This manual explains the features and operations of
Contents
1. Input Range 7 3 38400 57600 76800 115200 BAUDRATE 485 00 4800 9600 14400 19200 ADDRESS Slave Address when you set the remote 5485 CODE Characteristic numbers and communication code when 5232 control 3 2 10 Communication Setup SCHEDULE OPERATION This function allows the set pressure to be NOT USED TIMELY WEEKLY 00 00 00 00 00 00 adusted based on schedle If on certain days MONTHLY PROGRAM of the week you wanted the set pressure to be TUESDAY different you would set schedule operation to TEN WEEKLY then set the pressures for the days of the week SJE Rhombus VFDC 4100 Controller User Manual 13 3 3 Setup Menu Display amp Input Method Example for the Data Setup Change PUMP SET PRESSURE CONTROL SENSOR VFD PROTECT SYSTEM PROGRAM COMM SET ALARMS DATA LOG lt Fig 1 gt Menu Setup Screen 4 0 RUN 12 22 WED 11 00 00 lt Fig 2 gt Data Setup Change Screen 4 0 RUN 2005 12 22 11 00 00 lt Fig 3 gt Date Setup Change Screen 1 The display will change to lt Fig 2 gt if you press the enter button after selecting the Date Time on the Menu Setup lt Fig 1 gt 2 Moved to the set position which needs to be changed Year Month Day Week by Right amp Left key Press the Enter key and edit when flashing 3 Change the value by using the Up Down keys 4 Save the change2. dy gt des Output Actions 6 1 5 1 HOA VFD 2 HOA VFD etc Opr Pre 58 PSI P1 HOA FLT Cause Set Pre 60 PSI 00 00 00 2 Fly Reset AS E output Actions SJE Rhombus VFDC 4100 Controller User Manual The discharge pressure was higher than the HIGH Limit Pressure while the system was operating Auto reset clear The discharge pressure drops below the High Limit Pressure and the system has stopped LCD Display ERROR LED BUZZER Please check the pipe and system The discharge pressure was less than the Low Limit Pressure while the system was operating Indicative of a broken pipe If the discharge pressure rises above Low Limit Pressure before the Low Pressure Alarm the pumps will not stop If not the pump stop and will require a manual reset LCD Display ERROR LED BUZZER Please check for broken pipes and leaks The system will stop if the alarm is active for longer than the set time refer to 3 2 4 Press RESET to clear this fault Low suction pressure was detected by a pressure switch optional on suction piping present while the system was operating If LOW SUCTION RST is set to MANUAL the RESET button must be pressed to clear the alarm If set to AUTO the alarm will clear itself based on the LOW SUCTION RST TMR LCD Display ERROR LED BUZZER Please check the suction pressure piping low water level wiring and change the low water level sensor The system
3. lt SI El f gt ol al Al Al U LOW SUCTION AUXILARY ALARM PRESSURE TRANSDUCER 0 200PST 1 4 20 NPT 18 SJE Rhombus VFDC 4100 Controller User Manual 4 4 Typical Triplex Contorller Circuit Schematic OPER 1VFD ATL VF DC 4100 VFD1 1 ANALOG IN _ RS 2320 1E sia CN1 DA COM 5 ANALOG COMMON CN11 L O VFD READY FAULT pes a TO VFD ANALOG COMMONS FOVARD START 5 1 2 3 S al MIAZ MA a I T Tro PRESSURE TRANSMITTER 0 200 PSI 4 20 mA INPUT COMMON 1 2 LOW SUCTION INPUT PUMP1 0 24V GND H VFD1 00X At I I C1 24 READY FAULT 0 H 7 120VAC H 120VAC PUMP1 ATL _ DOX PUMP1 PUMPS MIA MPS1 H PUMP1 NFD Y PUMP2 AL 24N Y N M2A _ 2 2 2000 PUMP2 VFD 8 TB1 ALARM AUXILIARY M2B 4100 PARAMETERS CHANGED FROM DEFAULT VALUES PUMP3 ATL E LOW SUCTION TIMER 30 SEC UN SETIN RESET TA o FS M3B DUTPUT RELAY 5 GENERAL ALARM 55 re ER OUTPUT RELAY 6 P1 VFD RUN VED _ OUTPUT RELAY 7 P1 ATL RUN VFD STOP TIME 30 SEC HIGH PRE LIMIT 95 PSI OUTPUT RELAY 8 P2 VFD RUN VFD MINIMUM RATE 50 4 7 77 LOW PRE LIMIT 15 PSI OUTPUT RELAY 9 P2 ATL RUN 607 START LEAD PRESS 3 PSI OUTPUT RELAY 10 P3 VFD RUN ME EE ee START LAG PRESS 7 PSI OU
4. 2 17 4 3 Triplex VFD Power Circuit Schematic 1 0 18 4 4 Triplex Controller Circuit Schematic 1 19 Chapter 5 5 1 Troubl shoobma useiusuvaadmimett de 20 Chapter 6 6 1 Fault Alarm Display amp Corrective Actions 21 6 2 Alarm Data 7 22 6 3 Operation Data Log Screen Run TIMES 22 ModBus Communication Functions amp Adress 24 Serial Cable for RS232 26 SJE Rhombus VFDC 4100 Controller User Manual Chapter 1 1 1 Controller Description lt Front View gt Pre 60 0 PSI 2004 12 12 Set Pre 58 0 PSI 00 00 00 LCD Screen PUMP 1 0 2 PUMP 3 PUMP 4 ALARM 5 e LED Indicators ED SEDO 922 Push Buttons lt Rear View gt CN10 amp 11 COMM Ports CN1 Annalog Speed CN2 Sensor Terminal Refs CN8 Low Suction Set CN7 Fault Inputs CN5 Relay outputs CN4 DC Input Power 2 SJE Rhombus VFDC 4100 Controller User Manual Chapter 2 2 1 Description of Functions LCD Display The LCD Display is a user friendly operator interface with 240 x 64 pixels resolution it allows the user to quickly view the system status and log Multiple Pumps Parallel Operation The con
