PPC3 Series Pump Controller - Sta-Rite
Contents
1. 293 WRIGHT STREET DELAVAN WI 53115 WWW PUMPS COM PH 1 866 9 PENTEK 2013 Pentair Ltd All Rights Reserved QUICK START GUIDE PPC3 Series Pump Controller INSTALLATION Connect Transducer Install the transducer where pressure is to be maintained The PENTEK Assistant requires a 4 20 ma transducer Figure 2 The transducer s power lead should be attached to the 24 Volt connection shown below and the 4 20 ma output lead should be attached to terminal 5 Figure 3 The transducer has a red power lead and a black 4 20 ma output lead The jumper board eliminates the need to hand wire terminals 10 to 11 16 to 22 and 9 to 20 Before applying power make sure the front cover is on and the control module is in place Note that the transducer has 4 wires Attach the red and black leads as described above The bare lead is cable shielding and should be connected to terminal 1 The translucent lead is unused and should be tied off and insulated Startup the PENTEK Assistant Apply power to the unit and follow the steps on Pages 2 and 3 after the controller s screen is lit Transducer cable Transducer a FIGURE 2 Transducer and Cable FIGURE 3 Transducer connection to Terminal strip PN806 REV 02 19 13 Q INITIAL STARTUP PANEL DISPLAY Upon initial drive power up the user will be prompt ed to run the PENTEK ASSISTANT Scroll to YES and then select OK Wait while the assistant loads On s2. SETUP Press start to operate the pump Test system to ensure proper system response and sleep function Adjust group 40 parameters as needed PARAMETERS CHANGED RELATIVE TO PID CONTROL DEFAULTS Parameter Code PENTEK Code Parameter Code PENTEK Code 1002 Ext2 Commands Keypad 3201 Superv 1 Param Output Freq 1102 EXT1 EXT2 Sel EXT2 3202 SuperV 1 Lim Lo per 9907 1301 Minimum Al1 20 3203 SuperV 1 Lim Hi per 9907 1601 Run Enable Not Sel 3401 Signal 1 Param Current 1805 DO Signal Superv1 Over 3405 Output 1 Unit A 1806 DO On Delay 10 Seconds 3408 Signal 2 Param Speed Above Ground 3412 Output 2 Unit RPM 1806 DO On Delay is 3415 Signal 3 Param PID 1 FBK 1807 DO Off Delay ae gt sea ell ie 2001 Minimum Speed 0 Above Ground a mae 2001 Minimum Speed User Defined eL A ae Submersible 4006 Units PSI 2002 Maximum Speed Sync 4010 Set Point Sel Internal 2202 Accel Time 1 5 sec 4022 Sleep Selection Internal Above Ground 4024 PID Sleep Delay 10 sec 2202 Accel Time 1 1 sec Submersible 4027 PID Param Set DI3 3001 Al lt Min Fault 4101 Gain 1 0 3003 External Fault 1 DI5 4102 Integration Time 1 0 Sec 3006 Mot Therm Time 500 sec 4106 Units PSI Above Ground 4109 100 value Per 4009 3006 Mot Therm Time ere 4110 Set Point Sel Internal 3007 el Loadicune 100 4111 Internal Setpoint Per 401
3. gt PENTAIR PENTEK ABOUT The PENTEK PPC3 Pump Controller is pre jumpered and programmed with the PENTEK Assistant providing ease of setup for constant pressure applications The PENTEK Assistant defaults to pre defined parameters as described in this guide and also prompts the user for application specific information This guide covers the startup of the PENTEK Assistant for constant pressure applications For other programs refer to the ABB manual provided SAFETY A WARNING Hazardous voltage Can shock burn or cause death Ground pump before connecting to power supply Disconnect power before working on system components A Wire pump motor for correct voltage See motor nameplate A Ground motor to drive before connecting to power supply Meet National Electrical Code Canadian Electrical Code and local codes for all wiring California Proposition 65 Warning A WARNING This product and related accessories contain chemicals known to the State of California to cause cancer birth defects or other reproductive harm Local Remote e Motor Rotation Indicator Indicator Controller Mode ig PID Address andFunction Description REM U U PAR EDIT 9909 MOTOR NOM POWER 3 0 hp 00 00 iy Left Button a Left Te Function Right Button Buttons Local Tes Help Remote Stop sro a Start FIGURE 1 Control Panel Button Location
