ITT S-DRIVE IM213 User's Manual
Contents
1. _ 13 80 4 c izing S Input Wi IX Append 901 2206 Nbd 100602045 00602445 5 10 ndul 2 06 q108 su16u 1 TLEL CLCL 6901 1091 6671 OZEL L702 5481 8591 404 CLL LLSZ 9277 0991 7971 6ZE 6VOE LOLZ 8207 6 1 LSLE 6LVE 060 02EZ 7502 7467 884 6 0 LLOE 6276 yndu seud 0889 98S 5126 TEGE COVE 70 SY08 St 099 6005 9777 5666 616 0818 9 19 1675 67671 766117 901 7908 0 1 9081 1191 88 1 25 72 687121110001 16 PECL 06881 1 8991 90851 0 6901 GVOSE 19 688 10 9 6 IVES 1 9 61 68 696 958 786 6 961 8081 1021 6901 S06 vel 709 V6772 9661 Z9EL 9SLL Lv6 S08 S662 6002 78Z1 ZLSL 181 901 LISY 8410 9080 5672 1438 14 74 1445 7066 4966 JOLLE 00 lt 9022 0061 09 8 7118 96 6 ES87 gely 8 6162 seyd LvLv 1164961 664166101 816 EZL8 9969 9696 16 NOEZ 868961 8181 CEG L SSSEL 0100109801 8576 0649 17 ILLOTE 70981 8882. Other transformer configurations are acceptable Three single phase transformers can be used if they are identical for phase to phase symmetry and balance A wye connected primary neutral should never be grounded Great care should be taken with delta primary delta secondary configurations Any lack of phase to phase symmetry could result in circulating currents and unacceptable transformer heating Warning Never use phase converters with drives as nuisance tripping and possible damage may Hazardous occur Instead use single phase input power and 50 derate factor Warning Awarning Open Delta power systems should be sized using the 50 derate factor Consult factory Starting the System Section 7 Output Power Connections Run the motor lead wire from the motor or conduit box through metal conduit to the bottom of the controller Use metal conduit and metal conduit connectors Size the conduits according to the NEC or local codes Connect conduit and insert the wires through the second or third opening from the left Choose the opening that fits or is larger than the conduit used If the opening is larger than the conduit use conduit bushings to attach the conduit to the controller Starting the System Section 7 continued Consult motor manual to determine the wire size for the application Ensure the ground connection to the motor is continuous Connect wires to the output termi
3. between the pressure sensor cable and input or output wiring Ensure the pressure sensor cable is connected as follows Brown to terminal 7 24VDC SUPPLY White to terminal 6 TRANSDUCER INPUT Drain to chassis Connecting the Drain wire to the chassis electrically connects the sensor case to the chassis of the controller In some cases this drain wire must be disconnected from the controller chassis In cases where the there is grounded metal piping which is continuous between the transducer and the motor or the transducer is installed in grounded metal piping a ground loop can result so the drain wire must be disconnected from the chassis In cases where there are sections of nonmetallic piping between the transducer and motor or the transducer is installed in ungrounded piping this drain wire should be connected to the controller chassis Mounting the Controller Section 5 General Mount the controller in a well ventilated shaded area using 4 screws The controller must be mounted vertically Be sure to leave 8 inches of free air space on every side of the unit The controller must be in an area with an ambient between 22 F and 122 F If installation is above 3300 feet above sea level ambient temperatures are derated 1 per 330 feet above 3300 feet The altitude limit for this controller is 6500 ft Do not install above 6500 ft Mounting the Controller Section 5 continued Note Do not block the heat sink fins a
4. 020300 and SPD20300F must have temperature rating of 90 C minimum Danger The controller has a high leakage current to ground The input terminals marked GND 1 must be directly connected to the service entrance ground Failure to properly ground the controller or motor will create an electrical shock hazard Note If single phase input power is used the Motor Overload switches must be set to 50 or lower or nuisance input phase loss errors can result Note Do not use GFCI protection with this controller Nuisance tripping will result Danger Status Code Indicator Light is not a voltage indicator Always turn off disconnect switch and circuit breaker and wait 5 minutes before servicing Danger The controller will remain electrically charged for 5 minutes after power is turned off 15 Wait 5 minutes after disconnecting power before opening controller access cover as there is a severe shock hazard Starting the System Section 7 continued Setting the Motor Overload Switches The Motor Overload Setting Switches adjust the level of motor overload current protection necessary to protect the motor in case of an over current condition er Bank 1 switches 1 2 and 3 allow adjustment of the motor overload setting These switches adjust the motor overload protection as a percentage of the full load output current rating of the controller Choos
