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IM255
User Manual
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Xylem IM255 User Manual

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INSTRUCTION MANUAL
®
Aquavar
Intelligent
Pump Controller
Table of Contents
Introduction and Safety..................................................................................................................3
Introduction..................................................................................................................................3
Safety.............................................................................................................................................3
User safety.................................................................................................................................... 4
Environmental safety...................................................................................................................6
Transportation and Storage.......................................................................................................... 7
Inspect the delivery.....................................................................................................................7
System lifting................................................................................................................................7
Transportation guidelines.......................................................................................................... 7
Storage guidelines...................................................................................................................... 7
Table of Contents
Product Description........................................................................................................................8
Product overview.........................................................................................................................8
Motor thermal protection...........................................................................................................8
Frame size A description..........................................................................................................14
Frame sizes B and C description.............................................................................................15
Installation......................................................................................................................................16
Installation site checklist...........................................................................................................16
Frequency converter and motor pre-installation check list................................................. 16
Electrical Installation.................................................................................................................... 17
Precautions.................................................................................................................................17
Basic electrical connection.......................................................................................................19
Motor connection......................................................................................................................20
Wiring to control terminals...................................................................................................... 29
Common terminal wiring configurations............................................................................... 33
Local control panel....................................................................................................................42
Aquavar® Intelligent Pump Controller INSTRUCTION MANUAL 1
Table of Contents
Mechanical Installation................................................................................................................ 51
Installation requirements..........................................................................................................51
Operation.......................................................................................................................................55
Pre-start procedure...................................................................................................................55
Pre-startup inspections.............................................................................................................55
Apply power.............................................................................................................................. 56
Discharge time.......................................................................................................................... 56
Frequency converter programming....................................................................................... 57
Basic operational programming............................................................................................. 94
Induction motor setup..............................................................................................................95
PM motor setup.........................................................................................................................95
Check motor rotation................................................................................................................97
Local-control test.......................................................................................................................97
System start-up..........................................................................................................................98
Acoustic noise or vibration...................................................................................................... 98
Warnings and alarms....................................................................................................................99
System monitoring....................................................................................................................99
Warning and alarm types.........................................................................................................99
Warning and alarm displays.................................................................................................. 100
Warning and alarm definitions..............................................................................................108
Troubleshooting......................................................................................................................... 119
Start up and operation troubleshooting..............................................................................119
Technical Specification..............................................................................................................122
Power-dependent specifications.......................................................................................... 122
General technical data........................................................................................................... 128
Fuse specifications..................................................................................................................133
Parameter list...........................................................................................................................139
2 Aquavar® Intelligent Pump Controller INSTRUCTION MANUAL

Introduction and Safety

Introduction

Purpose of this manual
The purpose of this manual is to provide necessary information for:
• Installation
• Operation
• Maintenance
CAUTION:
Read this manual carefully before installing and using the product. Improper use of the product can cause personal injury and damage to property, and may void the warranty.
NOTICE:
Save this manual for future reference, and keep it readily available at the location of the unit.
Introduction and Safety
Qualified personnel
WARNING:
This product is intended to be operated by qualified personnel only.

Safety

WARNING:
• Correct and reliable transport, storage, installation, operation, and maintenance are
required for the trouble-free and safe operation of the frequency converter. Only qualified personnel are allowed to install or operate this equipment.
• Qualified personnel are defined as trained staff, who are authorized to install,
commission, and maintain equipment, systems, and circuits in accordance with pertinent laws and regulations. Also, the personnel must be familiar with the instructions and safety measures that are described in this document.
• The operator must be aware of safety precautions to prevent physical injury.
• Operating, installing, or maintaining the unit in any way that is not covered in this
manual could cause death, serious personal injury, or damage to the equipment. This includes any modification to the equipment or use of parts not provided by Xylem. If there is a question regarding the intended use of the equipment, please contact a Xylem representative before proceeding.
• Do not change the service application without the approval of an authorized Xylem
representative.
CAUTION:
You must observe the instructions contained in this manual. Failure to do so could result in physical injury, damage, or delays.
Aquavar® Intelligent Pump Controller INSTRUCTION MANUAL 3
Introduction and Safety

Safety message levels

About safety messages
It is extremely important that you read, understand, and follow the safety messages and regulations carefully before handling the product. They are published to help prevent these hazards:
• Personal accidents and health problems
• Damage to the product
• Product malfunction
Definitions
Safety message level Indication
DANGER:
A hazardous situation which, if not avoided, will result in death or serious injury

