8 TRANSDUCER LOSS
Signal from the pressure transducer is out of range. Check for and correct:
• Source and connection for analog input.
• Vacuum in the system. Remove sensor from piping to release vacuum.
• Failed pressure transducer. 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 11 (GND) and the red lead on terminal 10 (+24VDC SUPPLY)
- If functioning properly, the DC voltage will be 24VDC +/- 10%. 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 5.
- Set the meter to read DC current (mA)
- Connect the black lead from the meter to terminal 5 (AI2, 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.
Pressure Transducer Output vs. Applied Pressure
for a 300 PSI, 4-20mA Output Transducer
24
20
16
12
8
4
Transducer Output (mA)
0
050 100 150 200 250 300
Pressure (PSI)
9 MOT OVERTEMP
10 PANEL LOSS
12 MOTOR STALL
24
NOTE: The controller is programmed to automatically reset the Transducer Loss Fault every 10 seconds for 1 minute. If the fault is not corrected in this time the fault must be reset by pressing reset on the keypad or by cycling power to the controller.
Motor is too hot, based on the controller's estimate.
• Check for overloaded motor.
• Enter the Start-Up Assistant and ensure motor parameters are set
correctly.
Panel communication is lost drive is in local control mode (LOC). Check for and correct:
• Communication lines and connections
Motor stall. Motor is operating in stall region. Check for and correct:
• Excessive motor load.
• Insufcient motor power.
• Bound pump.
SECTION 9: TROUBLESHOOTING (CONTINUED)
FAULT LISTING
Fault
Code
16 EARTH FAULT
18 THERM FAIL
19 OPEX LINK
20
21
22 SUPPLY PHASE
26 DRIVE ID Internal fault. Conguration Block Drive ID is not valid. Contact factory.
27 CONFIG FILE Internal conguration le has an error. Contact factory.
34 MOTOR PHASE
35 OUTP WIRING
36 INCOMPATIBLE SW The drive cannot use the software. Internal fault. Contact factory.
37 CB OVERTEMP
38
Fault Name In Panel Description and Recommended Corrective Action
Possible ground fault detected in the motor or motor cables. The drive monitors for ground faults while the drive is running the motor and while the motor is stopped. Detection is motor sensitive when the drive is not running and can produce false positives. Possible corrections:
• Check for/correct faults in the input and output wiring.
• Verify the controller uses a recommended load reactor for long output
cable runs.
• A delta grounded input power supply and motor cables with high
capacitance may result in erroneous error reports during non-running.
Internal fault. The thermistor measuring the internal temperature of the drive is open or shorted. Contact factory.
Internal fault. A communication related problem has been detected on the
ber optic link between the control and OINT boards. Contact factory.
OPEX PWR
CURR MEAS
NO WATER/LOSS OF
PRIME
Internal fault. Exceptionally low voltage detected on the OINT power supply. Contact factory.
Internal fault. Current measurement is out of range. Contact factory.
Ripple voltage in the DC link is too high. Check for and correct:
• Missing mains phase
• Blown fuse
• Input wiring/connections
• High voltage unbalance on the input power supply
Fault in the motor circuit. One of the motor phases is lost. Check for and correct:
• Motor fault
• Motor cable fault
• Internal fault
Possible power wiring error detected. When drive is not running it monitors
for an improper connection between the drive input power and the drive output. Check for and correct:
• Proper input wiring - line voltage is NOT connected to drive output.
• The fault can be erroneously declared if the input power is a delta
grounded system and motor cable capacitance is large.
Drive control board is overheated. The fault trip limit is 88ºC. Check for and
correct:
• Excessive ambient temperature
• Fan failure
• Obstructions in the air ow.
This fault is detected when the pump load on the motor is lower than ex­pected. Check for and correct:
• Adequate well level or water supply
• Plugged suction screen
• Restriction in piping.
• Air bound pump.
• Deadheaded pump, pump running against a closed valve.
• Incorrect setting of motor parameters. Run the Start-Up Assistant and
verify motor settings.
NOTE: The controller will automatically restart after this fault is detected
when the No Water Restart Time set in the Start-Up Assistant expires.
25
WARNING
SECTION 9: TROUBLESHOOTING (CONTINUED)
FAULT RESETTING
CONSTANT RED LED
To reset the drive for faults indicated by a constant
(not ashing) LED, correct the problem and do one of
If an external source for start command is selected and it is active, the SPD Plus may start immediately after fault reset.
the following:
• Press RESET from the control panel.
• Turn the power off and wait 5 minutes. Turn the
power back on.
