Xylem IM250R03 User Manual
SUPPLEMENT MANUAL
IM250R03
AQUAVAR® CPC
SUPPLEMENT A - Variable Speed Drive
SUPPLEMENT TO THE INSTALLATION AND OPERATION MANUAL (IM167)
TABLE OF CONTENTS
SAFETY
Use of Warnings and Notes ...................................................................................................................................................3
INSTALLATION
Application ..............................................................................................................................................................................4
Input Disconnect Features and Functions ...........................................................................................................................4
Installation Flow Chart ............................................................................................................................................................6
Preparing for Installation (Supplement to Aquavar CPC-01/U1 User’s Manual) .............................................................7
Installing the Drive (Supplement to Aquavar CPC-01/U1 User’s Manual) .......................................................................9
Installing the Wiring (Supplement to Aquavar CPC-01/U1 User’s Manual) ................................................................. 10
MAINTENANCE
Maintenance Intervals ......................................................................................................................................................... 14
Drive Module Fan Replacement ........................................................................................................................................ 14
Enclosure Fan Replacement – NEMA 12 Enclosures ....................................................................................................... 15
Enclosure Air Filter Replacement – NEMA 12 Enclosures............................................................................................... 16
TECHNICAL DATA
Cable Sizing / Ratings .......................................................................................................................................................... 19
Fuse Sizing / Ratings ............................................................................................................................................................ 22
Ratings (Supplement to Aquavar CPC-01/U1 User’s Manual) ........................................................................................ 25
Input Power Connections (Supplement to Aquavar CPC-01/U1 User’s Manual) ........................................................ 26
Motor Connections .............................................................................................................................................................. 32
Cooling – R7/R8 .................................................................................................................................................................... 32
Dimensions and Weights (Supplement to Aquavar CPC-01/U1 User’s Manual) ......................................................... 33
Applicable Standards and Markings ................................................................................................................................. 40
INDEX .................................................................................................................................................................................. 42
2
SAFETY
WARNING! The AQUAVAR CPC adjustable speed AC drive with Input Disconnect should ONLY be
installed by a qualied electrician.
WARNING! 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-.
WARNING! Dangerous voltage is present when input power is connected. After disconnecting the
supply, wait at least 5 minutes (to let the intermediate circuit capacitors discharge) before removing the
cover.
WARNING! Even when power is removed from the input terminals of the AQUAVAR CPC, there may be
dangerous voltage (from external sources) on the terminals of the relay outputs.
WARNING! When the control terminals 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.
WARNING! The AQUAVAR CPC will start up automatically after an input voltage interruption if the
external run command is on.
WARNING! When the AQUAVAR CPC with Input Disconnect is connected to the line power, the Motor
Terminals T1, T2 and T3 are live even if the motor is not running. Do not make any connections when the
AQUAVAR CPC with Input Disconnect is connected to the line. Disconnect and lock out power to the
drive before servicing the drive. Failure to disconnect power may cause serious injury or death.
NOTE! For more technical information, contact the factory or your local AQUAVAR representative.
WARNING! Do not attempt to install or remove EM1, EM3, F1 or F2 screws while power is applied to
the drive’s input terminals.
WARNING! Do not control the motor with disconnecting device (disconnecting means); instead, use
the control panel start and stop keys, or commands via the I/O board of the drive. The maximum allowed
number of charging cycles of the DC capacitors (i.e. power-ups by applying power) is ve in ten minutes.
WARNING! The opening of a branch-circuit protective device may be an indication that a fault has been
interrupted. To reduce the risk of re or electric shock, current-carrying parts and other components of
the controller should be examined and replaced if damaged or equivalent.
USE OF WARNINGS AND NOTES
There are two types of safety instructions throughout this manual:
• Notes draw attention to a particular condition or fact, or give information on a subject.
• Warnings caution you about conditions which can result in serious injury or death and/or damage to the
equipment. They also tell you how to avoid the danger. The warning symbols are used as follows:
DANGEROUS VOLTAGE WARNING warns of high voltage which can cause physical injury and/or
damage to the equipment.
GENERAL WARNING warns about conditions, other than those caused by electricity, which can result
in physical injury and/or damage to the equipment.
3
INSTALLATION
Study these installation instructions carefully before proceeding. Failure to observe the warnings and instructions may cause a malfunction or personal hazard.
WARNING! Before you begin read “Safety” on page 3.
