Easy User Manual R3.1 - Automated Electric Systems Ltd
Contents
1. Symptom Probable Causes Remedies Pump does not stop at Zero flow condition Pump performance curve not capable of producing the setpoint pressure Pump not at zero flow Pump has lost prime or water level in wetwell too low Pump wear Lower the setpoint check pump curve to confirm pump can exceed desired setpoint Ensure all valves are closed and pump is not supplying any leaks Check water levels and confirm pump performance at normal flow rates Pump no longer performing to original curve repair or replace pump Alarm Screens Low pressure fault High pressure fault External fault circuit open VED tripped Loss of signal from pressure transmitter Flow rates beyond pump capacity check for unusual high demands or large leaks in the system Reset and check operation If a device has been wired to the optional fault terminals check the device and it s operation See inverter monitor and resetting page 14 Check wiring from panel to transmitter Page 13 Inverter Trip codes resetting and status monitoring With the power on open the control panel door Caution Do not touch any of the internal components wiring or termination points personal injury or death could result from electric shock If the display reads 0 0 the pump is stopped and the status is normal If the display shows a steady value or fluctuating value between 0 60 the pump is running and the va2. If the pump is a close coupled end suction frame mounted end suction or multi stage centrifugal type record motor name plate data on the form provided at the back of this manual Careful attention must be given to voltage and full load amperes FLA Compare the pump motor FLA with the Maximum Full Load Amp rating of the Easy Pump Control model specifications section 1 The Easy pump control MUST have a rating equal to or greater than the motor FLA ii Prime the pump by filling any suction line and pump bowl assemblies with water to prepare for starting ii In the case of submersible pump motor units record motor data prior to installation or from the accompanying manufacturer s literature In the case of newly installed submersibles open a valve on the discharge piping for 1 hour to allow water into the pump and riser pipe 3 Startup A After following the installation instructions Place the door mounted pump control selector switch to the OFF position then apply power to the panel Open the control panel door Caution Do not touch any of the internal components wiring or termination points personal injury or death could result from electric shock The display on the inverter will read 0 0 Note The Toshiba inverter contained in your Easy Pump Control is programmed for proper operation of your pump Changes or adjustment of any operational parameters is not required and could void the warranty The only param
3. 2 With rotation correct proceed to v step 5 below iv Step 4 If you are starting a submersible pump or have a pump that does not show the direction of rotation UI 2 3 4 5 Isolate the discharge piping by closing the discharge valve or closing all valves in the system thereby allowing the pump to produce pressure in a no flow condition As described in step 1 amp 2 above run the pump to approximately 30Hz for 60 seconds and watch the pressure gauge make note of the highest pressure produced at that speed Stop the pump by pressing the DOWN arrow button on the inverter keypad until 0 0Hz Release any pressure in the piping by opening a valve Turn off the power supply to the Easy Pump Control wait ten minutes for capacitor discharge Exchange the motor lead wires connected to terminals T1 and T2 remove both wires place former T1 to T2 position and former T2 to T1 position Restore power to the panel Close any discharge valves that were opened to release pressure press the UP arrow on the keypad to operate at the same speed 30Hz as tested in item 2 above the motor will run the opposite direction of rotation Check the pressure gauge note the pressure produced Page 7 6 The direction of rotation that produced the highest pressure is the right direction Follow item 4 above if motor rotation needs to be corrected and proceed to v step 5 below v Step 5 With rotation confirme
4. Easy touch Pump Control Featuring BUILT 4 EXTREMES Inverter Technology by TOSHIBA International Corporation amp Intel Logics Inside TOSHIBA T series PLC CONTENTS SPECT CA EE Page 1 Lee EECH Page 2 2 Installation INSteucti eet cesses vane nek ieee es Page 4 GEESCHT Page 5 A HME Touch EE Page 9 NEE Ee e Page 10 AD PRESSULE SetPOlNtoss rroen derriere career venaceveddcanes Page 10 k3 HNdVanCed SCW EE Page 11 5 Trouble Shooting Guide ee Page 13 VED Trip Codes amp Resetting deeg dE E Page 14 6 Warranty Registratnon Page 15 d e VECHMICAL SUP DOP ayiee aa NEE Page 16 Wiring Diagrams Ver 3 01 05 2010 230 volt single phase input Easy touch Pump Control models 230 volt three phase input Model HP Max Amps Model HP Max Amps 2015 7 2 7 8 2037 17 5 17 5 S2022 11 3 11 2055 27 7 5 27 5 S2055 16 5 16 5 2075 33 10 33 S2075 19 7 5 19 2110 54 15 54 S2110 35 10 35 2150 66 20 66 S2150 41 10 41 460 volt three phase input 575 volt three phase input Model HP Max Amps Model HP Max Amps 4015 4 2 4 1 6015 3 2 3 4022 5 3 5 5 6022 4 3 4 4037 9 5 9 5 6037 6 5 6 4055 14 15 14 3 6055 9 7 5 9 4075 17 10 17 6075 12 10 12 4110 27 15 SR 6110 17 15 17 4150 33 20 33 6150 22 20 22 General Specifications Voltage supply Single Phase 200 240 vac 3 Phase 200 230vac 3 Phase 380 500vac 3 phase 575V Frequenc
