AQUAVAR® CPC - FD - Depco Pump Company
Contents
1. 15 3 CPC5004xFD R2 15 5 CPC5006xFD R2 15 KTK R 15 1 5 CPC5009xFD R2 15 KTK R 15 10 CPC501TxFD R2 30 KTK R 30 15 CPC5017XFD R2 30 RTR R 30 20 CPC5022xFD R3 50 JJS 50 25 CPC5027xFD R3 50 JJS 50 30 CPC5032xFD R4 100 JJS 100 40 CPC5041xFD R4 100 JJS 100 50 CPC5052xFD R4 100 JJS 100 60 CPC5062xFD R4 100 JJS 100 75 CPC5077xFD R6 125 170M1368 100 CPC5099xFD R 125 170M1368 125 CPC5125xFD R6 160 170M1369 150 CPC5144xFD R6 200 170M1370 NOTE x represents both NEMA 1 and NEMA 12 enclosures Input Power Cables Wiring R7 R8 NEC Based on e NEC Table 310 16 for copper wires e 90 C 194 F wire insulation e 40 C 104 F ambient temperature e Not more than three current carrying conductors in raceway or cable or earth directly buried e Copper cables with concentric copper shield Max Load Current A Cu Wire Size AWG kcmil Cu Wire Size AWG kcmil Max Load Current A 400 MCM or 2 x 2 0 474 2x250 500 MCM or 2 x 3 0 534 2x 300 615 2x350 2 x 500 22 TECHNICAL DATA Drive s Povver Connection Terminals Supplement to Aquavar CPC User s Manual The following tables show maximum wire size and required tightening torque for incomming power and motor terminals and grounding terminal lug information 208 240 Volt Terminals 208 240 Volt Power Wiring Data Ground Frame Circuit sa Motor Lugs a Ty2. CPC5144xFD R 200 in lbs NOTE x represents both NEMA 1 and NEMA 12 25 TECHNICAL DATA Motor Connections Motor Connection Specifications R7 R8 Motor Connection Specifications Maximum Motor Cable Length Frame Size R7 R8 Maximum Motor Cable Length fiw 1 or 4 kHz 300 m 980 ft f 8 kHz or 12 kHz Does not apply WARNING Using a motor cable longer than specified in the chart above may cause permanent damage to the drive Cooling R7 R8 Method Cooling Specifications Internal fan flow direction from bottom to top Requirement e R7 R8 Free space in front of enclosure 152 mm 6 in e R7 R8 Free space above enclosure None required for cooling e R7 R8 Free space at sides of enclosure None required for cooling e R7 R8 Also see Additional Free Space Recommendations on page 33 Air Flow 380 480 Volt Drives R7 R8 The following table lists heat loss and air flow data for 380 480 Volt drives Drive Heat Loss Air Flow CPC xx Frame Size VV BTU Hr m h ft min 245A 4 R7 3850 13000 300 540 316A 4 R8 5300 18000 700 1220 368A 4 R8 6850 23000 700 1220 414A 4 R8 7000 24000 700 220 486A 4 R8 7600 26000 700 1220 526A 4 R8 7800 27000 700 1220 602A 4 R8 8100 28000 700 1220 645A 4 R8 9100 31000 700 1220 26 TECHNICAL DATA Dimensions and Weights Supplemen
3. NEMA 1 and 12 R7 R8 back against a wall top view Frame sizes R7 and R8 have mounting holes inside h Fastening points when installed Mounting Dimensions on page 28 po i Fastening points vvhen installed Where it is not possible to use either mounting hole back against back at the back of the base use an L bracket at the top of the enclosure to secure the cabinet to a wall or to the back of another enclosure Bolt the L bracket to the enclosure using the lifting lug bolt hole on the top of I l h Fastening the cabinet at the top the enclosure using L brackets side view L bracket M12 bolt 1 2 to 9 16 in Cabinet top Remove Side Panels R7 and R8 NEMA 1 and 12 Enclosures Cabinet Door 1 To open the cabinet door loosen the quarter turn screws that hold the cabinet door closed 2 Installation access is easier if these panels are kept off throughout the installation INSTALLATION Mount the Drive R7 R8 1 Use a hoist to move the cabinet into position NOTE If the cabinet location does not provide access to the cabinet sides be sure to re mount side panels before positioning cabinet 2 Install and tighten mounting bolts PC00003 Installing the VViring Supplement to Aquavar CPC User s Manual AN WARNING e Metal shavings or debris in the enclosure can damage electrical equipment and create a hazardous condition Where parts such as conduit plates require cutting or d
4. See Maintenance in Aquavar heatsink dustiness of the CPC User s Manual environment every 6 12 months Replace drive All Every 6 years See Maintenance in Aquavar module fan CPC User s Manual Replace enclosure NEMA 12 Every 3 years See Frame Sizes R7 R8 NEMA fan s 12 Enclosures on page 15 For other frame sizes see Maintenance in Aquavar CPC User s Manual Change capacitor R6 Frame sizes R5 and Every 10 years See Maintenance in Aquavar CPC User s Manual Replace battery in the All Assistant control panel Every 10 years See Maintenance in Aquavar CPC User s Manual Drive Module Fan Replacement The drive module fan cools the heatsink Fan failure can be predicted by the increasing noise from fan bearings and the gradual rise in the heatsink temperature in spite of heatsink cleaning If the drive is operated in a critical part of a process fan replacement is recommended once these symptoms start appearing Replacement fans are available from the factory Do not use other than Goulds Water Technology specified spare parts To monitor the running time of the cooling fan see Group 29 Maintenance Trig in the Aquavar CPC Users s Manual Frame Sizes R7 and R8 Refer to the installation instructions supplied with the fan kit 14 MAINTENANCE Enclosure Fan Replacement NEMA 12 Enclosures NEMA 12 enclosures include an additional fan or fans to move air through the