User safety

General safety rules
WARNING:
CAUTION:
Electrical Hazard:
NOTICE:
These safety rules apply:
• Always keep the work area clean.
• Pay attention to the risks presented by gas and vapors in the work area.
• Avoid all electrical dangers. Pay attention to the risks of electric shock or arc
hazards.
• Always bear in mind the risk of drowning, electrical accidents, and burn injuries.
A hazardous situation which, if not avoided, could result in death or serious injury
A hazardous situation which, if not avoided, could result in minor or moderate injury
The possibility of electrical risks if instructions are not followed in a proper manner
• A potential situation which, if not avoided, could result in undesirable conditions
• A practice not related to personal injury
flash
Safety equipment
Use safety equipment according to the company regulations. Use this safety equipment within the work area:
• Hard hat
• Safety goggles, preferably with side shields
• Protective shoes
• Protective gloves
• Gas mask
• Hearing protection
4 Aquavar® Intelligent Pump Controller INSTRUCTION MANUAL
• First-aid kit
• Safety devices
Electrical connections
Electrical connections must be made by certified electricians in compliance with all international, national, state, and local regulations. For more information about requirements, see sections dealing specifically with electrical connections.
Precautions before work
Observe these safety precautions before you work with the product or are in connection with the product:
• Provide a suitable barrier around the work area, for example, a guard rail.
• Make sure that all safety guards are in place and secure.
• Make sure that you have a clear path of retreat.
• Make sure that the product cannot roll or fall over and injure people or damage
• Make sure that the lifting equipment is in good condition.
• Use a lifting harness, a safety line, and a breathing device as required.
• Allow all system and pump components to cool before you handle them.
• Make sure that the product has been thoroughly cleaned.
• Disconnect and lock out power before you service the pump.
• Check the explosion risk before you weld or use electric hand tools.
Introduction and Safety
NOTICE:
Never operate a unit unless safety devices are installed. Also see specific information about safety devices in other chapters of this manual.
property.
Precautions during work
Observe these safety precautions when you work with the product or are in connection with the product:
• Never work alone.
• Always wear protective clothing and hand protection.
• Stay clear of suspended loads.
• Always lift the product by its lifting device.
• Beware of the risk of a sudden start if the product is used with an automatic level
• Beware of the starting jerk, which can be powerful.
• Rinse the components in water after you disassemble the pump.
• Do not exceed the maximum working pressure of the pump.
• Do not open any vent or drain valve or remove any plugs while the system is
• Never operate a pump without a properly installed coupling guard.
Wash the skin and eyes
control.
pressurized. Make sure that the pump is isolated from the system and that pressure is relieved before you disassemble the pump, remove plugs, or disconnect piping.
Follow these procedures for chemicals or hazardous fluids that have come into contact with your eyes or your skin:
Condition Action Chemicals or hazardous fluids in
eyes
1. Hold your eyelids apart forcibly with your fingers.
2. Rinse the eyes with eyewash or running water for at least 15 minutes.
3. Seek medical attention.
Aquavar® Intelligent Pump Controller INSTRUCTION MANUAL 5
Introduction and Safety
Condition Action Chemicals or hazardous fluids on
skin

Environmental safety

The work area
Always keep the station clean.
Waste and emissions regulations
Observe these safety regulations regarding waste and emissions:
• Appropriately dispose of all waste.
• Handle and dispose of the processed liquid in compliance with applicable environmental regulations.
• Clean up all spills in accordance with safety and environmental procedures.
• Report all environmental emissions to the appropriate authorities.
CAUTION: Radiation Hazard
Do NOT send the product to Xylem if it has been exposed to nuclear radiation, unless Xylem has been informed and appropriate actions have been agreed upon.
1. Remove contaminated clothing.
2. Wash the skin with soap and water for at least 1 minute.
3. Seek medical attention, if necessary.
Electrical installation
For electrical installation recycling requirements, consult your local electric utility.
Recycling guidelines
Always follow local laws and regulations regarding recycling.
Waste and emissions guidelines
Do not dispose of equipment containing electrical components together with domestic waste.
Collect it separately in accordance with local and currently valid legislation.
6 Aquavar® Intelligent Pump Controller INSTRUCTION MANUAL

Transportation and Storage

Inspect the delivery

Inspect the package

1. Inspect the package for damaged or missing items upon delivery.
2. Note any damaged or missing items on the receipt and freight bill.
3. File a claim with the shipping company if anything is out of order. If the product has been picked up at a distributor, make a claim directly to the
distributor.