4. 1 Above Ground 4122 Sleep Selection Internal 3007 Mot Load Curve 112 Submersible 4123 PID Sleep Level Per 4023 3013 Underload Function Fault 4124 PID Sleep Delay 10 sec 3014 Underload Time 10 sec 4125 Wake Up Deviation Per 4025 3022 Al2 Fault Limit 10 Upon initial startup the PENTEK ASSISTANT runs auto matically On subsequent runs use the steps below to run the PENTEK ASSISTANT 1 Use the MENU key to access the Menu List 2 Select Assistants 3 Select PENTEK ASSISTANT 4 Follow the screen instructions to configure the system NOTE The upper left hand corner of the display shows whether the drive is in local or remote control In LOC mode the drive holds a constant speed which can be adjusted using the up down buttons The speed which will be held is in the upper right hand corner In REM mode the drives holds a constant pressure The pressure as a percentage of full scale is shown in the upper right hand corner NOTE For common parameters and menu items use the Help key to display descriptions If you encounter Alarms or Faults use the Help key or refer to the Diagnostic section of the User s Manual DESCRIPTION OF INFORMATION REQUIRED BY THE PENTEK ASSISTANT 9905 Motor Nom Voltage This is the nominal voltage stated on the motor nameplate If the motor is rated for operation at multiple voltages select the voltage nearest the utility voltage Ensure the motor connections corre spond to the
5. CER 100 VALUE Enter the transducer s full range value which should be stated on the transducer body Scroll to select the pressure and then press SAVE The sample here shows 145 PSI NOTE DO NOT choose maximum pressure EXIT Loc wv 100 RPM A CHECK MOTOR 0 rpm ROTATION 0 0 PSI P the Local R t button ta harge local eee trol Check ab a x nie ee vvi shaft rotation For submers Gye y 4 ible 3 phase motors start and check performance Reverse any two power leads and check again The lead arrangement with best performance is correct REM PAR EDIT 9905 MOTOR NOM VOLT 9 MOTOR VOLTAGE 460 V SCREEN The screen EXIT 00 00 SAVE shows motor voltage Scroll to select the correct voltage for your motor as stated on the motor nameplate This sample shows 460 volts Press SAVE Ca wy 7 REM PAR EDIT 9909 MOTOR NOM POWER MOTOR HORSEPOWER 3 0 h p SCREEN Enter the motor EXIT 00 00 SAVE horsepower HP from the motor nameplate Scroll to select the horse power and press SAVE The sample here shows D s NN 3 0 HP 41 REM PAR EDIT 4023 PID SLEEP LEVEL PID SLEEP LEVEL SCREEN O rpm Enter the PID sleep level EXIT 00 00 SAVE This is a motor speed setting If the motor speed falls below this RPM the PID sleep function will be enabled This is a controller assigned value For additio
6. and making changes we recommend the parameter set be saved The parameter set can then be recalled if parameters get accidentally changed Pass Code The PENTEK VFD can be pass code protected Pass coding is enabled by parameter 1602 The pass code is entered in parameter 1603 Submersible Motor Application Submersible pump motors often have higher current draw than an equivalent above ground motor Submersible motor size is usually based upon service factor amps which is higher than full amps HELPFUL HINTS Continued Automatic Restarts After Power Failure The PENTEK VFD can be configured to automatically restart after power loss This will energize the motor whenever power is present To enable this mode set parameter 1002 to DI1 and set Dip Switch 1 on the jumper board to ON AWARNING Do not use this setting if unexpected starts may cause damage or injury FIGURE 4 Dip Switch ON INSTALLATION RECORD Record setup values here Drive Model Drive Description Pump Model Pump Description Motor Model Motor Nominal Voltage Motor Nominal Current Motor Nominal Frequency Motor Nominal Speed Motor Nominal Power Minimum Speed required for submersibles Pressure Setpoint Transducer Full value Sleep Level Wake Up Deviation Values required by the PENTEK ASSISTANT IMPORTANT INFORMATION Use of Premium Efficiency Motors Using variable frequency driv
7. dnesday and Friday from 8 00 AM to 10 00 AM Parameter Setting 3601 Timers Enable 7 Enabled 3602 Start Time 1 8 00 AM 3603 Stop Time 1 ee 10 00 AM 3604 Start Day 1 0 ee 1 Monday 3605 Stop Day 1 0 eee 1 Monday 3606 Start Time 2 ee 8 00 AM 3607 Stop Time 2 eee 10 00 AM 3608 Start Day 2 3 Wednesday 3609 Stop Day 2 essensen 3 Wednesday 3610 Start Time 3 oo 8 00 AM 3611 Stop Time 3 ee 10 00 AM 3612 Start Day 3 oe 5 Friday 3612 Stop Day 3 ee 5 Friday 3626 Timer FunciSCR 7 P3 P2 P1 4027 PID 1 Param Set 8 Timer Function 1 These instructions are only for systems that require tanks Pressure tanks are generally required to maintain system pressure during periods of low or no demand Tank precharge must be less than the pressure set point wake up deviation The tank can be sized using Boyle s law V1 x P1 V2 x P2 Units are in gallons and PSI Drawdown Total Tank Size x Precharge 14 7 Total Tank Size x Precharge 14 7 Setpoint 14 7 Wake Up Deviation Setpoint 14 7 Typically tanks are sized for approximately 20 of pump capacity For example a 150 gpm pump typically requires 30 gallon total tank size HELPFUL HINTS Alarm 2025 upon startup This is a normal alarm and occurs whenever motor data is changed The alarm shows for abou