5. T WILL CLEAR THE FAULT AND DISPLAY QUICK START SCREEN FOR REFILLING INSTRUCTIONS Sample alarm screen Alarm conditions include Low Pressure High Pressure Pressure Signal Fault VFD trip and external device fault 4 2 Setpoint _ SETPOINT Touching this button on the System Navigation screen MENU will show the pressure adjustment screen shown on next page Page 10 May 18 2010 04 33 45 PM SET OPERATING PRESSURE TOUCH THE XX X PSI FIELD FOR KEYPAD ENTRY OF NEW VALUE SETPOINT PRESSURE 00 0 PSI SYSTEM PRESSURE 0 0 PSI The setpoint operating pressure can be set and adjusted via this screen By touching the numeric PSI field a popup keypad will display where a new value can be entered Adjustment can made while pump is running or stopped Setting is in 1 PSI increments with a range of 40 100 PSI 4 3 Advanced Setup Advanced setup is a unique feature in the Easy Touch pump controller Factory default settings will operate any pump correctly when connected to the panel however user preferences for pump response and cycle duration may be manipulated using Advanced Setup The Advanced Setup screen shown next page displays two slider entry switches The yellow slider with blue setting button adjusts cycle rate and the white slider with red setting button adjusts pump response Page 11 Cycle Rate The default setting for cycle has the blue button approximately 1 4 down the slider from the lef
6. a Motor Manufacturer Horse Power Volts FLA SF RPM NEMA design Site conditions amp Startup Procedures Approximate wire length from Control to motor Wire Size Wire copper aluminum____ Installation steps followed___ Startup steps followed___ All power and control connections tight___ Pump stop at zero flow confirmed__ Motor full load amps FLA programmed into mverter see section 3 item B page 5 Please return to Automated Electric Systems Ltd Attention Warranty Department 5 3160 12 Ave North Lethbridge Alberta T1H 5V1 Fax 403 328 3882 Page 15 7 Technical Support Full technical support can be accessed by contacting Automated Electric Systems Ltd 8 00 AM to 5 00 PM MST Ph 403 328 4400 Toll Free 1 888 328 4408 Fax 403 328 3882 www automatedelectric com Page 16
7. ault light External closed loop fault circuit for connection of a low water float switch high water float switch low temperature alarm etc see diagrams Terminals labeled EXT F The connected power supply must have the correct voltage and capacity for the model as shown in the specifications Never connect power to the output motor terminals T1 T2 T3 as this will destroy the inverter Pressure sensor must be located on the discharge piping as shown on the typical installation drawing Pressure sensor cable may be extended when required provided a two conductor 18 AWG shielded cable is used and correct polarity is observed Pressure sensor cable must be run separately from all other wiring Connect three phase wiring from T1 T2 T3 terminals to the pump motor complete with required grounding Ensure correct wire sizing for motor load current In the event of long cable lengths from the controller to the pump motor ensure the wire size is large enough to compensate for voltage drop and does not require a load reactor see specification notes page 1 i Danger Equipment will be damaged or personal injury may result if lightning arrestors power factor capacitors or surge capacitors are connected to the load terminals T1 T2 T3 of the Easy Pump Control Page 4 Before applying power to the Easy Pump Control the connected pump and motor must be installed and plumbed according to the manufacturer s specifications i
8. d Open valves in the discharge piping then use HAND and UP arrow to run the pump at 35Hz to fill all plumbing lines and fixtures In cases where high elevation lift from the pump location to point of water use is experienced speed will need to be increased gradually until water reaches the highest point With the system fully charged with water close the valve s and increase pump speed to raise system pressure to 40 PSI Then stop the pump with the DOWN arrow button If pressure holds panel is ready for AUTO operation Move the door selector to the AUTO position The Easy Pump Control will operate the pump to maintain a constant discharge pressure at any flow rate within the pump s capacity At a zero flow condition the pump will come to a stop restarting automatically when water demand returns Important With the pump running in AUTO close all valves to provide a zero flow condition to confirm a pump stop If the pump does not stop at zero flow go to Trouble Shooting section 5 page 13 Page 8 4 HMI Touch Screen May 18 2010 01 57 17 PM PUMP READY STOPPED PUMP HOURS 0 HRS 00 MIN SYSTEM PRESSURE 0 0 PSI 0000 RPM _MENU _EVENTS Above is a display of HOME screen Information includes current date amp time pump status pump hour meter present pressure in the system setpoint pressure and pump speed After 30 minutes of no activity screen saver turns off the backlight to reactivate simply touch the blan