Inspect the unit

1. Remove packing materials from the product. Dispose of all packing materials in accordance with local regulations.
2. Inspect the product to determine if any parts have been damaged or are missing.
3. If applicable, unfasten the product by removing any screws, bolts, or straps. For your personal safety, be careful when you handle nails and straps.
4. Contact the local sales representative if there is any issue.
Transportation and Storage

System lifting

WARNING:
Assembled units and their components are heavy. Failure to properly lift and support this equipment can result in serious physical injury and/or equipment damage. Lift equipment only at the specifically identified lifting points. Lifting devices such as eyebolts, slings, and spreaders must be rated, selected, and used for the entire load being lifted.
WARNING: Crush Hazard
1) Always lift the unit by its designated lifting points. 2) Use suitable lifting equipment and
ensure that the product is properly harnessed. 3) Wear personal protective equipment. 4) Stay clear of cables and suspended loads.

Transportation guidelines

Precautions
DANGER: Crush Hazard
Moving parts can entangle or crush. Always disconnect and lock out power before servicing to prevent unexpected startup. Failure to do so could result in death or serious injury.

Storage guidelines

Storage location
The product must be stored in a covered and dry location free from heat, dirt, and vibrations.
NOTICE:
• Protect the product against humidity, heat sources, and mechanical damage.
• Do not place heavy weights on the packed product.
Aquavar® Intelligent Pump Controller INSTRUCTION MANUAL 7

Product Description

Product Description

Product overview

A frequency converter is an electronic motor controller that converts AC mains input into DC and then into a variable voltage, variable frequency output waveform. The following is a list of functions of the frequency converter:
• Regulates the frequency and voltage to control the motor speed or torque.
• Varies the speed of the motor in response to system feedback, such as changing temperature or pressure for controlling fan, compressor, or pump motors.
• Regulates the motor by responding to remote commands from external controls.
• Monitors the system and motor status.
• Issues warnings or alarms for fault conditions.
• Starts and stops the motor.
• Optimizes energy efficiency.
Operation and monitoring functions are available as status indications to an outside control system or serial communication network.
Approvals and certifications
The frequency converter complies with UL508C thermal memory retention requirements.