FLASHING RED LED
To reset the drive for faults indicated by a ashing red
LED:
• Turn the power off and wait 5 minutes. Turn the
power back on
CORRECTING ALARMS
The recommended corrective action for alarms is:
• Determine if the Alarm requires any corrective
action (action is not always required).
• Use "Alarm Listing" below to nd and address the
root cause of the problem.
ALARM LISTING
Fault
Code
Fault Name In Panel Description and Recommended Corrective Action
Current limiting controller is active. Check for and correct:
• Excessive motor load, pump overload.
2001 OVERCURRENT
• Insufcient acceleration time
• Faulty motor, motor cables or connections.
• Bound pump or locked rotor.
Overvoltage controller is active. Check for and correct:
• Static or transient overvoltages in the power supply.
2002 OVERVOLTAGE
• Deceleration time is too fast.
• Power wires routed too close to each other. Ensure at least 8" between
power wires and all other wiring.
Panel communication is lost and the drive is in local control mode (LOC).
2008 PANEL LOSS
Check for and correct:
• Communication lines and connections
Drive heatsink is hot. This alarm warns that a DEVICE OVERTEMP fault may be near. Check for and correct:
• Fan failure
2009 DEVICE OVERTEMP
• Obstructions in the air ow
• Dirt or dust coating on heatsink
• Excessive ambient temperature
• Excessive motor load
Motor is too hot, based on the controller's estimate. This alarm warns that a
2010
MOTOR OPERATING IN SERVICE FACTOR RANGE
MOT OVERTEMP fault trip may be near.
• Check for overloaded motor
• Enter the Start-Up Assistant and ensure motor parameters are set cor-
rectly.
2013 AUTORESET
2018 NO WATER DEMAND
This alarm warns that the drive is about to perform an automatic fault reset which may start the motor.
This alarm warns that the controller has turned off the pump due to lack of demand. The speed of the pump has dropped below the minimum speed.
Signals that the drive is performing a First Start evaluation of motor charac-
2025 FIRST START
teristics. This is normal the rst time the motor is run after the motor param­eters are entered or changed.
2027
NO WATER/LOSS OF
PRIME
This alarm is issued to warn that a No Water/Loss of Prime fault may be near. See Fault Code 38, No Water Loss of Prime for details.
2028 START DELAY Shown during the Start Delay. The start delay time is set to 1 second.
26
WARNING
SECTION 9: TROUBLESHOOTING (CONTINUED)
TROUBLESHOOTING FAULTS, ALARMS AND PERFORMANCE PROBLEMS
In Troubleshooting, always consider the following possibilities:
• Faults — Press Reset key rst, enter Start Up
Assistant and verify the settings are appropriate.
• Electrical supply/ motor/ wiring/grounding
— check your supply voltage, motor wiring, transducer wiring, and grounding.
• Mechanical/Pump/ Rotation — check pump
rotation, rubbing or other mechanical problems;
pump “run out”.
APPENDIX A: INPUT POWER SPECIFICATIONS
Do not operate the drive outside the nominal input line voltage range. Over-voltage can result in permanent damage to the drive.
SOMETIMES DRIVE INPUT ISOLATION TRANSFORMERS ARE SPECIFIED TO DEAL WITH ONE OR MORE OF THE FOLLOWING ISSUES:
1) Short Circuit Protection: Input transformers are sometimes used to provide impedance to reduce the available short circuit current to levels that the input clearing devices, such as fuses or circuit breakers, are rated to handle. Line reactors can
perform this impedance function much more cost effectively.
• Hydraulic System/ Piping — check to ensure
proper suction and discharge piping layout, proper NPSHa, air entrainment, vortex, friction loss, system curve compensation etc.
• Environment — protect from high temperatures,
direct sun, freezing temperatures, high altitude,
dust, vibration, lack of air ow.
to ground transient protection. Isolation transformers are not required for this protection within those energy levels. Additional distribution transformer primary transient surge arrestors may be required if the potential transient energy
reected to the drive exceed those levels. MOV's
are rated to handle high levels of one shot transient energy. MOV's are not meant to handle continuously recurring transients. A problem of continuously recurring transients should be corrected before connecting a drive.
3) Harmonic Mitigation: Input transformers are sometimes used to provide impedance to reduce the harmonic currents generated in the drive. Line
reactors can perform this function much more cost effectively.