9. e inverter from a tripped condition After recording the trip condition and taking corrective action the drive can be reset by pressing the door mounted reset button or pressing the inverter keypad STOP button twice Page 14 6 Warranty Registration Terms and conditions The Easy Pump Control is manufactured by Automated Electric Systems Ltd and is made with the highest quality components strict quality control during assembly and full factory testing of each unit before shipping The Easy Pump Control is warranted for a period of 12 months from date of purchase The warranty shall extend to the repair or replacement of any component found to be defective during this time Warranty does not extend to cover costs for damage or injury resulting from component failure Warranty does not include labor or expenses incurred in the replacement of any component found to be defective Warranty will not extend to the mistreatment application or abuse of products supplied as determined by Automated Electric Systems Ltd Registration Complete and return the following registration form within 30 days of purchase and Automated Electric Systems Ltd will extend your warranty by 6 months for a total of 18 months at no extra charge Name Address City Province State Postal Code Zip Phone Email optional Easy Pump Control Model Number Serial Number Date of purchase Date of Startup Pump Manufacturer Model Motor Name Plate Dat
10. e the correct voltage and capacity for the model as shown in the specifications Compare the pump motor FLA with the Maximum Full Load Amp rating of the Easy Pump Control model specifications page 1 The Easy pump control MUST have a rating equal to or greater than the motor FLA Never connect power to the output motor terminals T1 T2 T3 Permanent damage will result Pressure sensor cable may be extended when required provided a two conductor 18 AWG shielded cable is used and correct polarity is observed Page 2 The pump connected to the Easy Pump Control must have a performance curve capable of exceeding the maximum desired setpoint pressure When evaluating the pump curve compatibility for setpoint pressure be sure to include all site conditions affecting the pump s performance such as NPSH maximum suction lift total well drawdown etc If unsure record the pump brand and model number call tech support for curve specifications Failure to confirm compatibility will result in permanent pump damage General Precautions Never disassemble modify or repair This can result in electric shock fire and injury For repairs call Tech Support Never remove the front cover when power is on or open door if enclosed in a cabinet The unit contains many high voltage parts and contact with them will result in electric shock Don t stick your fingers into openings such as cable wiring hole and cooling fan co
11. eter that must be field set is the motor full load current This parameter must be programmed at time of installation and prior to startup The electronic thermal overload protection for the pump motor will not function and motor damage can result if the procedure described below is not carefully followed Page 5 i Step 1 Press the MODE button display will show AUH This is the display for the first basic parameter ii Step 2 By pressing the UP or DOWN arrow buttons scroll the display until the tHr parameter is displayed tHr is the parameter that must be programmed with motor current if you pass this parameter while using the arrow buttons you can get back to it by using the opposite arrow iii Step 3 With the tHr parameter shown on the display press the ENT button The display will change to show the full output amp capacity of the inverter iv Step 4 Using the DOWN arrow change the value to the motor FLA you have recorded The UP arrow can be used if the correct number is passed v Step 5 With the motor FLA shown on the display press the ENT button The unit will accept the new value by flashing the tHr and FLA alternately twice Example You have an Easy Pump Control model 2055 27 and your pump motor FLA is 19 6 amp You will find the factory default value of 27 5 in the tHr parameter Using the arrows change the value to 19 6 and press ENT Display will flash tHr and 19 6 vi Step 6 Press the MODE b