5. ences to the detailed information needed for the correct installation of the unit NOTE References in the middle column below are to the Aquavar CPC User s Manual IM167 References in the third column below are to this manual Refer to the Task Aquavar CPC User s Manual Installation Section Additional Reference in this Manual PREPARE for Preparing for Installation R7 R8 Lifting the Drive installation on page 7 Drive Identification on page 8 e Suitable Mounting Location on page 9 PREPARE the Prepare the Mounting Location R7 R8 Prepare the Mounting Mounting Location R7 and R8 on Location page 9 Dimensions and Weights Supplement to Aquavar CPC User s Manual on page 27 REMOVE the Remove Front Cover R7 R8 Remove Side Panel R7 and front cover R8 NEMA 1 and 12 Enclosures on I page 9 MOUNT the drive Mount the Drive R7 R8 Mount the Drive on page 10 INSTALL wiring Wiring Overview and Installing the Wiring Supplement Install the Wiring to Aquavar CPC User s Manual starting on page 10 CHECK installation Check Installation REINSTALL the Reinstall Cover cover Y APPLY power Apply Power Y START UP Start Up INSTALLATION Preparing for Installation Supplement to Aquavar CPC User s Manual Lifting the Drive R7 R8 Frames WARNING Handle and ship floor
6. enclosure Frame Sizes R7 R8 NEMA 1 2 Enclosures The enclosure fan is located in the exhaust box on top of the NEMA 12 enclosure 1 Remove the left and right filter frames of the exhaust fan box by lifting them upwards 2 Disconnect the fan s electrical connector from the cabinet roof top right Inside the cabinet PC00018 3 Undo the four fastening screws at the corners of the fan frame The screws are through bolts with nuts on the inside of the cabinet Do not drop the hardware into the drive PC00018 PC00014 PC00017 4 Remove the fan and fan frame as one unit Neos PC00014 5 Disconnect the fan vviring and capacitor from the fan frame Then remove the four screws attaching the fan to the fan frame Remove the old fan PC00020 6 Install the nevv fan and capacitor vvith the replacement part for Goulds VVater Technology in the reverse order of the above Ensure the fan is centered on the velocity Velocity stack and rotates freely aek Capacitor PC00014 MAINTENANCE Enclosure Air Filter Replacement NEMA 12 Enclosures Frame Sizes R5 R6 Enclosure Inlet Air Filter This procedure applies to disconnect configurations in R5 and R6 frame sizes with NEMA 12 enclosures This filter is located at the bottom of the enclosure Use the following procedure to check and replace filters 1 On the enclosure remove the screw holding the filter bracket in place 2 Slide the filt
7. mounted enclosures only in the upright position These units are not designed to be laid on their backs 1 Use a pallet truck to move the package enclosure to the installation site CAM 2 Remove the cabinet side panels from NEMA 1 and 12 enclosures for access to the cabinet pallet mounting bolts Six 6 torx screws hold each cabinet side panel in place Leave the side panels off until later 3 Remove the 4 bolts that secure the cabinet to the shipping pallet WARNING Use the lifting lugs bars at the top of the unit to lift R7 R8 drives 4 Use a hoist to lift the drive Do not place drive in final position until mounting site is prepared PC00003 INSTALLATION Preparing for Installation Supplement to Aquavar CPC User s Manual Drive Identification To identify the type of device you are installing refer to the type code number on the device identification label e Wall mounting base drives label attached on the side surface of the heat sink e Packaged drive with screw cover label attached to outside surface on the left ide of the enclosure e Enclosure with hinged cover door label on inside surface of the cover door Type Code Number Use the following to interpret the type code found on the identification label CPC 4 370 1 FD AQUAVAR Series Voltage 2 208 240 Volt 4 480 Volt 5 575 Volt Amps 370 Amps See Technical Section NEMA Enclosur