2) Transient Protection: Input transformers are sometimes used to provide transient surge impedance. All the SPD Plus drives have capacitors and MOV's (Metal Oxide Varistor transient protectors) providing 120 to 360 joules, line to line
INPUT POWER SPECIFICATIONS
InputPower(mains)ConnectionSpecications
208/220/230/240 VAC 3-phase or 1-phase – 15% …+10% for SPD2XXXX Voltage (U1) 380/400/415/440/460/480 VAC 3-phase -15%...+10% for SPD4XXXX
500/525/575/600 VAC 3-phase -15%....+10% for SPD5XXXX
Prospective Short- Maximum allowed prospective short-circuit current in the supply is 100 kA Circuit Current providing that the input power cable of the drive is protected with (IEC 629) appropriate fuses. US: 100 000 AIC.
Frequency 48…63 Hz
Imbalance Maximum ±3% of nominal phase to phase input voltage
Fundamental Power Factor (cos phi1)
0.98 (at nominal load)
27
APPENDIX A: INPUT POWER
L1
L1
SPECIFICATIONS (CONTINUED)
4) Power Factor Capacitor Isolation: Input transformers are sometimes used to provide impedance to isolate drives from line connected
power factor correction capacitors. PWM drive
inputs do not require power factor correction capacitors as drive power factors are generally
greater than 92% and cannot be signicantly
improved with power factor correction capacitors which only correct for fundamental. However drives should be isolated from power factor correction
capacitors by about 3 to 6% additional impedance
with respect to the drives. Line reactors can perform this function much more cost effectively than isolation transformers. SPD Plus drives have
either an internal 3% line reactor or an equivalent 3 to 5% bus reactor.
5) RFI/EMI Mitigation: Neither input isolation transformers nor line or bus reactors provide good
high frequency ltering although an isolation
transformer with a static shield will provide some RFI mitigation. If RFI/EMI mitigation is required,
an RFI/EMI lter mounted inside the drive should
be used together with all the proper wiring and
grounding techniques. Some RFI/EMI lters may
operate only on a power source with a grounded neutral. Establishing a local neutral ground may require the use of an input isolation transformer.
CORNER GROUNDED TN SYSTEMS
WARNING
Do not attempt to install or remove the EMC
lter screws EM1, EM3, F1 or F2 while power is
applied to the drive's input terminals.
Corner grounded TN systems are dened in the
following table. In such systems, disconnect the
internal ground connection through the EMC lter
capacitors (do this also if the grounding conguration
of the system is unknown), see SECTION 6: POWER SUPPLY AND WIRING for details.
The EMC lter capacitors make an internal ground
connection that reduces electro-magnetic emission.
Where EMC (electro-
magnetic compatibility) is a concern, and the system is symmetrically grounded,
the EMC lter may be
connected. For reference, the diagram on the right illustrates a symmetrically grounded TN system (TN-S system).
FLOATING NETWORKS
WARNING
Do not attempt to install or remove the EMC
lter screws EM1, EM3, F1 or F2 while power is
applied to the drive's input terminals.
For IT systems (an ungrounded power system or a high-resistance-grounded [over 30 ohm] power system):
• Disconnect the ground connection to the internal EMC lter, see SECTION 6: POWER SUPPLY AND
WIRING for details.
• Where EMC requirements exist, check for
excessive emission propagated to neighboring low voltage networks. In some cases, the natural suppression in transformers and cables is
sufcient. If in doubt, use a supply transformer
with static screening between the primary and secondary windings.
• Do NOT install an external RFI/EMC lter. Using an EMC lter grounds the input power through the lter capacitors, which could be dangerous
and could damage the drive.
L2 L3
Grounded at the corner of the delta
Single phase, grounded at an end point
28
Corner Grounded TN Systems — EMC Filter must be disconnected
L1
Grounded at the mid point of a delta leg
L2 L3
L1
Three phase "Variac" without solidly grounded neutral
L2
N
L3
L1
L2 L3
L1
L2
L3
APPENDIX B: FUSE AND WIRE SIZING
FUSES
Branch circuit protection must be provided by the end user and sized per national and local electric codes. The following tables provide fuse recommendations for short circuit protection on the drive's input power.
The rated fuse currents given in the tables are the maximums for the mentioned fuse types. If smaller
fuse ratings are used, check that the fuse Arms current rating is larger than the input current.
Check that the operating time of the fuse is below
0.5 seconds. The operating time depends on the
fuse type, the supply network impedance as well as the cross-sectional area, material and length of the supply cable. In case the 0.5 seconds operating time is exceeded with the gG or T fuses, ultra rapid (aR) fuses will in most cases reduce the operating time to an acceptable level.