WARNING! When the Aquavar CPC with Input Disconnect is connected to the line
power, the Motor Terminals T1, T2, and T3 are live even if the motor is not running. Do
not make any connections when the Aquavar CPC with Input Disconnect is connected
to the line. Disconnect and lock out power to the drive before servicing the drive. Failure to disconnect power may cause serious injury or death.
Application
This manual contains supplemental information that is unique to Aquavar CPC input dis-
connect congurations (“FD” sufx). Refer to the base manual, Aquavar CPC User’s Manual
(IM167), for all other information.
Input Disconnect Features and Functions
The Aquavar CPC with Input Disconnect is an Aquavar CPC AC adjustable frequency drive
packaged with an input disconnect switch, and with a door mounted, external operating
handle. The operating handle can be padlocked in the OFF position (padlock not supplied).
Enclosure options are NEMA 1, NEMA 12 and NEMA 3R (UL Type 1, UL Type 12 and UL Type
3R).
The following is a typical power diagram:
Disconnect Switch
or Circuit Breaker
3 Phase
Input Power
or
1 Phase
Input Power
3
Drive with Input Disconnect
Aquavar
CPC
Drive
3Ø
3
Motor
4
INSTALLATION
The following gures show the front view of the Aquavar CPC Input Disconnect standard
congurations and identify the major components.
R1 … R4 R5, R6 R7, R8
NEMA 1 & 12 NEMA 1 & 12 NEMA 1 & 12
Enclosures Enclosures Enclosures
Aquavar CPC Drive
Control Panel
BP0096
BP0094
Operating Handle
for Disconnect Switch
BP0093
5
INSTALLATION
Installation Flow Chart
The installation of Input Disconnect congurations for Aquavar CPC drives follows the outline
below. The steps must be carried out in the order shown. At the right of each step are references to the detailed information needed for the correct installation of the unit.
NOTE! References in the middle column below are to the Aquavar CPC User’s Manual
(IM167). References in the third column below are to this manual.
Refer to the
Task Aquavar CPC User’s Manual
Additional Reference
in this Manual
“Installation” Section
PREPARE for “Preparing for Installation” • R7/R8: “Lifting the Drive”
installation on page 7.
• “Drive Identication” on page 8.
• “Suitable Mounting Location”
on page 9.
PREPARE the “Prepare the Mounting Location” • R7/R8: “Prepare the Mounting
Mounting Location – R7 and R8” on
Location page 9.
• “Dimensions and Weights
(Supplement to Aquavar CPC
User’s Manual)” on page 27.
REMOVE the “Remove Front Cover” R7/R8: “Remove Side Panel- R7 and
front cover R8 NEMA 1 and 12 Enclosures” on
page 9.
MOUNT the drive “Mount the Drive” R7/R8: “Mount the Drive” on
page 10.
INSTALL wiring “Wiring Overview” and “Installing the Wiring (Supplement
“Install the Wiring” to Aquavar CPC User’s Manual)”
starting on page 10.
CHECK installation “Check Installation” —
REINSTALL the “Reinstall Cover” —
cover
APPLY power “Apply Power” —
START-UP “Start-Up” —
6
INSTALLATION
Preparing for Installation (Supplement to Aquavar CPC User’s Manual)
Lifting the Drive
R7…R8 Frames
WARNING! Handle and ship oor mounted enclosures only in
the upright position. These units are not designed to be laid on their backs.
1. Use a pallet truck to move the package/enclosure to the installation site.
2. Remove the cabinet side panels from NEMA 1 and 12 enclosures for
access to the cabinet/pallet mounting bolts. (Six (6) torx screws hold
each cabinet side panel in place. Leave the side panels off until later.)
PC00005
3. Remove the 4 bolts that secure the cabinet to the shipping pallet.
WARNING! Use the lifting lugs/bars at the top of the unit
to lift R7/R8 drives.
4. Use a hoist to lift the drive. (Do not place drive in nal position until
mounting site is prepared.
2
R70010
30º
PC00003
7
INSTALLATION
Preparing for Installation (Supplement to Aquavar CPC User’s Manual)
Drive Identication
To identify the type of device you are installing, refer to the type code number on the device
identication label.
• Wall mounting base drives – label attached on the side surface of the heat sink.
• Packaged drive with screw cover – label attached to outside surface on the left ide of the
enclosure.
• Enclosure with hinged cover/door – label on inside surface of the cover/door.