8. 5 CPC2024xFD R2 30 KTK R 30 10 CPC2031xFD R2 50 JJS 50 15 CPC2046xFD R3 80 JJS 80 20 CPC2059xFD R3 80 JJS 80 25 CPC2075xFD RA 100 JJS 100 30 CPC2088xFD R4 125 170M1368 40 CPC2114xFD R4 160 170M1369 50 CPC2143xFD R 200 170M1370 60 CPC2178xFD R 250 170M1371 75 CPC2221xFD R 315 170M1372 100 CPC2248xFD R 315 170M1372 NOTE x represents both NEMA 1 and NEMA 12 enclosures 20 TECHNICAL DATA 380 480 Volt Fuses 380 480 Volt Base Drive Input Fuse Ratings Drive HP Identification jdn CNN 1 1 5 CPC4 xFD R1 15 KTK R 15 2 CPC4 xFD R1 15 3 CPC4006xFD R1 15 KTK R 15 7 5 CPC4012xFD R1 15 KTK R 15 10 CPC4015xFD R2 30 15 CPC4023xFD R2 30 20 CPC4031xFD R3 50 JJS 50 25 CPC4038xFD R3 50 30 CPC4044xFD R3 100 JJS 100 40 CPC4059xFD R4 100 50 CPC4072xFD R4 100 JJS 100 60 CPC4077xFD R5 125 170M1368 75 CPC4096xFD R5 125 100 CPC4124xFD R 160 170M1369 125 CPC4157xFD R 200 150 CPC4180xFD R 250 170M1371 200 CPC4245xFD R7 400 250 CPC4316xFD R8 400 300 CPC4368xFD R8 400 JJS 400 350 CPC4414xFD R8 600 400 CPC4486xFD R8 600 JJS 600 450 CPC4526xFD R8 800 500 CPC4602xFD R8 800 JJS 800 550 CPC4645xFD R8 800 JJS 800 NOTE x represents both NEMA 1 and NEMA 12 enclosures 21 TECHNICAL DATA 500 600 Volt Fuses 500 600 Volt Base Drive Input Fuse Ratings Drive HP Identification den area dc 2 CPC5002xFD R2 15 KTK R
9. Lay the filter frames on a flat work surface e The wire retainers have a square U shape Remove by squeezing the open end of the U towards the middle of the square until the retainer top open end of U clears the filter frame PC00001 PC00019 e Save the retainers for reinstallation 3 Remove and inspect the filter 4 Install clean filters NOTE When installing DUSTLOR filter media the white side must face to outside of the cabinet and the orange side faces in Be sure to tuck the filter edges into the groove around the entire filter frame This detail is very important for proper operation 5 Reinstall the filter restrainers Install each filter frame to the bonnet on top of the e Insert the base of a retainer bottom of U shape into a filter frame channel e Squeeze the open end of the U until it clears the filter frame e Seat the open end of the U in the filter frame channel e Release the retainer to its relaxed square shape PCO0019 PC00001 cabinet A e Carefully align the frame s mounting hooks with the slots in the bonnet The hooks should be pointing down e Press down at the top of the filter frame The filter frame slides down approximately 34 inch e Check all around the filter frame for a secure seal to PC00012 PC00011 the exhaust box TECHNICAL DATA Ratings Supplement to Aquavar CPC User s Manual IM167 NOTEI The ratings
10. RR ER EE d epp d PER 26 cover GTTIOVO oec eodd OU OUR EE SEO t atus 6 current rating code isses 8 34 D dimensions mounting RT R6 LL LL 27 MOUNTING RT RO sae oce eee sepe nens 28 outside NEMA 12 R1 R4 u e 30 outside NEMA 12 R5 R6 32 outside NEMA 1 R1 RA u e ee 29 outside NEMA 1 R5 R6 Le 31 outside NEMA 1 NEMA 12 R7 R8 33 disconnect diagram u e 4 features functions drive fan replacement Lu uo cece eee ee 14 identification u e LL LL 8 proper lifting ies exe ee den be ese dies 7 Weight 2 0 cee n 28 INDEX E enclosure protection class code 8 enclosure NEMA 12 air filter maintenance e lees 16 fan replacement ue dre 15 F fan drive module maintenance interval esses 14 replacement procedure 14 fan enclosure maintenance interval esee 14 replacement procedure 14 filter enclosure R5 R6 inlet maintenance interval 14 R5 R6 inlet maintenance procedure 16 R7 R8 exhaust maintenance interval 14 R7 R8 exhaust maintenance procedure 18 R7 R8 inlet maintenance interval 14 R7 R8 inlet maintenance procedure 16 free space forxdaccess RZ RB xs ke onu gc Re OR o 33 TOF Coolin
11. SUPPLEMENT MANUAL IM250 AQUAVAR CPC FD Variable Speed Drive with Fused Disconnect SUPPLEMENT TO THE INSTALLATION AND OPERATION MANUAL IM167 GOULDS WATER TECHNOLOGY a xylem brand TABLE OF CONTENTS SAFETY Seo ram cs an NOLO era ene ipie geo Setar cas Beas DES etr EEEE I I Pid al tots ee 3 INSTALLATION POCA On eT 4 Input Disconnect Features and Functions sssssssssesseeeeeseeeeeene tenentes 4 Installation Fow Chan snien E E Lu up UM NI MEI DUMMIES exei 6 Preparing for Installation Supplement to Aquavar CPC 01 U1 User s Manual sese 7 Installing the Drive Supplement to Aquavar CPC 01 U1 User s Manual 9 Installing the Wiring Supplement to Aquavar CPC 01 U1 User s Manual sse 10 MAINTENANCE Maintenance Interval Susreti M 14 Drive Module Fan Replacement sse eene eee tren retener retenti etre 14 Enclosure Fan Replacement NEMA 12 Enclosures umiinne entente nre nnns 15 Enclosure Air Filter Replacement NEMA 12 Enclosures tenete 16 TECHNICAL DATA Ratings Supplement to Aquavar CPC 01 U1 User s Manual sess 19 Input Power Connections Supplement to Aquavar CPC 01 U1 User s Manual sss 20 Motor ConnectionS emet MN EE 26 Cooling REAR 8 3o eee t i eee belga eee tae nb ee atenci eeetta esti IER A e ei der 26 Dimensions and Weights Supplement to Aquavar CPC 01 U1 User s Manual 27 Applicabl