Motor thermal protection

Motor thermal protection can be implemented using various techniques: PTC sensor in motor windings, mechanical thermal switch, (Klixon type) or Electronic Thermal Relay (ETR).
Protection against motor overheating comes from 1-90 Motor Thermal Protection. If the ETR function is desired, set 1-90 Motor Thermal Protection to data value [4] ETR trip (default value) or data value [3] ETR warning.
NOTICE: The ETR function is initialized at 1.16 x rated motor current and rated motor frequency. The ETR function provides class 20 motor overload protection in accordance with the NEC.
Motor thermal protection prevents the motor from overheating. The ETR function is an electronic feature that simulates a bimetal relay that is based on internal measurements. The characteristic is shown in the following figure.
8 Aquavar® Intelligent Pump Controller INSTRUCTION MANUAL
Product Description
The X-axis shows the ratio between I
actual and I
motor
nominal. The Y-axis shows the
motor
time in seconds before the ETR cuts off and trips the frequency converter. The curves show the characteristic nominal speed, at twice the nominal speed and at 20% of the nominal speed. The curve shows that at lower speed the ETR cuts off at lower heat due to less cooling of the motor. In that way, the motor is protected from overheating even at low speed. The ETR function calculates the motor temperature that is based on actual current and speed. The calculated temperature is visible as a readout parameter in 16-18 Motor Thermal in the frequency converter.
Motor thermal protection can also be achieved using an external thermistor. Set 1-90 Motor Thermal Protection to data value [2] Thermistor trip or data value [1] Thermistor warning. Set 1-93 Thermistor Source to the input to which the thermistor is connected. Refer to the examples below for wiring details.
The thermistor cut-out value is >3kΩ. Integrate a thermistor (PTC sensor) in the motor for winding protection.
The following examples show various ways to connect the PTC/Thermistor to the drive.
• Using a digital input and the 24V as a power supply.
• Parameter set-up:
• Set 1-90 Motor Thermal Protection to Thermistor Trip [2]
• Set 1-93 Thermistor Source to Digital Input 19 [4]
Aquavar® Intelligent Pump Controller INSTRUCTION MANUAL 9
Product Description
• Using a digital input and the 10V as a power supply.
• Parameter set-up:
• Set 1-90 Motor Thermal Protection to Thermistor Trip [2]
• Set 1-93 Thermistor Source to Digital Input 19 [4]
• Using an analog input and 10V as a power supply
• Parameter set-up:
• Set 1-90 Motor Thermal Protection to Thermistor Trip [2]
• Set 1-93 Thermistor Source to Analog Input 54 [2]. Do not use Analog Input 54 as any other feedback or reference source. Be sure to configure the analog input configuration switches properly.
10 Aquavar® Intelligent Pump Controller INSTRUCTION MANUAL
Product Description
NOTE: Check that the chosen supply voltage follows the specification of the thermistor element.
Summary
Input Digital/analog
Supply Voltage V Cut-out Values
Threshold
Cut-out Values Digital 24 < 6.6kΩ — > 10.8kΩ Digital 10 < 800kΩ — > 2.7kΩ Analog 10 < 3.0kΩ — > 3.0kΩ
With the Torque limit feature the motor is protected from being overloaded independent of the speed. With the ETR the motor is protected from being overheated and there is no need for any further motor protection. That means when the motor is heated up the ETR timer controls how long the motor can be operated at the high temperature before it is stopped in order to prevent overheating. If the motor is overloaded without reaching the temperature where the ETR turns off the motor, the torque limit will protect the motor from being overloaded.
The ETR function is activated in 1-90 Motor Thermal Protection and is controlled in 4-16 Torque Limit Motor Mode. The time before the torque limit warning trips the drive is set in 14-25 Trip Delay at Torque Limit.
Aquavar® Intelligent Pump Controller INSTRUCTION MANUAL 11
A2 A3 A4 A5 B1 B2
B2 B3 C1 C2 C3 C4
Top and bottom mounting holes
Top and bottom mounting holes (B4+C3+C4 only)
IP20/21* IP20/21* IP55/66 IP55/66 IP21/66 IP21/55/66
IP20/21* IP20/21* IP21/55/66 IP21/55/66 IP20/21* IP220/21*
Product Description
Dimensions
12 Aquavar® Intelligent Pump Controller INSTRUCTION MANUAL
Frame Size (HP):
208–230 V 380–460 V
1.5–3
1.5–5
575 V
Enclosure IP20
OPEN
Height in (mm) Enclosure 9.69
(246)
with decoupling
14.72 (374)
plate Backplate 10.55
(268)
Distance between
10.12
(257) mounting holes
Width in (mm) Enclosure 3.54
(90)
Backplate 3.54
(90)
Distance between
2.76 (70)
mounting holes
Depth in (mm) Without A/B
Option Card* With A/B
Option Card*
8.07
(205)
8.66
(220) Screw holes inches (mm) Screw hole c 0.31
(8)
Screw hole d 0.43
(11)
Screw hole e 0.22
(5.5)
Screw hole f 0.35
(9)
Max. weight —
11 (5) 12 lb (kg)
Product Description
Mechanical Dimensions
A2 A3 A4 A5 B1 B2 B3 B4 C1 C2 C3 C4
5
7.5–10
1.5–10
1.5–3
1.5–5
1.5–5
1.5–10
1.5–10
7.5–15 15–25 15–25
20 30–40 15–40
7.5-15 15–25 15–25
20-25 30–50 30–50
25-40 50–75 50–75
50-60
100–
125
50–125
30-40 60–75 60–75
50-60
100–
125
100–
125
NEMA1IP20
OPEN
14.65 (372)
(246)
- 14.72 (374)
14.76 (375)
13.78 (350)
10.55 (268)
10.12 (257)
3.54 (90)
(130)
3.54 (90)
(130)
2.76 (70)
(110)
8.07
(205)
(205)
8.66
(220)
(220)
0.31
(8)
0.43 (11)
0.22
(5.5)
0.35
(9)
(5.5)15(6.8)16(7.3)
9.69
5.12
5.12
4.33
8.07
8.66
0.31 (8)
0.43
(11)
0.22
(5.5)
0.35 (9)
NEMA1NEMA
NEMA
14.65 (372)
15.35 (390)
12
4X
NEMA
12
NEMA
4X
16.54 (420)
NEMA
1
NEMA
12
NEMA
4X
18.90 (480)
NEMA
1
NEMA
12
NEMA
4X
25.59 (650)
- - - - - 16.5
14.76 (375)
13.78 (350)
(130)
(130)
(110)
(205)
(220)
5.12
5.12
4.33
8.07
8.66
0.31 (8)
0.43
(11)
0.22
(5.5)
0.35 (9)
15.35 (390)
15.79 (401)
7.87
(200)
7.87
(200)
6.73
(171)
6.89
(175)
6.89
(175)
0.32 (8.2)
0.47 (12)
0.26
(6.5)
0.24
(6)
16.54 (420)
15.83 (402)
9.53
(242)
9.53
(242)
8.46
(215)
7.87
(200)
7.87
(200)
0.32 (8.2)
0.47 (12)
0.26
(6.5)
0.35
(9)
18.90 (480)
17.87 (454)
9.53
(242)
9.53
(242)
8.27
(210)
10.24 (260)
10.24 (260)
0.47 (12)
0.75 (19)
0.35
(9)
0.35
(9)
25.59 (650)
24.57 (624)
9.53
(242)
9.53
(242)
8.27
(210)
10.24 (260)
10.24 (260)
0.47 (12)
0.75 (19)
0.35
(9)
0.35
(9)
22 (10) 31
(14.1)51(23.1)60(27.2)27(12.2)52(23.6)
IP20
OPEN
13.78 (350)
(419)
15.71 (399)
14.96 (380)
6.50
(165)
6.50
(165)
5.51
(140)
9.76
(248)
10.31 (262)
0.31 (8)
0.47
(12)
0.27
(6.8)
0.31
(7.9)
IP20
OPEN
18.11 (460)
23.43 (595)
20.47 (520)
19.49 (495)
9.09
(231)
9.09
(231)
7.87
(200)
9.53
(242)
9.53
(242)
- 0.47
- 0.75
0.33 (8.5)
0.59 (15)
NEMA
NEMA
NEMA
26.77 (680)
12
4X
NEMA
1
1
NEMA
12
NEMA
4X
30.31 (770)
- - 24.8
26.77 (680)
25.51 (648)
12.13 (308)
12.13 (308)
10.71 (272)
12.20 (310)
12.20 (310)
30.31 (770)
29.09 (739)
14.57 (370)
14.57 (370)
13.15 (334)
13.19 (335)
13.19 (335)
0.47
(12)
(12)
0.75
(19)
0.35
0.39 (9.8)
100
(45.4)
(9)
(19)
0.35 (9)
0.39
(9.8)
144
(65.3)78(35.4)
IP20
OPEN
19.29 (490)
(630)
21.65 (550)
20.51 (521)
12.13 (308)
12.13 (308)
10.63 (270)
13.11 (333)
13.11 (333)
- -
- -
0.33 (8.5)
0.67 (17)
IP20
OPEN
23.62 (600)
31.5
(800)
25.98 (660)
24.84 (631)
14.57 (370)
14.57 (370)
12.99 (330)
13.11 (333)
13.11 (333)
0.33
(8.5)
0.67 (17)
111
(50.4)
Aquavar® Intelligent Pump Controller INSTRUCTION MANUAL 13
Product Description