5. ERROR FLAG Error Flag AD 03 70 OE 00 01 CH CL TIME AD 03 80 01 7 00 01 CH CL SETUP VFD SETUP AD 03 81 01 5 00 01 CL PRESSURE AD 03 82 01 60001 CH CL SETUP 24 2 E MA J o 2 lt TI lt O O lt D 3 CONTROL SETUP SENSOR SETUP VFD SETUP PREVENTION SETUP ERROR COUNT AD ADDRESS _ Description Address Hex Scaling SP Set Pressure x 10 gt Hex value change CH CRC HIGH CL CRC LOW SJE Rhombus VFDC 4100 Controller User Manual 25 Serial Cable for RS232 Communications with the VFDC 4100 9 PIN Male PC 9 PIN Male VFDC 4100 26 SJE Rhombus VFDC 4100 Controller User Manual ONE YEAR LIMITED WARRANTY SJE RHOMBUS warrants to the original consumer that this product shall be free of manufacturing defects for one year after the date of purchase During that time period and subject to the conditions set forth below SJE RHOMBUS will repair or replace for the original consumer any component which proves to be defective due to defective materials or workmanship SJE RHOMBUS ELECTRICAL WIRING AND SERVICING OF THIS PRODUCT MUST BE PERFORMED BY LICENSED ELECTRICIAN THIS WARRANTY DOES NOT APPLY A to damage due to lightning or conditions beyond the control SJE RHOMBUS to defects or malfunctions resulting from failure to properly install operate or maintain the unit C to failures resulti
6. User Manual 4400 Pre 50 0 2004 12 12 Set Pre 58 0 00 00 00 ta Tx LA z PUMP 1 PUMP 2 PUMP 3 PUMP 4 ALARM FEES 60 This manual explains the features and operations of the VFDC 4100 controller which is specifically designed for Pressure Booster Pump Systems The VFDC 4100 controller is capable of maintaining a constant discharge pressure by adjusting the speed of up to 4 Variable Frequency Drives VFDs one VFD and up to 3 across the line ATL starters or one Jockey pump and up to 3 main pumps AN WARNINGS Failure to read and understand the information provided in this manual may result in personal injury or death damage to the product or product failure Please read each section in its entirety and be sure you understand the information provided in the section and related sections before attempting any of the procedures or operations given Failure to follow these precautions could result in serious injury or death Keep these instructions with warranty after installation This product must be installed in accordance with National Electrical Code ANSI NFPA 70 so as to prevent moisture from entering or accumulating within the controller housing INIA LA ELECTRICAL SHOCK HAZARD Disconnect power before installing or servicing this product A qualified service person must install and service this product according to applicable electrical codes and electrical schem
7. the pump DI FR Menu Navigation and Data Entry Pressing the menu button will enter the main setup menu items The system will ask for a password if enabled Using the arrow buttons navigate to the item desired and press enter Navigate with the arrows and enter the item of choice to display its value Enter to change the value using the arrow buttons and again press the enter button to accept the new value or press esc to exit without saving Press the esc enter and arrow buttons as desired to move up drill down and navigate the screen as needed 8 SJE Rhombus VFDC 4100 Controller User Manual 2 5 Description of LCD Screen 2 5 1 Opening Screen PRESSURE BOOSTER CONTROLLER PCB 4000 VER 1 05 Opening Screen when the controller power is turned on the opening screen will be displayed for 3 seconds 2 5 2 Main Screen L Lead Pump 1 Current amp Set Pressure Display Pre 58 PSI 2004 12 42 2 Alarm amp Time Display Set Pre 60 PSI 09 00 00 fu P2 P3 P4 ae 22 y ES ES 6 Pump Number Display 3 Auto Stop Display 5 Pump Status Display 4 Output Frequency Display 0 100 0 60 2 1 Opr Pre current discharge pressure amp Set Pre set pressure Target pressure 2 Alarm amp Time Display Display of the current time and alarm list if an alarm is active 3 Auto Stop Display Display of the operating condition of the system AUTO Is in AUTO if any of the HAND OFF AU
8. 1317 Fax 218 847 4617 www sjerhombus com NOTES 28 SJE Rhombus VFDC 4100 Controller User Manual NOTES SJE Rhombus VFDC 4100 Controller User Manual 29 LIG 22650 County Highway 6 PO Box 1708 Detroit Lakes MN 56502 USA 1 888 DIAL SJE 1 888 342 5753 Phone 218 847 1317 Fax 218 847 4617 www sjerhombus com OSJE Rhombus 11 14 10369126