12. k screen Buttons EVENTS Touching this button will access a data log of station activity complete with time amp date stamp The data is stored in a flash memory area of the HMI meaning it is retained even on power down MENU Touching this button will access the navigation screen to information and user input areas of the processor Most areas are fully self explanatory on the respective screens displayed Further details for the ALARMS and SETPOINT buttons follows Three LED indications at the top of the HMI ALM red Flashing alarm condition in memory access alarm management to clear see 4 1 below COM green Off no communication established On communication normal Flashing communication error exists PWR orange On power applied Page 9 4 1 Alarms Touching this button on the System Navigation screen ALARMS MENU will show an alarm management screen An alarm condition that has been corrected can be cleared with an ACCEPT button at the bottom of the management screen This will also clear it from the notification banner on home screen All alarm conditions will cause a full screen notification with cause and corrective measures Once corrected the alarm management screen must be accessed to accept the alarm which removes it from the bottom banner of home screen THE PUMP CONTROL HAS BEEN SHUTDOWN DUE TO A LOW PRESSURE CONDITION BEFORE RESETTING TURN PUMP SELECTOR TO OFF Toa RESE
13. lue is a speed display of hertz Hz in normal operation If the inverter is in a tripped condition refer to the table below Display Problem Causes OC Overcurrent during accel Pump load change causing excess current OC2 Overcurrent during decel Check pump and motor for wear or damage OC3 Overcurrent during run OCA Arm overcurrent Contact Tech Support if OCA OCL Load overcurrent OPI Overvoltage accel System supply voltage may be fluctuating OP2 Overvoltage decel Pump motor is generating voltage because of OP3 Overvoltage run water spinning the pump Input line reactor may be required OLI Inverter overload A seized or hard turning pump and motor shaft OL2 Motor overload restart attempted after very short power fail EPHO Output phase failure Check motor and wiring for open phase load EPHI Input phase failure Check incoming power supply OH Overheat Inverter too hot check temp and fans if equip UPI Undervoltage trip Incoming voltage too low EF2 Ground Fault trip A phase to ground fault in load wires or motor E Emergency stop Keypad stop button pressed twice to halt inverter Err2 Main RAM fault Contact Tech Support in the event of these faults Err3 Main ROM fault Err4 CPU fault Err5 Remote comm Error EEP1 EEPROM fault Remove power for 120 seconds then restore If inverter does not recover from the error contact Tech Support Resetting th
14. setting range is adjustable from 40 100 PSI custom ranges available at no extra charge when specified at time of order Load reactors may be required where long cable lengths exist from the controller to the pump motor 230V gt 1 200 ft 460V gt 400 ft 575V gt 120 ft Specifications subject to change manufacturer reserves the right for product alterations and or improvements Page 1 Thank you for your purchase of the Easy touch Pump Control The Easy touch Pump Control is manufactured by Automated Electric Systems Ltd and is made with the highest quality components strict quality control during assembly and full factory testing of each unit before shipping The industry proven quality devices together with Intel Logics is your assurance of Easy installation and startup with years of trouble free operation 1 Safety Precautions Thoroughly read this manual to understand the installation and operation of your Easy touch Pump Controller Controller must be wired by a qualified Electrician Observe all National and Local electrical codes for wiring installation Ensure proper grounding in accordance with the codes Mount the panel at an elevation that places the touch screen HMI at eye level After mounting check all internal electrical connections Terminations may loosen during shipping Connect all field wiring to the terminal strip as shown on the wiring diagram The connected power supply must hav