Frame size A description

Figure 1: Exploded view of Frame Size A
1 LCP 10 Motor output terminals 96 (U), 98 (W) 2 RS-485 serial bus connector (+68, 69) 11 Relay 2 (01, 02, 03) 3 Analog I/O connector 12 Relay 1 (04, 05, 06) 4 LCP input plug 13 Brake (-81, +82) and load sharing (-88, +89) terminals 5 Analog switches (A53), (A54) 14 Mains input terminals 91 (L1), 92 (L2), 93 (L3) 6 Cable strain relief/PE ground 15 USB connector 7 Decoupling plate 16 Serial bus terminal switch 8 Grounding clamp (PE) 17 Digital I/O and 24 V power supply 9 Shielded cable grounding clamp and strain relief 18 Control cable cover plate
14 Aquavar® Intelligent Pump Controller INSTRUCTION MANUAL

Frame sizes B and C description

Figure 2: Exploded view of Frame Sizes B and C
1 LCP 11 Relay 2 (04, 05, 06) 2 Cover 12 Lifting ring 3 RS-485 serial bus connector 13 Mounting slot 4 Digital I/O and 24 V power supply 14 Grounding clamp (PE) 5 Analog I/O connector 15 Cable strain relief / PE ground 6 Cable strain relief/PE ground 16 Brake terminal (-81, +82) 7 USB connector 17 Load sharing terminal (DC bus) (-88, +89) 8 Serial bus terminal switch 18 Motor output terminals 96 (U), 98 (W) 9 Analog switches (A53), (A54) 19 Mains input terminals 91 (L1), 92 (L2), 93 (L3) 10 Relay 1 (01, 02, 03)
Product Description
Aquavar® Intelligent Pump Controller INSTRUCTION MANUAL 15

Installation

Installation

Installation site checklist

• The frequency converter relies on the ambient air for cooling. Observe the limitations on ambient air temperature for optimal operation.
• Ensure that the installation location has sufficient support strength to mount the frequency converter.
• Keep the manual, drawings, and diagrams accessible for detailed installation and operation instructions. It is important that the manual is available for equipment operators.
• Locate equipment as near to the motor as possible. Keep motor cables as short as possible. Check the motor characteristics for actual tolerances.
• For installations with motor leads longer than 50 feet, use the output filter option to protect the motor.
• Ensure that the ingress protection rating of the frequency converter is suitable for the installation environment. IP55 (Type 3R/12) or IP66 (Type 4) enclosures may be necessary.
CAUTION:
Ingress protection. IP54, IP55 and IP66 ratings can only be guaranteed if the unit is properly closed.
• Ensure all cable glands and unused holes for glands are properly sealed.
• Ensure that the unit cover is properly closed.
Device damage through contamination. Do not leave the frequency converter uncovered.