9. is programmed to perform adjustable Proportional Integral and Derivative control to provide consistent and reliable pressure control LCD Screen Saver The back light of the LCD display is programmed to automatically fade out if the keypad 1 not used for set time This function allows for maximum life span of the LCD monitor This function can be disabled if desired Jockey Pump Function The role of the Jockey pump is to maintain constant pressure during low flow conditions When utilized the jockey pump is typically much smaller than the main pumps is well suited to handle variations in flow at low flow rate When flow demand exceeds the capacity of the Jockey pump and the main pumps are called to run the Jockey will turn off after programmable delay time minimizing wear on the small pump Pre Charge Function In systems that drain out when not running the pre charge function allows for filling the piping system without causing damage This function allows for the lead pump to run at low preset speed for preset time prior to switching over to full automatic operation This greatly reduces water hammer to the piping system 2 2 Security The security system is designed to prevent access by unauthorized persons to the setup menu without entering user password If this function is turned on in the protect menu you will be required to enter the password to gain access to the setup screens When you press the Menu button
10. terminals HIGH LIMIT ALARM If the discharge pressure exceeds this value the 3 PSI 719 PSI Pre LOW LIMIT ALARM If the discharge pressure drops below this value 1 PSI 649 PSI PRESSURE the contoller will shutdown the pumps after delay SETUP START LEAD PRESSURE If the set pressure is 60 PSI and start lead 65 PSI 65 PSI pressure at 3 PSI the lead pump will start when the operating pressure drops below 57 PSI START LAG PRESSURE If the set pressure is 60 PSI and start lag 65 PSI 65 PSI pressure is 7 PSI the lag pump s will start when if lead pump is operating full speed 100 and the system pressure drops below 53 PSI STOP LAG PRESSURE If the set pressure is 60 PSI and the stop lag 0 PSI 65 PSI pressure is 3 PSI the lag pump will stop if it is operating at minimum speed example 50 and the current pressure is over 63 PSI PP Value Setup of PID Proportional 0 200 P Value Setup of PID Integral 0 200 3 2 4 Control Setup D Value Setup of PID Derivative 0 200 CYCLE TIME Sampling time of PID Control 0 999 m sec ALTERNATION Shifts the lead to the next available pump in the 0 999 HOURS set to 0 for sequence lead Change every cycle set to 999 for no alternation CONTROL Delay time after the main pump starts SET UP OPERATION TYPE Sets the operation type VFD multiple VFD VFD 1VFD ATL control system 1 VFD for each pump 1VFD ATL Single VFD control system combination of 1 VFD star
11. the password pop up window will appear You must enter your user password to access the setup menu screens Set the password in the password function under the protect menu item by using the up down amp right left key and press the enter button The password must consist of 4 numbers After entering the password and exiting the setup menu access to the setup screens will be locked The password will then need to be re entered to access the setup screens SJE Rhombus VFDC 4100 Controller User Manual 5 2 3 Default Values Menus SetupMenus Default inputRange Jo seo Jo fom SET UP PRESSURE SET UP pva 7 gt CONTROL SET UP m Jwmwm SENSOR SET UP 10 90 of VED DISP TYPE VED 100 60H PIPE FULL RATE 10 90 of VFD DISP TYPE or VFD PIPE FILL TIMER 30 SECONDS 5 600 SECONDS 6 SJE Rhombus VFDC 4100 Controller User Manual 2 Default Values PROTECT TESTCODE 10 0 9999 NOTUSED gt AVAILABLE SETTINGS FOR OUTPUTS NOT USED PUMPS STOPPED PUMPING SYSTEM GENERAL ALARM LOW SUCTION P1 P4 VFD RUN P1 P4 ALT RUN BUZZER LOW PRESSURE HIGH PRESSURE VFD14 FLTIHOA SENSOR FAULT SCHEDULE OPERATION NOT USED NOT USED TIMELY WEEKLY MONTHLY PROGRAM 00 00 00 00 00 00 NOT USED 0 PSI 650 PSI TUESDAY NOT USED 0 PSI 650 PSI FEBRUARY NOT USED 0 PSI 650 PSI BAUDRATE 232 9600 bps 2400 4800 9600 14400 19200 MM JE B