Input
Voltage
230V
460V
575V
Model
Number
SPD20400 114 150
SPD20400F 143 200
SPD20400N1 114 150
SPD20500 143 200
SPD20500F 178 250
SPD20500N1 143 200
SPD20600 178 250
SPD20600F 221 300
SPD20600N1 178 250
SPD40400 59 80
SPD40400F 72 90
SPD40400N1 59 80
SPD40500 72 90
SPD40500F 96 125
SPD40500N1 72 90
SPD40600 96 125
SPD40600F 96 125
SPD40600N1 96 125
SPD40750 124 175
SPD40750F 124 175
SPD40750N1 124 175
SPD41000 157 200
SPD41000F 157 200
SPD41000N1 157 200
SPD50400N1 52 60
SPD50500N1 77 100
SPD50600N1 77 100
SPD50750N1 99 150
SPD51000N1 144 200
Input
Current
(Arms)
Mains
Fuse Size
(UL Class T)
29
APPENDIX B: FUSE AND WIRE SIZING (CONTINUED)
WIRE SIZING
The tables below show the maximum recommended cable lengths for each model. Note that the tables
show the cable length which will produce a 5%
voltage drop on the cable. The recommended total
voltage drop across all system cables is 5%. Because
of this the lengths given in the table must be adjusted
so the total voltage drop does not exceed 5%. For
SPD PLUS INPUT WIRE SIZING CHARTS
MaximumAllowableConductorLength(50˚CAmbient,5%drop)
Controller
Controller
Input
230V
1Ø Input,
Output
230V
3Ø Input,
Output
460V
575V
Ratings
FLA
Input
Cur-
6 4 3 2 1 1/0 2/0 3/0 4/0 250 300 350 400 500 600 750 1000
rent
169.7
1636 2080
Motor HPMotor
20 54 95.4 393 505 648 826 1050 1247 1501 1760 2018 2518 3036 3810
25 68 120.2 501 642 820 978 1179 1385 1591 1989 2398 3015 3997
30 82 144.9 519 668 799 966 1137 1308 1639 1976 2490 3300
40 96
50 116 205.0 655 776 899 1135 1368 1736 2300
60 130 229.8 792
40 53 54.1 816 1043 1331 1690 2146 2723 3447
50 70 71.4 765 984
60 80 81.6 846 1084
75 96 98.0 881 1133 1456 1855
100 127 129.6 1363 1745 2083 2514 2955
40 43 43.8 784 1286
50 54 55.3 995 1273 1625
60 64 65.7 1052 1349 1719 2187
75 76 77.6 1121 1434 1832 2338
100 101 103.1 1335 1719
(LengthsinBoldRequire90˚CRatedWire)
1256
2634 3337
2064 2621
example, if the input wire sizing chart 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 must then
be adjusted to 75% of its value so that the maximum voltage drop of 5% is not exceeded.
ConductorSizefor75˚CRatedWire
1601
2040 2588 3277 3882
1386
3327
558
1772
2251 2855 3385
2783 3528
2969
2193
670
2359
2802 3374 3957
3763
2792 3320
812 958
1106
3398
1389 1675
1002
1208 1538 2038
2116 2804
30
APPENDIX B: FUSE AND WIRE SIZING (CONTINUED)
SPD PLUS OUTPUT WIRE SIZING CHARTS
MaximumAllowableConductorLength(50˚CAmbient,5%drop)
Controller
Output
230V
460V
575V
Controller
Ratings
Motor HPMotor
20 54
25 68
30 82
40 96
50 116
60 130
40 53 834 1066 1360
50 70 782 1005 1283
60 80 865 1108
75 96 901 1158 1487
100 127 1087 1393 1783 2128 2568 3018 3469
40 43 802 1315
50 54 1017 1301 1661
60
75 76 1146 1466 1871
100 101 1366
6
FLA
64 1076 1379 1756 2234
4 3 2 1 1/0 2/0 3/0 4/0 250 300 350 400 500 600 750 1000
408 522 667 846 1075 1364 1726 2181 2580 3100 3627
404 519 662 843 1074 1362 1723 2041 2454 2873 3289
420 539 689 881 1120 1420 1684 2026 2374 2720 3392
450 579 743 947 1204 1430 1722 2019 2316 2890 3484
603 771 984 1172 1413 1659 1906 2382 2871 3610
679 869 1038 1253 1472 1693 2118 2553 3214
1671
2124 2689 3407
ConductorSizefor75˚CRatedWire
(LengthsinBoldRequire90˚CRatedWire)
1726
2191
2780 3519
1635 2083
1416 1809 2298
2108 2676
3396
2842
2388
1758
2643 3346 3963
2914 3455
1894 2408 2861
3602
3032 3842
2242 2853 3391
3444
APPENDIX C: WEIGHTS AND DIMENSIONS
CONTROLLER DIMENSIONS
NEMA 1 Enclosures
NOTE
Controllers with an N1 sufx have a NEMA 1
enclosure and are rated for indoor use only.