Frequency converter and motor pre-installation check list

• Compare the model number of the unit on the nameplate to what was ordered to verify the proper equipment.
• Ensure each of the following are rated for same voltage:
• Mains (power)
• Frequency converter
• Motor
• Ensure that the frequency converter output current rating is equal to or greater than motor service factor current for peak motor performance.
• Motor size and frequency converter power must match for proper overload protection.
• If frequency converter rating is less than motor, full motor output cannot be achieved.
16 Aquavar® Intelligent Pump Controller INSTRUCTION MANUAL

Electrical Installation

Precautions

WARNING:
• EQUIPMENT HAZARD. Rotating shafts and electrical equipment can be hazardous. All electrical work must conform to national and local electrical codes. Installation, start­up, and maintenance must be performed by trained and qualified personnel. Failure to follow these guidelines could result in death or serious injury.
• FIRE HAZARD. Consult the Brake Design Guide IM257 for details on proper installation of a brake resistor.
NOTICE:
WIRING ISOLATION. Run input power, motor wiring and control wiring in three separate metallic conduits or use separated shielded cable for high frequency noise isolation. Failure to isolate power, motor and control wiring could result in less than optimum frequency converter and associated equipment performance.
Electrical Installation
For your safety comply with the following requirements:
• Electronic control equipment is connected to hazardous mains voltage. Extreme care should be taken to protect against electrical hazards when applying power to the unit.
• Run motor cable from multiple frequency converters separately. Induced voltage can charge equipment capacitors even with the equipment turned off and locked.
Overload and equipment protection:
• An electronically activated function within the frequency converter provides overload protection in the motor. The overload calculates the level of increase to activate timing for the trip (controller output stop) function. The higher the current draw, the quicker the trip response. The overload provides Class 20 motor protection. See Warnings and alarms section for details on the trip function.
• All frequency converters must be provided with short-circuit and over-current protection. Input fusing is required to provide this protection. If not factory supplied, fuses must be provided by the installer as part of installations. See Fuse specifications section for details.
Figure 3: Frequency converter fuses
Item Description 1 Fuses 2 Ground
Aquavar® Intelligent Pump Controller INSTRUCTION MANUAL 17
Electrical Installation
Wire type and ratings:
• All wiring must comply with local and national regulations regarding cross section and ambient temperature requirements.
• It is recommended the all power connections be made with a minimum 75°C rated copper wire.
• See Power-dependent specifications for recommended wire sizes.
Earth (grounding) requirements
WARNING:
For operator safety, it is important to ground the frequency converter properly in accordance with national and local electrical codes as well as instructions contained within this document. Ground currents are higher than 3.5 mA. Failure to ground the frequency converter properly could result in death or serious injury.
NOTICE:
It is the responsibility of the user or certified electrical installer to ensure correct grounding (earthing) of the equipment in accordance with national and local electrical codes and standards.
• Follow all local and national electrical codes to ground electrical equipment properly.
• Proper protective grounding for equipment with ground currents higher the 3.5 mA must be established. See the Leakage current (>3.5 mA) section for details.
• A dedicated ground wire is required for input power, motor power and control wiring.
• Use the clamps provided with the equipment for proper ground connections.
• Do not ground one frequency converter to another in a “daisy chain” fashion.
• Keep the ground wire connections as short as possible.
• Using high-strand wire to reduce electrical noise is recommended.
• Follow motor manufacturer wiring requirements.
Leakage current (>3.5 mA)
Follow national and local codes regarding protective earthing of equipment with a leakage current > 3.5 mA. Frequency converter technology implies high frequency switching at high power. This will generate a leakage current in the earth connection. A fault current in the frequency converter at the output power terminals might contain a DC component which can charge the filter capacitors and cause a transient earth current. The earth leakage current depends on various system configurations including RFI filtering, screened motor cables, and frequency converter power.
EN/EC61800–5–1 (Power Drive System Product standard) requires special care if the leakage current exceeds 3.5 mA. Earth grounding must be reinforced in one of the following ways:
• Earth ground wire of at least 8 AWG or 10 mm2.
• Two separate earth ground wires both complying with the dimensioning rules.
See EN60364–5–54 section 543.7 for further information.
Using GFCIs (RCDs)
Where Ground Fault Circuit Interrupters (GFCIs) and residual current devices (RCDs), also know as earth leakage circuit breakers (ELCDs), are used, comply with the following:
• Use GFCIs (RCDs) of type B only which are capable of detecting AC and DC currents.
• Use GFCIs (RCDs) with an inrush delay to prevent faults due to transient earth currents.
• Dimension GFCIs (RCDs) according to the system configuration and environmental considerations.
Grounding using shielded cable
grounding (earthing) clamps are provided for motor wiring.
18 Aquavar® Intelligent Pump Controller INSTRUCTION MANUAL
Electrical Installation
Figure 4: Grounding with shielded cable