12. will stop if the alarm is active for longer than the set time refer to 3 2 4 Press RESET to clear Low suction signal must not be preset to clear alarm 3 2 4 Press Cancel to reset and Run Stop to run the system again The pressure sensor has failed shorted or opened The sensor is normally operating LCD Display ERROR LED BUZZER Please check the connection to the pressure sensor and replace if necessary Press Run Stop to run the system after the sensor is replaced HAND OFF AUTO HOA selector switch is not in the AUTO position or the VFD Error Signal was present while the system was operating Error signal was cleared after VFD reset and the system has stopped LCD Display ERROR LED BUZZER Please check that the HAND OFF AUTO switch is in the AUTO position check the wiring to the controller input CN7 and VFD parameter 21 6 2 Alarm Data Screen Alarm Data Screen View Acknowledgement Method The system is able to record total 32 data Records and displays the alarm sequentially by Number Date Alarm Occur times and alarm type ALARM DATA 0 0 RUN 1 04 12 15 14 16 4 SENS OPEN 2 04 12 15 14 16 2 LOW PRESS 3 04 12 15 14 16 1 LOW WAT ST UP DOWN KEY Scroll the list each 1 line 6 3 Operation Data Log Screens and Run Times To access the Operation Data Data Log or the Run Times go to the Menu Setup screen DATE TIME PUMP SET PRESSURE Use the UP DOWN and RIGHT LEFT keys to go to the Data Log CONTROL
13. CD monitor and records the condition in a log that is date and timed stamped Operating Data Display and Storage The semi permanent operating data recording and storage for each pump allows efficient pump maintenance 4 SJE Rhombus VFDC 4100 Controller User Manual Prevention When this function is enabled the lead pump will automatically start at the VFD minimum output for 30 seconds and then shift to the next pump when the temperature is under 32 deg This will occur when all pumps are stopped for more than 30 seconds at the same time Idle Prevention If the lead pump does not run for the set time corrosion of some parts may occur In order to prevent this the system will automatically run the lead pump at the minimum operating speed for 60 seconds and then starts the next pump sequence The same process will be repeated if the succeeding lead pump does not run during the set time Password If the password function Is enabled pop up window will appear when you press the MENU button You must enter your password to access the setup screens This is to prevent access to the input values by an unauthorized person You can change or disable the user password if you wish however once enabled you must remember the value to gain access to the setup menu Communication It is possible to monitor the system remotely when connected via the RS 232 port See page 24 for details PID Control The microprocessor based controller
14. It is strongly recommended to change the password after the initial access If you set the system control to factory default setting the password is initialized to the default pass word 71234 NOTE The password feature is disabled by default 3 2 Details of Setup Menus 3 2 1 Date Time Setup Current Time Setup Menus Setup Menu Contents ImputRamge DATE TIME MINUTE Current Minute Display SECOND Current Second Display The time and date does not change should you set the set system to factory default 3 2 2 Pump Setup Menus SetupMenu Contents PUMP SETUP PUMP 4 Used or Not Used Used Not Used The lead pump must be set to a pump that is USED and not the Jockey pump If PUMP1 is set to JOCKEY the Jockey pump will always start first and cannot be the LEAD PUMP The jockey pump is not included in the lead lag sequencing The jockey pump will operate alone unless the set pressure cannot be main tained Then the lead pump and subsequent pumps will start based on lead lag sequencing The jockey pump will stop after the lead pump starts and preset delay times out JOCKEY STOP DELAY 10 SJE Rhombus VFDC 4100 Controller User Manual 3 2 3 Pressure Setup Contents Input Range SET PRESSURE Target pressure for the pump system discharge 2 PSI 650 PSI SET PRESSURE 2 To change the set pressure to this alternate 2 PSI 650 PSI value dry contact must close between G COM and 018 on the CN8
15. LPS Low Pressure Stop 12 23 14 43 33 0 0 1P 0 S0p Sensor Open 12 23 14 43 33 0 0 1P 0 Sap Sensor Shortage 12 23 14 43 33 0 0 1P O LWS Low Water StopRecords when power is supplied Displays as 12 23 14 43 33 0 0 0 Records when the system operation starts Displays as 12 23 14 43 33 0 0 1P O RUN Records when the system operation stops Displays as 12 23 14 43 33 0 0 1P 0 STP 1 RUN TIMES OPERA DATA 0 0 RUN P1 10 HOURS 42 MINS 47 MINS 41 MINS 0 MINS P2 10 HOURS P3 2 HOURS P4 0 HOURS record of each pump run time is logged on this screen SJE Rhombus VFDC 4100 Controller User Manual ModBus Communication Functions amp Address Code Functions Desoription Address heg _ SYSTEMON SystemRun AD10700D000100010HOL SYSTEMOFF _ System Off AD10700D00010001CHOL t SetPressure 108201 0001008PCHOL 2 Over Pressure 108202 000100SPCHCL Z o o o o PRESSURE 3 LowPressure AD108203 0001008POHOL gt gt SETUP 4 RunPressure 108204 000100SPCHCL O Z o o o 5 Sub Run Pressure AD108205 000100SPCHCL Z o Z o o 6 Sub Stop Pressure AD108206 0001008POHOL VFDiRunSeup VED run setup PUMP RUN A SETUP VFD3 Run Setup 0x04 VFD3 run setup VFD4 Run Setup 0x08 VFD4 run setup CURRENT PRESSURE AD 03 70 0B 00 01 CH CL Current Pressure x 10