15. t After a pump stop at no flow a 10 PSI drop is required before restart Moving the button further left will lengthen pump run time at low flow If the nature of your system has extended periods of time where small flows are used the 10 PSI pressure change can be avoided by keeping the pump running longer Moving the button right will shorten pump run time at low flows thereby increasing start stop cycles You should be aware that your VFD controlled pump is in no way adversely affected by repeated short cycles Hydraulic stresses to mechanical equipment and motor heating are eliminated with use of the VFD Response Rate The default setting for response has the red button approximately 1 3 down the slider from the left A faster response of pump speed to changes in flow rate can be set by moving the button further left Doing so will result in some pressure overshoot when flow rate drops quickly or stops suddenly Left side settings are best suited for accurate pressure control at higher flow rates with decreasing demands done in a gradual manner Moving the button right substantially reduces any pressure overshoot Right side settings work well for lower flow rate demands and is ideal for dampening the effects of speed changes on large horse power or high capacity pump curves After changing settings always test the pump system by running some normal demand rates to confirm satisfactory operation Page 12 5 Trouble Shooting Guide
16. utton twice to return to standard frequency monitor display The inverter display will show 0 0 Motor rotation check With the control panel door open switch the door mounted selector to the HAND position Whenever the selector is placed to HAND the inverter is controlled by the UP and DOWN arrow buttons of the keypad on the face of the inverter i Step 1 Using the UP arrow increase pump speed to 20Hz ii Step 2 In Hand with 20Hz flashing on the display the pump motor will be turning at approximately 30 of full speed Check the direction of motor rotation Then use DOWN arrow to decrease speed to 0 0Hz followed by the ENT button to stop the 0 0 from flashing Page 6 2 3 If rotation is correct for the pump as indicated go to v step 5 below If rotation is incorrect go to iii step 3 below If the pump shaft is not visible rotation direction is not indicated or your pump is a submersible go to iv step 4 below iii Step 3 Change pump rotation to the correct direction when incorrect rotation has been observed UI 2 Press the stop button on the inverter keypad wait for pump to stop and turn off the power supply to the Easy Pump Control wait ten minutes for capacitor discharge Exchange the motor lead wires connected to terminals T1 and T2 remove both wires place former T1 to T2 position and former T2 to T1 position Restore power to the panel and recheck rotation as described in ii step
17. vers This can result in electric shock or other injury Don t place or insert any kind of object into the inverter electrical wire cuttings rods wires This can result in electric shock or fire Do not allow water or any other fluid to come in contact with the inverter This can result in electric shock or fire Page 3 2 Installation A Install the Easy touch Pump Control in a location suitable for NEMA 1 electrical equipment NEMA 1 locations are indoors dry free of high concentrations of dust dropping or spraying water Mount the panel at an elevation that places the touch screen HMI at eye level Wiring must be performed by a qualified electrician see Safety Precautions Note i Care must be taken when drilling holes for conduit and cable entries metal filings must not fall into the electrical components and should be thoroughly cleaned up after drilling is complete Failure to do so can result in voided warranty equipment failure and electric shock or fire hazard ii Power supply conductors and motor load conductors must not be contained in or share the same conduit or cable Connect all field wiring to the terminal strip as shown on the wiring diagram i Minimum Easy Pump Control connections include grounding power supply L1 L2 L3 motor supply T1 T2 T3 and pressure sensor 24VDC SIGNAL and Shield ii Optional wiring includes a no voltage remote alarm contact two terminals labeled FLT L f
18. y 50 60Hz Tolerance Voltage 10 15 continuous operation Frequency 5 Control system Sine Wave PWM system and Intel Logics micro PC Overload Rating 150 FLA for 60 seconds Frequency Setting signal 0 10vdc pressure sensor included face mounted speed knob hand operation Carrier Frequency Preset at 2kHz Accel Decel Automatically adjusted for pumping demands Retry Operation Preset to 3 retry attempts for non critical faults Protective Functions Overpressure underpressure stall protection current limit output short circuit over voltage under voltage ground fault output single phase overload protection by electronic thermal setting over heat_and optional external fault circuit Power Failure Auto reset after power failure Keypad Seven segment four digit LED Displays inverter output frequency running and faults Installation Indoor 3300 feet altitude without derating protect from corrosive amp explosive gases Ambient Temperature 0 to 40 degrees C 32 to 104 degrees F Humidity 95 non condensating Pressure setting Range 40 100PSI adjustable on color touch screen HMI Dimensions Enclosure 24x20x10 inches 610x508x254 mm Approval Canadian Standards Association CSA as industrial motor control assemblies Notes Select Easy Pump Control model based on Maximum Amp capacity not horse power rating Standard pressure
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