12. Technology Customer Service Department The warranty excludes a Labor transportation and related costs incurred by the dealer b Reinstallation costs of repaired equipment c Reinstallation costs of replacement equipment d Consequential damages of any kind and e Reimbursement for loss caused by interruption of service For purposes of this warranty the following terms have these definitions 1 Distributor means any individual partnership corporation association or other legal relationship that stands between Goulds Water Technology and the dealer in purchases consignments or contracts for sale of the subject controllers 2 Dealer means any individual partnership corporation association or other legal relationship which engages in the business of selling or leasing controllers to customers 3 Customer means any entity who buys or leases the subject controllers from a dealer The customer may mean an individual partnership corporation limited liability company association or other legal entity which may engage in any type of business THIS WARRANTY EXTENDS TO THE DEALER ONLY Xylem ene Lars Salve Water 2881 East Bayard Street Ext Suite A Seneca Falls NY 13148 Phone 800 453 6777 Fax 888 322 5877 www xyleminc com brands gouldswatertechnology Goulds is a registered trademark of Goulds Pumps Inc and is used under license Aquavar is a trademark of Xylem Inc or one of i
13. V 11 mm 119 32 Measurements are center to center Weights The following table lists typical maximum weights for each frame size Variations within each frame size due to components associated with voltage current ratings and options are minor En Weight closure R1 R4 R5 R6 R7 R8 kg lb kg kg Ib kg Ib kg Ib kg Ib kg Ib NEMA 1 13 28 17 55 121 121 266 163 360 230 506 360 793 NEMA 12 15 33 19 57 125 123 271 166 375 250 551 380 837 NOTE 088A 2 114A 2 and 097A 4 NEMA 1 amp 12 units are R4 frame base drives in R5 enclosures R5 enclosure information applies 28 TECHNICAL DATA Outside Dimensions Outside Dimensions NEMA 1 R1 R4 Outside Dimensions Se r Lr LJ iy DS0301 DS0302 Input Disconnect NEMA 1 R1 R4 Dimensions R1 R2 R3 R4 Ref mm in mm in mm in mm in VV 198 7 8 198 7 8 260 110 2 260 10 2 H 729 28 7 829 32 6 1013 39 9 1147 45 2 D 283 11 2 295 11 6 304 11 9 332 13 1 NOTE 088A 2 114A 2 and 097A 4 NEMA 1 amp 12 units are R4 frame base drives in R5 enclosures R5 enclosure information applies TECHNICAL DATA NEMA 12 R1 R4 Outside Dimensions TES wd w m Ll n n a L DS0303 DS0304 Input Disconnect NEMA 12 R1 R4 Dimensions R1 R2 R3 R4 Ref mm in mm
14. al contains supplemental information that is unique to Aquavar CPC input dis connect configurations FD suffix Refer to the base manual Aquavar CPC User s Manual IM167 for all other information Input Disconnect Features and Functions The Aquavar CPC with Input Disconnect is an Aquavar CPC AC adjustable frequency drive packaged with an input disconnect switch and with a door mounted external operating handle The operating handle can be padlocked in the OFF position padlock not supplied Enclosure options are NEMA 1 NEMA 12 and NEMA 3R UL Type 1 UL Type 12 and UL Type 3R The following is a typical power diagram Disco EIER Drive with Input Disconnect or Circuit Breaker 3 Phase Aquavar Input Power c e CPC or 3 Drive 1 Phase Input Power L 4 INSTALLATION The following figures show the front view of the Aquavar CPC Input Disconnect standard configurations and identify the major components R1 R4 R5 R6 R7 R8 NEMA 1 amp 12 NEMA 1 amp 12 NEMA 1 amp 12 Enclosures Enclosures Enclosures Aquavar CPC Drive Control Panel i LLULL LLL FG I BP0094 Operating Handle for Disconnect Switch BP0093 INSTALLATION Installation Flow Chart The installation of Input Disconnect configurations for Aquavar CPC drives follows the outline below The steps must be carried out in the order shown At the right of each step are refer
15. e Rating 1 NEMA 1 2 NEMA 12 Fused Disconnect NOTE Standard equipment on 200 HP and above models R7 R8 Frames Options Consult factory for other options if available Not all combinations may be available Ratings and Frame Size Charts in the Ratings sections of the Aquavar CPC User s Manual and this manual list technical specifications and identify the drive s frame size NOTE Some instructions in this document vary depending on the drive s frame size To read the Ratings table you need the Output current rating entry from the type code see above INSTALLATION Suitable Mounting Location For selecting a suitable mounting location for FD configurations refer to e Preparing for installation in the Aquavar CPC User s Manual and e The Technical Data section of this manual for information on dimensions and weights Installing the Drive Supplement to Aquavar CPC User s Manual IM167 WARNING Metal shavings or debris in the enclosure can damage electrical equipment and create a hazardous condition Where parts such as conduit plates require cutting or drilling first remove the part If that is not practical cover nearby electrical components to protect them from all shavings or debris Prepare the Mounting Location R7 and R8 The Aquavar CPC should only be mounted where all of the requirements defined in Preparing for Installation are met PC00023 the enclosure base See