Basic electrical connection

This section contains detailed instructions for wiring the frequency converter. The following tasks are described:
• Wiring the motor to the frequency converter output terminals
• Wiring the AC mains to the frequency converter input terminals
• Connecting control and serial communication wiring
• After power has been applied, checking input and motor power; programming control terminals for their intended functions
Aquavar® Intelligent Pump Controller INSTRUCTION MANUAL 19
*
91 (L1) 92 (L2) 93 (L3)
PE
88 (-) 89 (+)
50 (+10 V OUT)
53 (A IN)
54 (A IN)
55 (COM A IN)
0/4-20 mA
12 (+24V OUT)
13 (+24V OUT)
18 (D IN)
20 (COM D IN)
15mA 200mA
(U) 96
(V) 97 (W) 98 (PE) 99
(COM A OUT) 39
(A OUT) 42
0/4-20 mA
03
0-10Vdc
+10Vdc
0-10Vdc
0/4-20 mA
240Vac, 2A
24Vdc
02
01
05
04
06
240Vac, 2A
24V (NPN) 0V (PNP)
0V (PNP)
24V (NPN)
19 (D IN)
24V (NPN) 0V (PNP)
27
24V
0V
(D IN/OUT)
0V (PNP)
24V (NPN)
(D IN/OUT)
0V
24V
29
24V (NPN) 0V (PNP)
0V (PNP)
24V (NPN)
33 (D IN)
32 (D IN)
1 2
ON
A53/S201
ON
21
A54/S202
ON=0-20mA OFF=0-10V
95
400Vac, 2A
P 5-00
(R+) 82
(R-) 81
37 (D IN)
+ - + -
130BA544.12
(P RS-485) 68
(N RS-485) 69
(COM RS-485) 61
0V
5V
S801
RS-485
RS-485
21
ON
BUS TER./S801
3 Phase power
input
DC bus
Switch Mode
Power Supply
Motor
Analog Output
Interface
relay1
relay2
ON=Terminated OFF=Open
Brake resistor
(NPN) = Sink
(PNP) = Source
Electrical Installation

Motor connection

20 Aquavar® Intelligent Pump Controller INSTRUCTION MANUAL
Figure 5: Basic electrical connection
WARNING:
INDUCED VOLTAGE. Run output motor cables from multiple frequency converters separately. Induced voltage from output motor cables run together can charge equipment capacitors even with the equipment turned off and locked out. Failure to run output motor cables separately could result in death or serious injury.
Be sure the following are adhered to:
• For maximum wire sizes see Power-dependent Specifications.
• Comply with local and national electrical codes
• Motor wiring knockouts or access panels are provided at the base of IP21 and higher (NEMA 1/12) units
• Do not install power factor correction capacitors between the frequency converter and the motor
• Do not wire a starting or pole-changing device between the frequency converter and the motor
• Connect the 3–phase motor wiring to terminals 96 (U), 97 (V), and 98 (W)
• Ground the cable in accordance with grounding instructions provided
• Torque terminals in accordance with the informations provided in Connection tightening torques.
• Follow motor manufacturer wiring requirements
Figure 6: Motor, mains and earth wiring for frame size A
Electrical Installation
Figure 7: Motor, mains and earth wiring for frame sizes B, C, and D using shielded cable
Aquavar® Intelligent Pump Controller INSTRUCTION MANUAL 21
Electrical Installation
Figure 8: Motor, mains and earth wiring for frame sizes B, C and D

Motor connection for A2 and A3

Follow these drawings step by step for connecting the motor to the frequency converter.
1. Connect the motor earthwire to terminal 99, place motor U, V and W wires in plug and tighten.
2. Mount cable clamp to ensure 360° connection between chassis and screen, note the outer insulation of the motor cable is removed under the clamp.
22 Aquavar® Intelligent Pump Controller INSTRUCTION MANUAL

Motor connection for A4 and A5

1. Terminate the motor earth.
2. Place motor U, V and W wires in terminal and tighten.
3. Ensure that the outer insulation of the motor cable is removed under the EMC clamp.
Electrical Installation

Motor connection for B1 and B2

1. Terminate the motor earth.
2. Place motor U, V and W wires in terminal and tighten.
3. Ensure that the outer insulation of the motor cable is removed under the EMC clamp.
Aquavar® Intelligent Pump Controller INSTRUCTION MANUAL 23
Electrical Installation

Motor connection for C1 and C2

1. Terminate the motor earth.
2. Place motor U, V and W wires in terminal and tighten.
3. Ensure that the outer insulation of the motor cable is removed under the EMC clamp.