NEMA 1 Enclosure Dimensions
Ref.
W 203 8.0 265 10.4 300 11.8
H 596 23.4 602 23.7 700 27.6
H2 583 23.0 578 22.8 698 27.5
H3 689 27.1 739 29.1 880 34.6
D 262 10.3 286 11.3 400 15.8
R4 R5 R6
mm in mm in mm in
31
APPENDIX C: WEIGHTS AND DIMENSIONS (CONTINUED)
NEMA 1 Mounting Dimensions
Ref.
W1* 160 6.3 238 9.4 263 10.4
W2* 98 3.9
H1* 578 22.8 588 23.2 675 26.6
a 6.5 0.25 6.5 0.25 9 0.35
b 13 0.5 14 0.55 14 0.55
c 8 0.3 8.5 0.3 8.5 0.3
d 6.5 0.25 6.5 0.25 9 0.35
*Center to center dimension.
R4 R5 R6
mm in mm in mm in
NEMA 1 Weights
R4 R5 R6
kg lb. kg lb. kg lb.
22.8 50.2 37 82 78 176
32
APPENDIX C: WEIGHTS AND DIMENSIONS (CONTINUED)
NEMA 3R Enclosures
Frame Size N4 Frame Size N5
Frame Size N6
NEMA 3R Enclosure Dimensions
Ref.
W 530.9 20.9 762.0 30.0 914.4 36
H 967.7 38.1 990.6 39.0 1590.0 62.6
D 388.6 15.3 33.7 15.5 546.1 21.5
N4 N5 N6
mm in mm in mm in
NEMA 3R Wall Mounting Dimensions
Ref.
W1 398.8 15.7 723.9 28.5
H1 916.9 36.1 876.3 34.5
N4 N5 N6
mm in mm in mm in
Not Applicable
Self Standing Unit
NEMA 3R Weights — Without Filter
N4 N5 N6
kg lb. kg lb. kg lb.
87.5 193 92.1 203 178.7 394
NEMA 3R Weights — With Filter
N4 N5 N6
kg lb. kg lb. kg lb.
98.9 218 107.0 236 204.1 450
33
NOTES
34
NOTES
35
LIMITED WARRANTY
This warranty applies to this Xylem Inc. product.
Any part or parts found to be defective within the warranty period shall be replaced at no charge to the dealer during the warranty period. The warranty period shall exist for a period of twenty-four (24) months from date of installation or thirty (30) months from date of manufacture, whichever period is shorter.
A dealer who believes that a warranty claim exists must contact the authorized Xylem Inc. distributor from whom the equipment was purchased and furnish complete details regarding the claim. The distributor is authorized to adjust any warranty claims utilizing the Xylem Inc. Customer Service Department.
The warranty excludes:
(a) Labor, transportation and related costs incurred by the dealer;
(b) Reinstallation costs of repaired equipment;
(c) Reinstallation costs of replacement equipment;
(d) Consequential damages of any kind; and,
(e) Reimbursement for loss caused by interruption of service.
Forpurposesofthiswarranty,thefollowingtermshavethesedenitions:
(1) “Distributor” means any individual, partnership, corporation, association, or other legal relationship that stands between Xylem Inc. and the dealer in purchases,
consignments or contracts for sale of the subject equipment.
(2) “Dealer” means any individual, partnership, corporation, association, or other legal relationship which engages in the business of selling or leasing equipment to
customers.
(3) “Customer” means any entity who buys or leases the subject equipment from a dealer. The “customer” may mean an individual, partnership, corporation, limited
liability company, association or other legal entity which may engage in any type of business.
THIS WARRANTY EXTENDS TO THE DEALER ONLY.
Xylem, Inc.
2881 East Bayard Street Ext., Suite A Seneca Falls, NY 13148
Phone: (800) 453-6777 Fax: (888) 322-5877 www.centripro.com
CentriPro and Aquavar are trademarks of Xylem, Inc. or one of its subsidiaries.
© 2012 Xylem Inc. IM244 Rev. 4 July 2013
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