8. eep Options Other devices such as flow or float switches can be used to trigger sleep mode Parameter 4022 determines the method to trigger sleep mode These options can be used for pump up pump down and other on off applications Multiple Systems Setpoints The PENTEK VFD includes 2 independent process con trol sets groups 40 and 41 Group 41 parameters can be selected using Digital Input DI3 When first set up groups 40 and 41 are identical A set can be changed later with parameters for a second process Constant Flow After running the PENTEK Assistant the drive can be configured for constant flow by adjusting parameters 4006 Units and 4009 100 Value Constant Flow Example 1 Using a 4 20ma velocity meter with a range of O to 10 ft sec We want the display to be ft sec Set 4006 to ft sec Set 4009 to 10 Constant Flow Example 2 Same setup as example 1 but we have a 4 pipe and want the display to be gpm Set 4006 to gom Set 4009 to 393 this is the flow in a 4 pipe which results in a 10 ft sec velocity Constant Flow Example 3 Using a 4 20ma flow meter with a range of 0 to 100 gpm We want the display to be gpm Set 4006 to gom Set 4009 to 100 Single Phase Connection If you have single phase input power use a single phase drive Saving and Recalling Settings The PENTEK VFD can save and recall 2 sets of user parameters use parameter 9902 After running the PENTEK Assistant
9. es may cause an increase in voltage spikes and motor temperature These are caused by but not limited to several application factors These include motor lead length voltage quality motor loading Since many of these factors are beyond our control we recommend using premium efficiency motors Premium efficiency motors normally contain better winding insulation and wire and run cooler Output Filters and Reactors Variable frequency drives produce voltage wave reflec tion This is a function of the voltage rise time and the length of the motor cables As reflected waves return to their source and encounter other waves the values add causing higher peak voltage Higher peak voltage can decrease motor life expectancy Installing output reactors and filters can increase motor life expectancy in many applications Output reactors and filters are available from your PENTEK distributor Motor Service Factor In some applications submersible motors can operate into its designed service factor Parameter 3007 can be set to allow motors to operate into the service factor range Example When using a non modified catalog product in water under 86 F with proper flow conditions cooling the motor parameter 3007 can be set to 112 Submersible motors should always operate within its ser vice factor limit Program Change Set Parameter 3007 to the percentage the motor is operating into service factor Use of Output Reactors and Filte
10. nal Vv information refer to the ACS350 Users Manual Scroll to select the speed and then press SAVE The sample here shows 0 RPM waiting to be set A WARNING Burn Hazard If the sleep level is set too low the pump my run without flow This can boil water inside the pump causing dangerously high pressure and temperature DAA CHECK FOR STOP THE PUMP SYSTEM Press the STOP button HARMONICS While the pump is running scroll motor speed up to check for harmonics Verify that harmonics do not exist above the PID sleep level O MOTOR CURRENT SCREEN Enter the motor current from the motor nameplate not maximum amps Scroll to select the current and press SAVE FOR SUBMERSIBLE PUMPS ONLY Enter the minimum speed allowed by the motor vendor consult motor lit erature This is to prevent motor bearing damage a2 WAKE UP DEVIATION SCREEN Enter the wake up deviation This is the amount pressure drops PSI below the pressure set point before the drive restarts This sample is waiting to be set and shows 0 PSI a7 CHANGE TO REMOTE OPERATION Press the Loc Rem button to change to remote control REMC PAR EDIT 9906 MOTOR NOM CURR 3 8 A EXIT 00 00 SAVE lt S Gy a REM PAR EDIT 2001 MIN SPEED O RPM EXIT 00 00 SAVE 2 REM PAR EDIT 4025 WAKE UP DEV 0 0 PSI EXIT 00 00 SAVE WT TEST SYSTEM