AC mains connection

• Size wiring based upon the input current of the frequency converter. For maximum wire sizes, see Power-dependent specifications section.
• Comply with local and national electrical codes for cable sizes.
• Connect 3–phase AC input power wiring to terminals L1, L2, and L3.
24 Aquavar® Intelligent Pump Controller INSTRUCTION MANUAL
Electrical Installation
• Depending on the configuration of the equipment, input power will be connected to the mains input terminals or the input disconnect.
• Ground the cable in accordance with grounding instructions in Earth (Grounding) Requirements.
• All frequency converters may be used with an isolated input source as well as with ground reference power lines. When supplied from an isolated mains source (IT mains or floating delta) or TT/TN-S mains with a grounded leg (grounded delta), set 14-50 RFI Filter to OFF. When off, the internal RFI filter capacitors between the chassis and the intermediate circuit are isolated to avoid damage to the intermediate circuit and to reduce earth capacity currents in accordance with IEC 61800-3.

Control wiring

• Isolate control wiring from high power components in the frequency converter.
• If the frequency converter is connected to a thermistor, for PELV isolation, optional

Control wiring access

• Remove access cover plate with a screwdriver.
• Remove front cover by loosening attaching screws.
thermistor control wiring must be reinforced/double insulated. A 24 V DC supply voltage is recommended.
Figure 9: Control wiring access for A2, A3, B3, B4, C3, and C4 enclosures
Aquavar® Intelligent Pump Controller INSTRUCTION MANUAL 25
130BT334.10
1
4
2
3
130BA012.12
61
68
69
39
42
50
53
54
55
12
13
18
19
27
29
32
33
20
Electrical Installation
Figure 10: Control wiring access for A4, A5, B1, B2, C1, and C2 enclosures
Table 1: Tightening torques for covers (nM)
Frame IP20 Open IP21/Type 1 IP55/Type 12 IP66/Type 4X
A3/A4/A5 — — 2 2
B1/B2 — * 2.2 2.2
C1/C2/C3/C4 — * 2.2 2.2
* No screws to tighten — Does not exist

Control terminal types

Figure 11: Control terminal locations
• Connector 1 provides four programmable digital inputs terminals, two additional digital terminals programmable as either input or output, a 24 V DC terminal supply voltage, and a common for optional customer supplied 24 V DC voltage.
• Connector 2 terminals (+)68 and (-)69 are for an RS-485 serial communications connection.
26 Aquavar® Intelligent Pump Controller INSTRUCTION MANUAL
Electrical Installation
• Connector 3 provides two analog inputs, one analog output, 10 V DC supply voltage, and commons for the inputs and output.
• Connector 4 is a USB port available for use with the frequency converter.
• Also provided are two Form C relay outputs that are in various locations depending upon the frequency converter configuration and size.
• Some options available for ordering with the unit may provide additional terminals. See the manual provided with the equipment option for details and configuration.
Table 2: Terminal descriptions
Terminal number Parameter number Default setting or
Description
function
Relay outputs 01, 02, 03 5–40 Relay 1 [160] No Alarm Form C Relay output.
04, 05, 06 5–40 Relay 2 [5] Running
Usable for AC or DC voltages and either resistive or inductive loads. Refer to the relay wiring section for relay contact current and voltage ratings.
Aquavar® Intelligent Pump Controller INSTRUCTION MANUAL 27
Electrical Installation
Terminal number Parameter number Default setting or
Description
function
Digital I/O 12, 13 – +24V DC 24V DC supply
voltage. Maximum output current is 200mA total for all 24V loads. Usable for digital inputs and external transducers.
18 5–10 [8] Start Start/Stop digital
input signal for the drive. Connect input to 24V to start. Open the input to stop. This is a required connection.
19 5–11 [0] No Operation Unused digital input.
This input can be configured for use as a Pump Protect Warning or Alarm Input. See Pump Protect section to enable the Warning or Alarm associated with this input.
27 5–12 [0] No Operation Unused digital input.
This input can be configured for use as a Pump Protect Warning or Alarm Input. See Pump Protect section to enable the Warning or Alarm associated with this input.
29 5–13 [63] No Water/Loss of
Prime Restart (CMP3)
Selectable for digital input or output. Default configuration is an output that is configured for use as a No Water/Loss of Prime Restart signal. Refer to the Pump Protection section for details.
32 5–14 [1] Reset Digital input.
Configured for use as a Reset for the No Water/Loss of Prime Restart function. Refer to the Pump Protection section for details.
33 5–15 [23] SP1/SP2 Select Digital input.
Configured for use as a Setpoint 1/Setpoint 2 select (SP1/SP2).
20 – Common Common for digital
inputs and reference for 24V supply
28 Aquavar® Intelligent Pump Controller INSTRUCTION MANUAL
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