5. 30 C 40 C 50 C Generator Input Output Input Output Input Output Input Output Voltage Frame Model Full Load Fuse Size Cable Cable Cable Cable Cable Cable Cable Cable Size Number Output Current Size VA Min AWG Min AWG Min AWG AWG Min AWG Min Min AWG Min AWG 1 17 8 50 300 7700 10 14 10 14 10 12 8 12 PT 26 4 75 40 0 11400 8 12 8 10 8 10 6 8 SPD20100F 37 0 10 0 50 0 16000 8 10 8 8 6 8 4 8 230 Ot 47 4 15 0 700 20500 4 8 4 8 4 6 3 6 SPD20200F 60 6 20 0 80 0 26200 4 6 4 6 4 4 2 4 j 76 0 25 0 110 0 32800 2 4 2 4 1 3 1 0 2 SPD20300F 94 0 30 0 135 0 40600 2 3 17 3 1 2 1 0 1 ast 8 9 5 0 15 0 7700 14 14 14 14 14 14 14 14 SPD40075F 13 2 75 20 0 11400 12 14 12 14 12 14 10 14 ne 18 5 10 0 30 0 16000 10 14 10 14 10 12 8 12 460 2 a 23 7 15 0 40 0 20500 8 12 8 12 8 10 6 10 30 3 20 0 50 0 26200 8 10 8 10 6 10 4 8 375 25 0 60 0 32400 6 8 6 8 4 8 4 8 SPD40300F 47 0 30 0 70 0 40600 4 8 4 8 4 6 3 6 90 C Wire Required on input to controller Power Supply and Wiring Section 6 continued Input Power and Line Transformer Requirements The line input voltage and transformer power must meet certain phase and balance requirements If you or your installing electrical contractor is in doubt of the requirements the following provide guidelines for installation When in doubt contact the local power utility o
6. Phase Connection For small drives with diode rectifier front end it is possible to run a three phase output with a single phase input Only part of the three phase input bridge is used Ripple current becomes 120 Hz rather than 360 This places a greater demand on the DC filter components capacitor bank and DC choke The result is that the drive must be derated to 50 current The chart below shows the full load output current ratings of the controller when single phase or 3 phase power is used If single phase input power is used the Motor Overload switches must be set to 50 or lower Nominal Controller Full Load HP Rating Output Current Rating Supply Frame Model 3 Phase 1 Phase 3 Phase 1 Phase Voltage Size Number Input Input Input Input l aN 2 0 17 8 8 1 20100 100 5 0 37 0 17 8 208 230 POIs 15 0 75 47 4 26 4 sPD20200F 09 10 0 60 6 33 0 SPD20300F 209 15 0 94 0 47 4 SPD40075F 132 100 18 5 i 23 7 20 0 30 3 s spp40300F 209 47 0 Power Supply and Wiring Section 6 continued Conduit Wire and Fuse Sizing The use of metal conduit with metal conduit connectors is recommended for all electrical connections Use the NEC or CEC to determine the required conduit size for the application Refer to the chart below f
7. charge in your tank would be required Use the higher tank pre charge setting if the system drifts over 5 PSI ata constant flow rate NOTE Pre charge your tank before filling with water Caution Maximum working pressure of HydroPro bladder tank is 125 psi Pressure Installing the Pressure Sensor The pressure sensor requires a 1 4 FNPT fitting for installation Install the pressure sensor with the electrical connector pointing up to avoid clogging the pressure port with debris Install the pressure sensor in a straight run of pipe away from elbows or turbulence For optimum pressure control install the pressure sensor in the same straight run of pipe as the pressure tank Ensure the pressure sensor is within 10ft of the pressure tank Installing the pressure sensor far away from the pressure tank may result in pressure oscillations Do not install the pressure sensor in a location where freezing can occur A frozen pipe can cause damage to the pressure Sensor Section 4 continued The pressure sensor cable is prewired to the controller The cable can be shortened for a cleaner installation Longer cable lengths are available consult factory Maximum recommended pressure sensor cable length is 300ft Avoid leaving a coil of pressure sensor cable as this can induce unwanted transient voltages and noise into the system Do not run the pressure sensor cable alongside the input or output wiring Maintain a distance of at least 8