16. SENSOR VFD vienu PROTECT SYSTEM PROGRAM COMM SET ALARMS DATA LOG Menu Setup Screen DATE TIME PUMP SET PRESSURE CONTROL SENSOR VFD Press ENTER button to open the Data Log Menu PROTECT SYSTEM PROGRAM COMM SET ALARMS DATA LOG Use the A or keys to select between OPERA DATA AW RUN TIME Enter to display 22 SJE Rhombus VFDC 4100 Controller User Manual 6 3 1 Operation Data Log Screen It is able to record total 2000 data Records and displays in the following format Month Date Hour Minute Second Current Pressure Lead Pump Current Output and Condition OPERA DATA 0 0 RUN 12 24 12 24 12 24 12 24 12 24 12 24 13 24 08 13 29 39 13 32 39 13 43 39 13 42 21 13 55 21 78 77 78 78 48 40 RUN UP DOWN KEY Scroll the list each 1 line RIGHT LEFT KEY Scroll the list each 60 lines 6 3 2 Records List Records regularly while operating Set the system when the system is operating Records regularly based on the Operation Data Interval set value 12 23 14 43 33 0 0 1P 0 Records when an alarm occurred 12 26 14 43 33 0 0 1P 0 Hip High Pressure Alarm 12 23 14 43 33 0 0 0961 Low Pressure Alarm 12 23 14 43 33 0 0 0961 Low Water Alarm 12 23 14 43 33 0 0 1P 0 l1E VFD 1 Error 12 23 14 43 33 0 0 1P 0 2 VFD 2 Error 12 23 14 43 33 0 0 1P 0 3 Error 12 23 14 43 33 0 0 1P O I4E VFD 4 Error 12 23 14 43 33 0 0 1P O
17. TO selector switches in AUTO position Input STOP is displayed if none of the HAND OFF AUTO selector switches are in AUTO position 4 VFD Output Frequency Display Display of the output value of the VFD running The VFD output display can be configured in percentage 90 or in frequency 50Hz or 60 2 5 Pump Status Display Idle Running VFD Fault or Jockey 6 Pump Number Display of the total pumps and Lead pump and numbers The Lead pump is labeled L the other pumps are labeled SJE Rhombus VFDC 4100 Controller User Manual Chapter 3 3 1 Security The security system is programmed to prevent access by unauthorized persons to control setup without User Password lt PASSWORD INPUT gt INPUT PASSWORD o op lt Password Input Screen gt 04 12 01 Ver 1 03 When you press the MENU button the password pop up window will appear as shown in the figure above You must enter your user password 1234 to access the menu items screen e Set the password by using the Up Down Right Left Key and press the Enter button e The password must consist of 4 numbers e The default User Password is 1234 NOTE After entering the password access to the setup screen will be granted until the LCD backlight timer times out The password will then need to be re entered to access the setup screens If you don t give any controls on the Setup Menu Screen it will automatically return to the Main Screen
18. TPUT RELAY 11 P3 ATL RUN STOP LAG PRESS 3 PSI SJE Rhombus VFDC 4100 Controller User Manual Chapter 5 5 1 Troubleshooting Troubles Major Cause Pump air locked Check valve back flow defective Insufficient pump capacity Bad connection to the pressure transducer The infiltration of foreign object into the pump Broken coupling Pump reverse rotation The discharge valve closed Air infiltration into the discharge pipe Discharge pipe crack low pressure alarm condition Damage on the pressure transducer Incorrect VFD stop rate Increase VFD stop rate Bad connection to the pressure transducer Connect the pressure transducer hose Pump does Defective pressure transducer Compare pressure gauge to transducer replace if necessary not stop Check valve back flow Consult your mechanical contractor Pump repeats Abnormal air pressure tank Consult your mechanical contractor start and stop too Insufficient pressure tank capacity Consult your mechanical contractor frequently Abnormal voltage Check the voltage Defective motor Consult your mechanical contractor Over current HEE The pump is broken Consult your mechanical contractor and trip while The infiltration of foreign object into the pump Consult your mechanical contractor Circuit breaker off Turn on the circuit breaker No water in the reservoir Fill the reservoir with water The motor is out of order Repair the motor or replace it Pump does not Abnormal voltag