11. rs The Load Reactor or KDR dampens voltage spikes on the PWM Pulse Width Modulated wave from the AC drive to the motor and should be used on standard efficiency or non premium efficiency above ground motors A KDR will normally eliminate voltage spikes above 1100 volts The Load Filter or KLC is a KDR with the addition of a capacitor resistor network that adds regulation of the PWM output to further dampening the voltage dampening achieved in the KDR This further reduces potential for motor damage due to voltage spikes A KLC will normally eliminate voltage spikes above 950 volts The reasons you would use a KLC over the KDR 1 Where excessive motor lead lengths are used over 250 feet 2 Where the cost of replacing the motor would be prohibitive 3 When using a submersible motor required with motors over 230 volts TECHNICAL WARRANTY SUPPORT Before calling technical support record the model and serial number of your drive controller Also note the firm ware version of the drive and keypad PENTEK technical support number is 1 866 9 PENTEK
12. t 15 seconds while the drive performs a motor calibration Fault 14 External Fault 1 External fault 1 is triggered when the VFD s output fre quency exceeds motor nameplate frequency for more than 10 seconds Parameter 1806 controls the time delay for this fault If the system includes a large tank or requires more time to reach the setpoint increase param eter 1806 as needed This fault is designed to protect against loss of prime broken shafts etc To disable this fault adjust parameter 2002 Maximum speed to the motor nameplate rpm Sleep The PENTEK VFD monitors pump speed to determine demand The pump is shut off when the rpm goes below parameter 4023 PID Sleep Level Always set parame ter 4023 high enough to trigger sleep mode during low demand conditions Note that the shut off head at param eter 4023 RPM must be higher than the pressure set point The PID sleep level can be determined by putting the drive in local mode closing the discharge valve and slowly increasing speed until the set point pressure is reached The PID sleep level can also be found by using the BEC2 program or see www bec2 net Systems that use small tanks or have a flat performance curve may cycle rapidly at intermediate flows Correct this by increasing Parameter 4024 PID Sleep Delay Caution Do NOT increase parameter 4024 to a level that will allow the pump to run with zero flow dead head The water in the pump can overheat Sl
13. ubsequent startups the PENTEK ASSISTANT can be found in the ASSISTANTS menu 5 MOTOR FREQUENCY SCREEN Enter the motor frequency Hz from the motor nameplate Scroll to select the frequency and select SCROLL TO SELECT CONSTANT PRESSURE POINT Example shows 40 PSI a3 ASSISTANT COMPLETE This ends setup of the PENTEK ASSISTANT The following steps complete the setup of the pump system t CHOICE Do you want to run the Pentek assistant REM RE EXIT 00 00 OK D Vv 2 Please Select Mtr Type Above Ground aaa Submersible Scroll to select the type SS installation and then press EXIT 00 00 OK REM PAR EDIT 9907 MOTOR NOM FREQ 60 0 Hz EXIT 00 00 SAVE a s aD NN REM PAR EDIT 4011 INTERNAL SET PNT 40 PSI EXIT 00 00 SAVE Cay al Do X EXIT Pentek Assistant Complete 00 00 OK REM PAR EDIT 9908 MOTOR NOM SPEED 3450 rpm Q MOTOR SPEED SCREEN Enter the motor speed RPM from the motor nameplate Scroll to select the speed and press SAVE The sample here shows 3450 RPM REM PAR EDIT 4009 100 VALUE 145 0 PSI 00 00 SAVE a s aD Ww Use this Full Range Value range 0 10 bar 145 psi max pressure 25 bar 362 5 psi UE 30 380 VDC PS Do NOT use Maximum Pressure OUT 4 20mA Load lt N 8V 0 02A TRANSDU
14. voltage selected 9906 Motor Nom Current This is the nominal current found on the motor nameplate Do not use service factor amps 9907 Motor Nom Freq This is the nominal frequency found on the motor nameplate 9908 Motor Nominal Speed This is the nominal speed found on the motor nameplate Use the number on the motor nameplate Do not enter 3600 1800 etc 9909 Motor Nom Power This is the nominal horsepower found on the motor nameplate Do not include service factor unless the service factor is greater than 1 15 2001 Min Speed Required for Subs only This is the minimum speed the motor is allowed to run This mini mum is set to prevent damage to the motor thrust bear ings Refer to motor literature to determine setting 4011 Internal Setpoint This is the pressure the system will maintain 4009 100 Value This is the full scale reading of the transducer le The 100 Value of a 200PSI transducer is 200PSI 4023 PID Sleep Level Operation below this rpm will cause the drive to stop 4025 Wake Up Dev This is the pressure drop that will trigger the drive to restart For example if the set point is 60 PSI and the Wake Up Deviation is 10 PSI the drive will restart at 50 PSI TANK SIZING Timer Function The PENTEK VFD includes four timer functions Each timer function can include up to four daily weekly start and stop times The following example show the parameter changes required to use PID Set 2 on Monday We
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