16. e Standard PEE TREE ALI DLL 34 INDEX SAFETY p pe je e Ie mg WARNING The AQUAVAR CPC adjustable speed AC drive with Input Disconnect should ONLY be installed by a qualified electrician WARNING Even when the motor is stopped dangerous voltage is present at the Power Circuit terminals U1 V1 W1 and U2 V2 W2 and depending on the frame size UDC and UDC or BRK and BRK WARNING Dangerous voltage is present when input power is connected After disconnecting the supply wait at least 5 minutes to let the intermediate circuit capacitors discharge before removing the cover WARNING Even when power is removed from the input terminals of the AQUAVAR CPC there may be dangerous voltage from external sources on the terminals of the relay outputs WARNING When the control terminals of two or more drive units are connected in parallel the auxiliary voltage for these control connections must be taken from a single source which can either be one of the units or an external supply WARNING The AQUAVAR CPC will start up automatically after an input voltage interruption if the external run command is on WARNING When the AQUAVAR CPC with Input Disconnect is connected to the line power the Motor Terminals T1 T2 and T3 are live even if the motor is not running Do not make any connections when the AQUAVAR CPC with Input Disconnect is connected to the line Disconnect and lock out power to the drive before servicing the drive Failur
17. e to disconnect power may cause serious injury or death NOTE For more technical information contact the factory or your local AQUAVAR representative USE OF WARNINGS AND NOTES There are two types of safety instructions throughout this manual Notes draw attention to a particular condition or fact or give information on a subject Warnings caution you about conditions which can result in serious injury or death and or damage to the equipment They also tell you how to avoid the danger The warning symbols are used as follows pe DANGEROUS VOLTAGE WARNING warns of high voltage which can cause physical injury and or damage to the equipment GENERAL WARNING warns about conditions other than those caused by electricity which can result in physical injury and or damage to the equipment INSTALLATION Study these installation instructions carefully before proceeding Failure to observe the vvarn ings and instructions may cause a malfunction or personal hazard 4 WARNING Before you begin read Safety on page 3 WARNING When the Aquavar CPC with Input Disconnect is connected to the line power the Motor Terminals T1 T2 and T3 are live even if the motor is not running Do not make any connections when the Aquavar CPC with Input Disconnect is connected to the line Disconnect and lock out power to the drive before servicing the drive Fail ure to disconnect power may cause serious injury or death Application This manu
18. er bracket forward until the hooks on the bracket clear the slots on the enclosure base This step allows the filter and bracket to drop free from the enclosure Back of Enclosure Enclosure Mounting gt Filter Bracket Screw 3 Lift the filter out of the filter bracket and replace as appropriate 4 With the filter in the filter bracket align the hooks on the bracket with the slots in the enclosure base and press the hooks up into the slots 5 Slide the filter bracket back making sure that the hooks catch on the enclosure 6 Replace the mounting screw Tighten until the gasket on the bracket is about 5096 compressed Frame Sizes R7 R8 Nema 12 Enclosure Inlet Air Filter The inlet air filter for the R7 R8 NEMA 12 enclosure is located in the enclosure front door 1 While holding the top of the filter frame pull up on the bottom of the frame The filter frame will slide up approximately 34 inch and can then safely removed by tilting away from the cabinet and lifting up PC00015 PC00010 MAINTENANCE 2 Lay the filter frame on a flat work surface Remove the 3 retaining brackets by squeezing the tabbed corners in towards the middle of each bracket until the bracket clears the filter frame Save these brackets for replacement Remove and inspect the filter PC00009 PC00007 3 Install the replacement filter Be sure to tuck the filter into the grove around the entire filter frame This is very imp
19. g gus eo er ere a ees 26 DUCTU EPI HR 20 208 240 volt drives 0 ll e esses 20 380 480 volt drives esses 21 500 600 volt A VeS s escis Rer CR mes 22 G grounding GquilermielitS eee desee Po HK Ee eei een 10 H heat LOSS Sei eet eA LADEN MEL ME 26 heatsink maintenance interval esee 14 I input disconnect see disconnect input power cable wire requirements 22 USC Ses te fie RENTRER ERE I RR 20 installation flow chari e eai sasssa segell apor Dqea Led ea otra a tence 6 preparation 0 cece eee eee ee eens 7 L label YPE COJE i rigor kobe dep ete Sana a bate bd 8 location mounting vau kee eee eee 9 M maintenance drive module fan replacement 14 enclosure fan replacement 14 intervals diusia e i aE ae ae eee ee 14 R5 R6 enclosure inlet filter 16 R7 R8 enclosure exhaust filter 18 R7 R8 enclosure inlet filter 16 manuals listing sss ii motor connection specifications 26 motor cable maximum lengths ssa oreen 26 N NEMA 1 Goden esa tea ea meta Vp RR PUER E E RE 8 NEMA 12 COAG cs pte Dos Dep ea teg oc cn sea 8 R zie m TE 19 i e 7 Swoi i r 6 S Safety Lees nde Seca at SH ETE in Uer e ice 3 specifications COOLING wren ced edo aeo deg aoo bns 26 motor CONNECTIONS 2 eee esee 26 Standards ilios esde Vibe ena da de yoke 34 C22 2 N