19. Y3 C 055 RELAY4 A 056 RELAY4 C RELAY5 A 058 RELAY5 C 059 VFD1 RUN OUTPUT VFD2 RUN OUTPUT VFD3 RUN OUTPUT 7 8 ALARM AUXILIARY CONTACT CONTROL LOW SUCTION TIMER 30 SEC LOW SUCTION RESET AUTO LOW SUCTION RESET TIMER 30 SEC VFD MINIMUM RATE 50 7 VFD STOP RATE 60 7 SJE Rhombus VFDC 4100 Controller User Manual CN1 DA COM CN7 15 GCOM CN7 11 HANA 0 CHAND VFD1 ons RELAY 1 Ja CN1 DA COM CN7 15 GCOM CN7 12 00 CHAND LE VFD2 HOA ons RELAY 2 Ja CN1 DA COM CN7 15 GCOM 0N7 13 0 HAND l VFD3 CNS RELAY 3 1 0 ANALOG IN ANALOG COMMON VED READY FAULT OUTPUT RUN HAND FOWARD START INPUT COMMON VF De ANALOG IN ANALOG COMMON VFD READY FAULT OUTPUT RUN HAND FOWARD START INPUT COMMON 1 0 ANALOG IN ANALOG COMMON VFD READY FAULT OUTPUT RUN HAND START INPUT COMMON 17 4 3 Typical Triplex VFD Power Circuit Schematic OPER 1VFD ATL NOTE ALL PUMPS MUST BE THE SAME SIZE AND 15HP OR LESS INCOMING POWER 1 12 L3 OPTIONAL MAIN BREAKER WITH LOCKABLE DOOR OPERATOR TB1 1 FU3 200 VA o TT 1x1 120V X2 2 5 AMP CLASS CC FUSE GRD FAN 1 m y HOR O_O CHD ROT THERMOSTAT oo
20. atics Do not install in area with excessive or conductive dust corrosive or flammable gas moisture or rain excessive heat regular impact shocks or excessive vibration Do not place in water or let water leak onto the controller Do not allow debris to fall inside the unit during installation Double check all the wiring before turning on the power supply Do not touch live wires Stay as far as possible from high voltage cables and power equipment Leave a minimum of 10 mm space for ventilation between the top and bottom edges of the controller and enclosure walls EXPLOSION OR FIRE HAZARD Do not use this product with flammable liquids Do not install in hazardous locations as defined by National Electrical Code ANSI NFPA 70 Table of Contents Chapter 1 EE DE ENE EEE 2 1 2 Controller Outline Dimension 3 Chapter 2 2 1 Description of Functions 4 2 60 5 25 DUN ee 6 2 4 Function Keys amp Icon Descriptions 8 25 Description of LOD EN 9 Chapter 3 cn 10 3 2 Details of Setup 10 3 3 Setup Menu Display amp Input 14 Chapter 4 4 1 Triplex VFD Power Circuit Schematic VFD 16 4 2 Triplex Controller Circuit Schematic 2
21. cal Triplex VFD Power Circuit Schematic OPER TYPE VFD 480 VAC INCOMING POWER 1 12 15 OPTIONAL MAIN BREAKER WITH LOCKABLE DOOR OPERATOR TB1 1 AMP CLASS CC FUSE 1 AMP 2 5 AMP CLASS CC FUSE THERMOSTAT TBS O ai ai 1 Sl SG Ho TV l PRESSURE TRANSDUCER LOW SUCTION AUXILARY ALARM 0 200PS1 4 20mA DISCHARGE SIDE 16 SJE Rhombus VFDC 4100 Controller User Manual 4 2 Typical Triplex Controller Circuit Schematic OPER VFD VF DC 4100 RS 232C DSUB 11 SENSOR PRESSURE TRANSMITTER 0 200 PSI 4 20 mA 1141121 LOW SUCTION INPUT PUMP 1 VFD 1 Al READY FAULT PUMP2 H VFD2 1 kis p IX READY FAULT PUMP3 a VFD3 1 hi p READY FAULT 24V 24V GND VFDC 4100 PARAMETERS CHANGED FROM DEFAULT VALUES PUMP SET USED Pe USED P3 USED PRESSURE SET PRESSURE 60 PSI HIGH PRE LIMIT 95 PSI LOW PRE LIMIT 15 PSI START LEAD PRESS 3 PSI START LAG PRESS 7 PSI STOP LAG PRESS 3 PSI SENSOR TRANS TYPE 200 PSI SYSTEM OUTPUT RELAY 1 OUTPUT RELAY 2 OUTPUT RELAY 3 OUTPUT RELAY 5 VED VED STOP TIME 30 SEC VFD1 0 10V 030 VFD2 0 10V 031 DC GND DA COM TO VFD ANALOG COMMONS CNS RELAY1 A 050 RELAY1 C 051 RELAY2 A 052 RELAY2 C 053 RELAY3 A 054 RELA
22. d value by pressing the Enter key 5 Exit to the main screen by pressing the ESC key 14 SJE Rhombus VFDC 4100 Controller User Manual Example for the Pressure Setup Change Opr Pre 58 PSI 2004 12 12 Set Pre 60 PSI 00 00 00 ga E lt Fig 1 gt Main Screen PUMP SET PRESSURE CONTROL SENSOR VFD PROTECT SYSTEM PROGRAM COMM SET ALARMS DATA LOG lt Fig 2 gt Menu Setup Screen DATE TIME PUMPSET GENTA CONTROL SENSOR VFD PROTECT SYSTEM PROGRAM COMM SET ALARMS DATA LOG lt Fig 3 gt Pressure Setup Change Screen PRESSURE SETUP 60 0 RUN SET PRESSURE 60 PSI HIGH PRE LIMIT 150 PSI LOW PRE LIMIT 20 PSI lt Fig 4 gt Pressure Setup Change Screen PRESSURE SETUP 60 0 RUN SET PRESSURE 6 PSI HIGH PRE LIMIT 150 PSI LOW PRE LIMIT 20 PSI lt Fig 5 gt Pressure Setup Change Screen PRESSURE SETUP 60 0 RUN SET PRESSURE 6 PSI HIGH PRE LIMIT 150 PSI LOW PRE LIMIT 20 PSI lt Fig 6 gt Pressure Setup Change Screen SJE Rhombus VFDC 4100 Controller User Manual Press the MENU button Use the UP DOWN and RIGHT LEFT keys to go to the Pressure Menu Press ENTER button to open the Pressure Menu Moved to the set position which needs to be changed using the UP DOWN key Press ENTER key Use the UP DOWN and RIGHT LEFT keys to edit Save the changed value by pressing the Enter key Exit to the main screen by pressing the ESC key 15 Chapter 4 4 1 Typi