Type Code Number
Use the following to interpret the type code found on the identication label.
CPC 4 370 1 FD
AQUAVAR® (Series)
Voltage
2 – 208-240 Volt
4 – 480 Volt
5 – 575 Volt
Amps
370 Amps
*See Technical Section
NEMA Enclosure Rating
1 – NEMA 1
2 – NEMA 12
Disconnect with Drive Fuses
NOTE: Standard equipment on 200 HP and above models, R7-R8 Frames.
Options
* Consult factory for other options, if available. Not all combinations may be available.
Ratings and Frame Size
Charts in the “Ratings” sections of the Aquavar CPC User’s Manual and this manual list
technical specications, and identify the drive’s frame size.
NOTE! Some instructions in this document vary, depending on the drive’s frame size. To
read the Ratings table, you need the “Output current rating” entry from the type code (see
above).
8
INSTALLATION
Suitable Mounting Location
For selecting a suitable mounting location for FD congurations, refer to:
• Preparing for installation in the Aquavar CPC User’s Manual, and
• The Technical Data section of this manual for information on dimensions and weights.
Installing the Drive (Supplement to Aquavar CPC User’s Manual - IM167)
WARNING! Metal shavings or debris in the enclosure can damage electrical
equipment and create a hazardous condition. Where parts, such as conduit plates
require cutting or drilling, rst remove the part. If that is not practical, cover nearby
electrical components to protect them from all shavings or debris.
Prepare the Mounting Location – R7 and R8
The Aquavar CPC should only be mounted where all of
the requirements dened in “Preparing for Installation”
are met.
PC00023
Frame sizes R7 and R8 have mounting holes inside
the enclosure base. See “NEMA 1 and 12, R7…R8
Mounting Dimensions” on page 28.
Where it is not possible to use either mounting hole
at the back of the base, use an L-bracket at the top of
the enclosure to secure the cabinet to a wall or to the
back of another enclosure. Bolt the L-bracket to the
enclosure using the lifting lug bolt hole on the top of
the enclosure.
Remove Side Panels – R7 and R8 NEMA 1 and 12 Enclosures
Cabinet Door
Fastening points when installed
back against a wall (top view)
Fastening points when installed
back against back
Fastening the cabinet at the top
using L-brackets (side view)
L-bracket
M12 bolt (1/2 to 9/16 in)
Cabinet top
2
1. To open the cabinet door, loosen the quarter-turn screws
that hold the cabinet door closed.
2. Installation access is easier if these panels are kept off
throughout the installation.
R70020
9
INSTALLATION
Mount the Drive
R7…R8
1. Use a hoist to move the cabinet into position.
NOTE! If the cabinet location does not provide access to the cabinet
sides, be sure to re-mount side panels before positioning cabinet.
2. Install and tighten mounting bolts.
Installing the Wiring (Supplement to Aquavar CPC User’s Manual)
WARNING!
• Metal shavings or debris in the enclosure can damage electrical equipment and create a
hazardous condition. Where parts, such as conduit plates require cutting or drilling, rst
remove the part. If that is not practical, cover nearby electrical components to protect
them from all shavings or debris.
• Do not connect or disconnect input or output power wiring, or control wires, when power
is applied.
30º
PC00003
• Never connect line voltage to drive output Terminals T1, T2 and T3.
• Do not make any voltage tolerance tests (Hi Pot or Megger) on any part of the unit.
Disconnect motor wires before taking any measurements in the motor or motor wires.
• Make sure that power factor correction capacitors are not connected between the drive
and the motor.
Wiring Requirements
Refer to the “Wiring Requirements” Section in the Aquavar CPC User’s Manual. The
requirements apply to all Aquavar CPC drives. In particular:
• Use separate, metal conduit runs for the following different classes of wiring:
– Input power wiring
– Motor wiring
– Control/communications wiring
• Properly and individually ground the drive, the motor and cable shields.
• Ground the pressure transducer or piping back to the Aquavar chassis or common
grounding point.
10
INSTALLATION
Wiring Overview
Power Connection – Standard Input Disconnect (R1…R6, Wall Mounted)
The following gures show the Standard Input Disconnect (wall mounted) wiring connection
points. Refer to the Aquavar CPC User’s Manual for control connections to the drive.