20. in mm in mm in VV 222 8 7 222 8 7 267 10 5 267 10 5 H 744 DO 8 844 SIL 1030 40 6 1163 45 8 D 283 11 2 295 11 6 304 119 332 12 1 NOTE 088A 2 114A 2 and 097A 4 NEMA 1 8 12 units are R4 frame base drives in R5 enclosures R5 enclosure information applies 30 TECHNICAL DATA NEMA 1 R5 R6 Outside Dimensions BP0063 Input Disconnect NEMA 1 R5 R6 Dimensions R5 R6 Ref mm in mm in VV 713 28 1 713 28 1 H 212 ATE 1212 47 7 D 484 OM 484 19 1 NOTE 088A 2 114A 2 and 097A 4 NEMA 1 8 12 units are R4 frame base drives in R5 enclosures R5 enclosure information applies TECHNICAL DATA NEMA 12 R5 R6 Outside Dimensions BP0062 E Input Disconnect NEMA 12 R5 R6 Dimensions R5 R6 Ref mm in mm in VV 734 28 9 734 DS H 1371 54 0 1371 54 0 D 484 OM 484 19 1 NOTE 088A 2 114A 2 and 097A 4 NEMA 1 8 12 units are R4 frame base drives in R5 enclosures R5 enclosure information applies 32 TECHNICAL DATA NEMA 1 amp 12 R7 R8 Outside Dimensions W gt ii F I AS BP0017 Enclosure x z in W 806 Sm 806 31 7 NEMA 1 H 2125 83 7 2125 83 7 D 659 25 9 659 25 9 Ww 806 SI 806 Sm NEMA 12 H 2377 93 6 2377 93 6 D 659 25 9 659 25 9 Addi
21. lbs 60 CPC4077xFD RA 62 in lbs 41 0 42 0 75 CPC4096xFD id 70 in lbs 132 in lbs 100 CPC4124xFD R6 300 MCM 3 x 3 0 200 in lbs 300 MCM 300 MCM 250 in lbs dE Berea a 200 in Ibs 354 indbs 150 CPC4180xFD R 350 MCM 200 CPC4245xFD R7 2x250 350 in lbs MCM 2x250 250 CPC4316xFD R8 275 in lbs MCM 500 in lbs 300 CPC4368xFD R8 2 x 500 2x500 5 Bus Bar 350 CPC4414xFD R8 MCM MCM Holes 400 CPC4486xFD R8 275 in lbs 500 in lbs 13 32 450 CPC4526xFD R8 2x600 Bolts 500 CPC4602xFD R8 3x400 MM 500 in lbs MCM to 375 in lbs a 550 CPC4645xFD R8 MCM 500 in lbs NOTE x represents both NEMA 1 and NEMA 12 24 TECHNICAL DATA 500 600 Volt Terminals 500 600 Volt Povver VViring Data Ground Frame circuit pini Motor Lugs HP Type cede mie Breaker oe Terminals NEMA 1 amp 12 2 CPC5002xFD R2 3 CPC5004xFD R2 5 CPC5006xFD R2 6 8 8 4 7 5 CPCBOO9XFD R2 62 in lbs 7 in lbs 12in lbs 35 in lbs 10 CPCBOTTXFD R2 15 CPC5017xFD R2 20 CPC5022xFD R3 3 3 3 25 CPC5027xFD R3 62 in lbs 18 in lbs 24 in lbs 30 CPC5032xFD R4 1 40 CPC5041xFD R4 18 in lbs 2 50 CPC5052xFD RA i 0 8 0 1 0 50 in lbs 62 in lbs 55 in lbs 180 in lbs 60 CPC5062xFD R4 dis 62 in lbs 75 GPCBUZZxFD R6 1 0 100 CPC5099xFD R6 300MCM 70in lbs 300 MCM 3x 3 0 125 CPC5125xFD R6 200 in lbs 300 MCM 354 in lbs 250 in lbs 150
22. listed belovv are exceptions to the ratings listed in the Aquavar CPC User s Manual Ratings 380 480 Volt Drives Type Code Valid up to 40 C 104 F Normal Use Heavy Duty Use Sama lis AQUAVAR CPC FD lon Py Iona Ppa see below A HP A HP CPC4245xFD 245 200 192 150 R7 CPC4316xFD 316 250 240 200 R8 CPC4368xFD 368 300 302 250 R8 CPC414xFD 414 350 368 300 R8 CPC486xFD 486 400 414 350 R8 CPC526xFD 526 450 477 400 R8 CPC602xFD 602 500 515 450 R8 CPC645xFD 645 550 590 500 R8 NOTE ay Motor current draw normal P Normal rated power Iona Heavy duty current rating Pig Heavy duty NEMA power rating TECHNICAL DATA Input Povver Connections Supplement to Aquavar CPC User s Manual Fuses NOTEI Although fuses listed are similar in functional characteristics to fuses listed in the Aquavar CPC User s Manual physical characteristics may differ Fuses from other manufacturers can be used if they meet the functional characteristics of those in these tables Drive input fuses are provided to disconnect the drive from povver in the event that a component fails in the drive s povver circuitry 208 240 Volt Fuses 208 240 Volt Base Drive Input Fuse Ratings Drive HP Identification oe S S 1 CPC2004xFD R1 15 KTK R 15 2 CPC2007xFD R1 15 KTK R 15 3 CPC2012xFD R1 15 KTK R 15 5 CPC2017xFD R1 30 KTK R 30 7
23. o 14 cee 34 UL BBC m ster am e due dece a 34 T terminals power WIFE SIZeS eee ee eee 23 type code oer e Re da datades d estas 8 V voltage rating Codec ua eu cet ertet e e gne 8 VV vvarning automatic startup esses srera rE EE EEE RES 3 dangerous voltages cece eee eee eee 3 listing i a e ea 3 parallel control connections 3 qualified installer 3 weight EIN ERE teta ea en ot ITI a e aT 28 wiring connection diagrams floor mounted 12 connection diagrams wall mounted 11 line input installation 13 OVEIVIEW 2 2 eee eee n 11 FEGUITEIMENTS a uuo a goa es cR pe Re A der Rs 10 35 GOULDS WATER TECHNOLOGY LIMITED WARRANTY This warranty applies to all Aquavar CPC controllers manufactured by Xylem Inc Any part or parts found to be defective within the warranty period shall be replaced at no charge to the dealer during the warranty period The warranty period shall exist for a period of twenty four 24 months from date of installation or thirty 30 months from date of manufacture whichever period is shorter A dealer who believes that a warranty claim exists must contact the authorized Goulds Water Technology distributor from whom the controller was purchased and furnish complete details regarding the claim The distributor is authorized to adjust any warranty claims utilizing the Goulds Water