23. e SET PADRES 0 Lom o CN FO ALARM DATA 32 MOST RECON ALARNS SAVED OPERA DA OPERATION DATA SELECTION RUN LOG RUN LOG PUMP RUN TIMES Total 2000 lines of data saved Refer to Chapter 6 SJE Rhombus VFDC 4100 Controller User Manual 7 2 4 Function Keys amp Icon Description 2 4 1 Function Description LCD Screen LED Indicators Keypad Pre 600 PSI 2004 12 12 Set Pre 58 0 00 00 00 1 LCD Displays on the screen the operating status and setting 2 LED Displays the operation alarm operating pump etc Four PUMP LED displays the operation of each pump LED Off PUMP stopped LED On PUMP running 0 3 Function Keys MENU Used to access the main setup screen System may ask for password if enabled Navigation Buttons MENU RESET ESC ENTER RESET ENTER Used to clear faul codes ESC Press to accept a value after the fault condition is Press to move up in or navigate down within removed Some Faults may the menu structure or menu item require you to cycle power cancel an entry without saving 2 4 2 Description of Icon Pump Setting Pump 1 gt 4 Set to USED when the pump is available for use Pump Setting Pump 1 When you set Jockey Pump Pump Setting Pump 1 gt 4 Set to NOT USED when the pump is NOT available for use The VFD faulted while operating
24. e Check the voltage start after turning VFD tripped Reset VFD on the power The pressure transducer is out of order Repair the pressure transducer or replace it Bad motor wiring Check the motor wiring and correct it if required Pump running out Bad panel control cable connection Correct the cable connection of sequence LOD display is Tum off the power and turn on or reset not viewable defective Replace LCD Actions Consult your mechanical contractor Consult your mechanical contractor Consult your mechanical contractor Consult your mechanical contractor Consult your mechanical contractor Consult your mechanical contractor Consult your mechanical contractor Consult your mechanical contractor Consult your mechanical contractor Consult your mechanical contractor Replace the pressure transducer The operating pressure does not increase after pump starts pump runs 20 SJE Rhombus VFDC 4100 Controller User Manual Chapter 6 6 1 Fault Alarm Display amp Corrective Action 6 1 1 High Pressure Alarm Opr Pre 150 PSI HIGH PRESS Cause Set Pre 60 PSI 00 00 00 Reset z 00 100 output 6 1 2 Low Pressure Alarm Cause Opr Pre 0 PSI LOW PRESS Set Pre 60 PSI 00 00 00 Reset 8 E Output Actions 6 1 3 Low Water Level Alarm Cause Opr Pre 0 PSI LOW WATER Set Pre 60 PSI 00 00 00 a fu Output Actions 6 1 4 Sensor Fail Open Circuit Cause i
25. erating speed for 60 seconds Then it will switch lead pump The same process will be repeated if the succeeding lead pump does not run for 10 days etc FREEZE PREVENTION When set to USED the lead pump automatically USED NOT USED start the VFD minimum output for 30 seconds and then shift to the next pump when the temperature is under 32 deg This will occur when all pumps are stopped for more than 30 seconds at the same time PASSWORD USE See password section for description USED NOT USED 12 SJE Rhombus VFDC 4100 Controller User Manual 3 2 8 System Setup RETURN MAIN SCREEN Returns to the main screen after set time if user 10 300 does not use any key controls LCD LIGHT TIME After the set time LCD back light automatically turns 10 999 off This can be disabled by setting value to 999 DATA LOG Sets the sampling rate for the Operation data log 10 999 5 TEST CODE Internal code to check the system 0 9999 SET UP RELAY OUTPUT 1 5 Relay output 1 5 allows for up to amp 250V DIGITAL OUTPUT 6 13 Digital output is transistor out High 5V Low 0V Available settings for outputs are NOT USED PUMPS STOPPED PUMPING GENERAL ALARM LOW SUCTION P1 P4 VFD RUN P1 P4 ATL RUN BUZZER LOW PRESSURE HIGH PRESSURE VFD 1 4 FLT HOA SENSOR FAULT LANGUAGE Language selection English Espanol PRESS UNIT Unit of measure for analog input PSI BAR 3 2 9 Communication Setup menus Sep Mena
26. ng from abuse misuse accident or negligence D to units which are not installed in accordance with applicable local codes ordinances or accepted trade practices and E to units repaired and or modified without prior authorization from SJE RHOMBUS Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you Some states do not allow the exclusion or limitation of incidental or conse quential damages so the above limitation or exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state TO OBTAIN WARRANTY SERVICE The consumer shall assume all responsibility and expense for removal reinstallation and freight of controller deemed defective Any controller to be repaired or replaced under this warranty must be returned to SJE RHOMBUS or such place as designated by SJE RHOMBUS ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS ARE LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY SJE RHOMBUS SHALL NOT IN ANY MANNER BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES AS A RESULT OF A BREACH OF THIS WRITTEN WARRANTY OR ANY IMPLIED WARRANTY Warranty void if back cover of this product is removed Call factory with servicing questions 1 800 RHOMBUS 1 800 746 6287 Rhombus 22650 County Hwy 6 1708 Detroit Lakes MN 56502 USA 1 888 DIAL SJE 1 888 342 5753 218 847