R1…R4
NEMA 1 & 12
Enclosures
BP0058
Ground
Motor
Terminals
Gnd
Input Power
Terminals
Disconnect Switch
or Circuit Breaker
Input Power
Terminals
I/O Conduit
(Bottom)
Aquavar
CPC
Lug(s)
R5, R6
NEMA 1 & 12
Enclosures
I/O Conduit
(Top)
Motor
Terminals
BP0057
11
INSTALLATION
Power Connection – Standard Input Disconnect (R7…R8, Floor Mounted)
The R7 and R8 Aquavar CPC Standard Input Disconnect units are congured for wiring access
from the top and include a removable conduit mounting plate. The following gure shows the
Standard Input Disconnect (oor mounted) wiring connection points. Refer to the Aquavar
CPC User’s Manual for control connections to the drive.
Motor
Terminals
Input Power
Terminals
Disconnect Switch
or Circuit Breaker
R7
NEMA 1 & 12
Ground Lug
Bar
CPC
Terminals
Input Power
Terminals
Disconnect Switch
or Circuit Breaker
Motor
CPC
R8
NEMA 1 & 12
Ground Lug
Bar
12
BP0054 BP0055
INSTALLATION
Install the Line Input Wiring
Line Input Connections – Standard Input Disconnect Congurations
Connect input power to the terminals of the disconnect switch or circuit breaker. Connect the
equipment grounding conductor to the ground lug. The gure below shows the connection
points for Standard Input Disconnect congurations.
R1…R4
NEMA 1 & 12
Enclosures
BP0058
Input
Power
Dashed line is ground run.
R5, R6
NEMA 1 & 12
Enclosures
BP0057
Input
Power
R7, R8
NEMA 1 & 12
Enclosures
BP0054
R7 shown.
R8 similar to R7.
WARNING! Check the motor and motor wiring insulation before connecting the
Aquavar CPC to line power. Follow the procedure in the Aquavar CPC User’s Manual.
Before proceeding with the insulation resistance measurements, check that the Aquavar
CPC is disconnected from incoming line power. Failure to disconnect line power could
result in death or serious injury.
NOTE! For the remainder of the installation and start-up (motor and control wiring) refer to
the Aquavar CPC User’s Manual.
13
MAINTENANCE
Maintenance Intervals
If installed in an appropriate environment, the drive requires very little maintenance. This table
lists the routine maintenance intervals recommended by CentriPro.
Maintenance Conguration Interval Instruction
Check/replace R5/R6 R5/R6 NEMA 12 Check every 3 “Frame Sizes R5/R6 – Enclosure
enclosure inlet air lter enclosures months. Replace Inlet Air Filter” on page 16.
as needed.
Check/replace R7/R8 R7/R8 NEMA 12 Check every 3 “Frame Sizes R7/R8 – NEMA 12
enclosure inlet air lter enclosures months. Replace Enclosure Inlet Air Filter” on
as needed. page 16.
Check/replace R7/R8 R7/R8 NEMA 12 Check every 6 “Frame Sizes R7/R8 – NEMA 12
enclosure exhaust air enclosures months. Replace Enclosure Exhaust Filters” on
lter as needed. page 18.
Check and clean All Depends on the See “Maintenance” in Aquavar
heatsink dustiness of the CPC User’s Manual.
environment
(every 6…12
months)
Replace drive All Every 6 years See “Maintenance” in Aquavar
module fan CPC User’s Manual.
Replace enclosure NEMA 12 Every 3 years See “Frame Sizes R7/R8 – NEMA
fan(s) 12 Enclosures” on page 15. For
other frame sizes, see
“Maintenance” in Aquavar CPC
User’s Manual.
Change capacitor Frame sizes R5 and Every 10 years See “Maintenance” in Aquavar
R6 CPC User’s Manual.
Replace battery in the All Every 10 years See “Maintenance” in Aquavar
Assistant control panel CPC User’s Manual.
Drive Module Fan Replacement
The drive module fan cools the heatsink. Fan failure can be predicted by the increasing
noise from fan bearings and the gradual rise in the heatsink temperature in spite of
heatsink cleaning. If the drive is operated in a critical part of a process, fan replacement is
recommended once these symptoms start appearing. Replacement fans are available from
the factory. Do not use other than CentriPro specied spare parts.
To monitor the running time of the cooling fan, see “Group 29: Maintenance Trig” in the
Aquavar CPC Users’s Manual.
Frame Sizes R7 and R8
Refer to the installation instructions supplied with the fan kit.
14
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