24. on nteni BP0054 Dashed line is ground run R7 shown R8 similar to R7 WARNING Check the motor and motor wiring insulation before connecting the Aquavar CPC to line power Follow the procedure in the Aquavar CPC User s Manual Before proceeding with the insulation resistance measurements check that the Aquavar CPC is disconnected from incoming line power Failure to disconnect line power could result in death or serious injury NOTE For the remainder of the installation and start up motor and control wiring refer to the Aquavar CPC User s Manual MAINTENANCE Maintenance Intervals If installed in an appropriate environment the drive requires very little maintenance This table lists the routine maintenance intervals recommended by Goulds Water Technology Maintenance Configuration Interval Instruction Check replace R5 R6 R5 R6 NEMA 12 Check every 3 Frame Sizes R5 R6 Enclosure enclosure inlet air filter enclosures months Replace Inlet Air Filter on page 16 as needed Check replace R7 R8 R7 R8 NEMA 12 Check every 3 Frame Sizes R7 R8 NEMA 12 enclosure inlet air filter enclosures months Replace Enclosure Inlet Air Filter on as needed page 16 Check replace R7 R8 R7 R8 NEMA 12 Check every 6 Frame Sizes R7 R8 NEMA 12 enclosure exhaust air enclosures months Replace Enclosure Exhaust Filters on filter as needed page 18 Check and clean All Depends on the
25. ortant for proper installation PC00013 4 Reinstall the 3 filter restraining brackets These will prevent the filter from being pulled out of the filter frame e Install the center bracket first e Install the 2nd bracket overlapping the center bracket by 1 to the left PC00007 PCO0009 e Install the 3rd bracket overlapping the center bracket by to the right ILI 1st filter retaining bracket ERTI 1st and 2nd filter retaining brackets All 3 filter retaining brackets 5 Install the filter frame back to the cabinet door Carefully align the mounting hooks to the slots in the cabinet door The hooks should be pointing down Press in at the center of the filter frame with your knee and gently press down with your hands at the top of the frame The filter frame will slide down approximately 34 inch and should be sealed securely to the door around the entire filter frame i PC00006 PC00008 17 MAINTENANCE Frame Sizes R7 R8 NEMA 12 Enclosure Exhaust Filters The exhaust filters in the R7 R8 NEMA 12 enclosure are located in the exhaust box at the top of the enclosure There are 2 filter frames attached to the exhaust box 1 Remove each filter frame mn TAI e Lift up on the filter frame until it slides approximately 34 inch TUA m e Pull away from the exhaust box to remove PC00021 For each filter frame remove the wire retainers that hold the filters in place e
26. pe Code Size Breaker Terminals NEMA 1 amp 12 1 CPC2004xFD R1 2 CPC2007xFD SI 62 in lbs 7 in lbs 12 in lbs 3 CPC2012xFD R1 4 5 CPC2017xFD R1 SE indbs 7 5 CPC2024xFD R2 6 7 in lbs 8 10 CPC2031xED R2 62 in lbs 6 12 in lbs 18 in lbs 15 CPC2046xFD R3 3 3 3 20 CPC2059xFD R3 62 in lbs 18 in lbs 24 in lbs 25 CPC2075xFD RA 0 did 62 in lbs 55in lbs 2 30 CPC2088xFD R4 ditis 10 50 inlis 2 0 70 in lbs 180 in lbs 40 cPC2114xFD R4 200inlbs 2 0 200 in lbs 50 CPC2143xFD R 300 MCM 300 MCM 300 MCM 60 CPC2178xFD R6 200 in lbs 200 in lbs 354 in Ibs 3 x 3 0 250 in lbs 75 CPC2221xFD R6 2x250 2x250 559 MCM MON MENS 35ddndbs 100 CPC2248xFD R6 275 in lbs 275 in lbs NOTE x represents both NEMA 1 and NEMA 12 23 TECHNICAL DATA 380 480 Volt Terminals 380 480 Volt Povver VViring Data Ground Frame circuit oii Motor Lugs me Type Code Size Breaker a Terminals NEMA 1 amp 12 3 CPC4006xFD R1 5 CPCAO08xFD R1 62 in lbs 7 in lbs 12 in lbs aT 7 5 CPC4012xFD R1 ES 10 CPCAO15xFD R2 6 8 8 15 CPC4023xFD R2 62 in lbs 7 in lbs 12 in lbs 20 CPCAO31xFD R3 3 3 3 25 CPC4038xFD R3 62 in lbs 18 in lbs 24 in lbs 30 CPC4044xFD RA 1 2 40 CPC4059xFD R4 18 in lbs 1 0 1 0 goania 50 CPC4072xFD R4 11 0 62 in lbs 55 in lbs 31 0 180 in