27. omatically selects the next pump in sequence to be the lead pump This function 15 designed to reduce the system life cycle cost The system make all pump operate for equal period of time as to prevent the over use of a particular pump resulting in high parts wear of the pump The alternation may also be cycle based rather than time based Faulty Pump s Skip Function The system automatically skips any pump sending a fault signal to the controller and immediately changes the operating sequence to the functioning pumps The faulty VFD Pump will continue to report its fault until maintenance personnel can diagnose and repair the fault condition fault can be any of the following VFD fault starter overload trip when using starters or HAND OFF AUTP HOA selector switch is not in the AUTO position Dry Run Prevention The system automatically stops the running pump s upon the detecting a Low pressure signal Low Water This func tion prevents the pump s from dry running that may result in damage to the pump s Program Used to program the set pressure to change based on a time day month basis Dual Set Pressures An additional SET PRESSURE is available the PRESSURE menu can become the active set pressure by activat ing input 018 on CN8 This function can be useful for systems with large fluctuations in suction pressure or large varia tions in demand flow Alarm Display and Logging The system displays alarm conditions on the L
28. ters suction pressure Method used to reset the low suction shut down valve LOW SUCT RST TMR When low scution rest is set to auto this is the 10 999 SECS 2 78 hrs time the controller will wait before attempting to reset pressure fault DEFAULT All parameters are set to factory defaults YES NO except data setup SJE Rhombus VFDC 4100 Controller User Manual 11 3 2 5 Sensor Setup SENSOR TRANSDUGER TYPE Range Setup of Sensor 29 PSI 720 PSI SETUP SENSOR ADJUST Sensor Offset Value 72 PSI 72 PSI 3 2 6 VFD Setup SetupMenu Input Range VFD STOP TIME Time delay for when the last pump stops after 0 60 SECONDS the slike drops to the VFD minimum rate IET VFD STOP RATE The last pump stops when its speed is less than 20 90 Er VFD AUTO RESET Reset times after an alarm happened while the 0 20 VFD was operating PIPE FILL Enable or disable the pipe fill function ON OFF PIPE FILL RATE The preset speed the pump will run on start up 10 90 or VFD min speed slowly fill the pipes Runs for the PIPE FILL TIMER or the SET PRESSURE is reached PIPE FILL TIMER The length of time the pump will run If the set 5 600 SECONDS pressure is reached during this time the system will switch to PID immediately 3 2 7 Protect Setup IDLE PREVENTION When set to USED if the lead pump has not ran USED NOT USED for 10 days the system will automatically run the lead pump at the minimum op
29. troller is able to control up to four 4 pumps utilizing all VFD s or VFD with up to ATL across the line starters for the lag pumps Lead Lag Operation fully automatic lead lag operation based on the variation of the system discharge flow allows you to significantly reduce your energy cost and consistently maintain the system pressure While the lead pump is operating the system will sequentially start and stop lag pump s based on variation of the system pressure Across The Line ATL Pump Operation When enabled and utilized this function allows for multiple pumps to be controlled in a true PID pressure control system while only needing one VFD When the output of the lead pump VFD is at 100 the controller changes that pump over to direct ATL operation and switches on the first lag pump using the VFD In the same way lag pump 2 and 3 can be added as needed for heavy flow conditions The pump being controlled by the VFD will always be varying its speed as needed to maintain the set pressure Automatic Re Start Should the system shutdown by a sudden power loss it will automatically restart when the power is restored No manual reset is required The system automatically returns to the running condition programmed and stored in the system memory Lead Pump Alternation When selected as set time based the alternation will occur when the total operating time of the lead pump reaches to the alternation time the system aut
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