27. rilling first remove the part If that is not practical cover nearby electrical components to protect them from all shavings or debris e Do not connect or disconnect input or output power wiring or control wires when power is applied e Never connect line voltage to drive output Terminals T1 T2 and T3 e Do not make any voltage tolerance tests Hi Pot or Megger on any part of the unit Disconnect motor wires before taking any measurements in the motor or motor wires e Make sure that power factor correction capacitors are not connected between the drive and the motor Wiring Requirements Refer to the Wiring Requirements Section in the Aquavar CPC User s Manual The requirements apply to all Aquavar CPC drives In particular Use separate metal conduit runs for the following different classes of wiring Input power wiring Motor wiring Control communications wiring e Properly and individually ground the drive the motor and cable shields e Ground the pressure transducer or piping back to the Aquavar chassis or common grounding point INSTALLATION VViring Overvievv Povver Connection Standard Input Disconnect R1 R VVall Mounted The following figures show the Standard Input Disconnect wall mounted wiring connection points Refer to the Aquavar CPC User s Manual for control connections to the drive R1 R4 Aquavar R5 R6 NEMA 1 amp 12 NEMA 1 amp 12 I i CE Enclosures I O Conduit Enclosure
28. s Top Input Power Terminals Motor Disconnect Switch Terminals or Circuit Breaker Input Power Terminals El BP0058 O Conduit Bottom INSTALLATION Power Connection Standard Input Disconnect R7 R8 Floor Mounted The R7 and R8 Aquavar CPC Standard Input Disconnect units are configured for wiring access from the top and include a removable conduit mounting plate The following figure shows the Standard Input Disconnect floor mounted wiring connection points Refer to the Aquavar CPC User s Manual for control connections to the drive R7 R8 NEMA 1 amp 12 NEMA 1 amp 12 Motor Ground Lu G dL g round Lug Tesi Bar xa CPC Bar Input Povver l Motor Terminals ee Terminals aay I Input Povver e eg l HH Terminals NIL El em Hd i m Disconnect Switch Disconnect Switch i I or Circuit Breaker or Circuit Breaker B 1l BP0054 BP0055 INSTALLATION Install the Line Input VViring Line Input Connections Standard Input Disconnect Configurations Connect input power to the terminals of the disconnect switch or circuit breaker Connect the equipment grounding conductor to the ground lug The figure below shows the connection points for Standard Input Disconnect configurations R1 R4 1 R5 R6 R7 R8 NEMA 1 amp 12 E NEMA 1 amp 12 Input NEMA 1 amp 12 Enclosures i Enclosures Power a Enclosures pum 1 DECTUER TERT y uem icy Y VV NS BP0057 dlapeeream teseseees
29. t to Aquavar CPC User s Manual Mounting Dimensions NEMA 1 amp 12 R1 R6 Mounting Dimensions R1 R4 See Detail A Y f CVV VV VV VN See Detail B DS0301 W2 BP0057 Detail A Detail B NEMA 1 and NEMA 12 Mounting Dimensions for each Frame Size R1 R2 R3 R4 R5 R6 mm in imm in mm in immi in mm in mm in W1 98 39 98 29 160 6 3 160 6 3 600 23 6 600 23 6 W2 98 29 98 29 160 6 3 160 6 3 600 23 6 600 23 6 H 712 28 0 812 32 0 983 38 7 1117 44 0 1175 46 3 1175 463 Ref a 5 5 02 55 02 6 5 10 25 6 5 1025 6 5 025 9 0 0 35 b 10 0 0 4 10 0 1 0 4 13 0 0 5 13 0 0 5 14 0 0 55 14 0 0 55 c 55 BE 5 5 NUM 20 NUSM 50 ROR 85 EOE 05 NUS d 5 5 02 55 02 6 5 10 251 6 5 1025 6 5 025 9 0 0 35 Mounting Hardware M 1 4 M6 1 4 M6 1 4 M6 1 4 M8 5 16 M8 5 16 Measurements are center to center NOTE 088A 2 114A 2 and 097A 4 NEMA 1 amp 12 units are R4 frame base drives in R5 enclosures R5 enclosure information applies TECHNICAL DATA NEMA 1 amp 12 R R6 Mounting Dimensions NEMA 1 and NEMA 12 Dimensions for each Frame Size Ref R7 amp RB Top View mm in VV 806 81 7 D 659 2510 e m o a 675 26 6 b 474 5 163 7 b D c 61 DA c d 65 5 2 6 o o Mounting Hardvvare V
30. tional Free Space Recommendations In addition to the free space requirements for cooling Cooling R7 R8 allow e 800 mm 31 5 in in front of R7 R8 enclosures room for the cabinet door to swing open e 305 mm 12 in above R7 R8 IP54 UL Type 12 enclosures room for fan replacement 33 TECHNICAL DATA Applicable Standards Drive compliance with the following standards is identified by the standards marks on the type code label Mark Applicable Standards U UL 508C and UL Standard for Safety Power Conversion Equipment second 3 L he C22 2 No 14 edition and CSA Standard for Industrial Control Equipment LISTED UL 508A UL Standard for Safety Industrial Control Panels C22 2 No 14 CSA Standard for Industrial Control Equipment Compliance is valid with the following provisions e The motor and control cables are chosen as specified in this manual e The installation rules of this manual are followed INDEX Refer to the Aquavar CPC User s Manual IM1 67 index for topics not listed here A ali TOW pakrana e v LES dal E ER eh ete 26 c cable requirements Input DOWeF iccse ere Creme e epp etd 22 capacitor change maintenance interval 14 connection points floor mounted enclosures 12 wall mounted enclosures 11 model code Lee vu vu duu eee 8 control panel maintenance interval battery 14 cooling ike beeb E
31. ts subsidiaries DUSTLOK is a registered trademark of Fiberbond Corp 2012 Xylem Inc 1M250 Revision Number 1 July 2012
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