8. the White wire in the sensor cable The meter will display the output of the sensor If functioning properly the output of the sensor will be between 4mA and 20mA depending on the pressure in the system Refer to the chart below to determine the sensor feedback at various pressures Pressure Transducer Output vs Applied Pressure for a 300 PSI 4 20mA Output Transducer 20 N lt 3 2 2 5 150 Pressure PSI The following formula gives the transducer output based on applied pressure Output Current C4 ut Current Rage y System Prese 4mA Pressure Range Where e Output Current is the transducer output e Output Current Range is the maximum output signal of the transducer minus the minimum output signal of the transducer In this case Output Current Range 20mA 4mA or 16mA Pressure Range is the pressure that corresponds to the maximum output signal For a 300 PSI transducer the Pressure Range 300 PSI 0 PSI 300 PSI System Pressure is the system pressure as read on the pressure gauge Troubleshooting Red Light Codes continued Flashes Controller Status Description Pump or Motor Bound This fault can be caused by e Mechanical binding from debris in pump Electrical failure of the motor Incorrect setting of Motor Overload Setting switches e Incorrect rotation e Motor phase loss This fault will be displa
9. to 75 PSI when used with a 300 PSI transducer When the switch is open pressure set point 1 is enabled preset to 50 PSI when used with a 300 PSI transducer PRESSURE DROP This input allows the user to select the amount of pressure drop in the system before the pump starts This input can be controlled by an external non powered switch Connect the contacts of a non powered external switch to terminals 5 or 9 COM and 12 PRESSURE DROP When the switch is closed the system pressure will drop 20 PSI when used with a 300 PSI transducer before restarting the pump When the switch is open the system pressure will drop 5 PSI when used with a 300 PSI transducer before restarting the pump RUN RELAY This output indicates when the pump motor is running This output can be used to control power to a light an alarm or other external device When the pump motor is off terminal 13 RELAY1 NO will be open and terminal 14 RELAY 1 NO will be connected to terminal 15 RELAY1 COM When the pump motor is on terminal 13 RELAY1 NO will be connected to terminal 15 RELAY1 COM and terminal 14 RELAY 1 NC will be open The relay rating is 250Vac 5 amps maximum FAULT RELAY This output indicates when the system is faulted This output can be used to control power to a light an alarm or other external device When the system is not faulted terminal 16 RELAY2 NO will be open and terminal 17 RELAY 2 NO will be connected to
10. 8 0 7 6 7 1 6 2 4 5 3 6 1 SPD40050F ae 13 2 12 5 11 9 11 2 10 6 9 2 6 6 5 3 SPD40075F 460 oe 18 5 17 6 16 7 15 7 14 8 13 0 9 3 7 4 5 040100 2 SFD40150 23 7 22 5 21 3 20 1 19 0 16 6 11 9 9 5 SPD40150F 30 3 28 8 27 3 25 8 24 2 21 2 15 2 12 1 SPD40200F ae 37 5 35 6 33 8 31 9 30 0 26 3 18 8 15 0 3 SPD40250F 47 0 44 7 42 3 40 0 37 6 32 9 23 5 18 8 SPD40300F Starting the System Section 7 continued Caution Failure to properly set the Motor Overload Setting switches can result in loss of motor overload protection and will void the motor warranty Nuisance tripping or motor damage can occur if these switches are not set properly Setting the Acceleration Deceleration Switches Switch 4 from bank 1 and switches 1 and 2 from bank 2 control the acceleration deceleration ramp times The acceleration deceleration switches ACCEL DECEL RAMP SETTINGS control how fast the controller will change the speed of the motor The ramp setting is the time it takes the motor to change from minimum speed to maximum speed For example if the ramp setting is set to 1 second and the minimum speed is set to 30Hz the motor will ramp up from 30Hz to 60Hz 1 second A faster ramp setting should be used in systems where the flow rate can change quickly This means that the motor can react faster to maintain the set pressure A slower ramp setting should be used in systems where the
11. 9L ELZSLESEL 96511 9349 1818 069 LE jPSE67 97170 61612 77 61 996 1 16 14144 9501 96166190696 5986 61681 79061121801 O9ELSIELSLV EELOE VZSSE 000 CE 69780 811 60 66 8Z 902 99270 7786 61141 8911 8991 7 51 0 1 SELL 7001 8116 0002 8181 6061 CVE 90 V8LZ 9122 LLOZ 0975 9616 6897 YELE L6EE 9SCL 2589 CECI 796 6057 1706 LES8 79 9819 8196 11 180118 001 67208 E6ZL ELSVL 50 2 169721 2241 60801 LE66 1706 11061 656 6691 19661 9517 610611801 D SL 215 10Npuo doug uquy 2 0 ulBu 1 ajqemojjy yuan yndu yndu 1 lo11uop syey 21 a 1ndul 26 Commercial Water GOULDS PUMPS LIMITED WARRANTY This warranty applies to all water systems pumps manufactured by Goulds Pumps 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 Pumps distributor from whom the pum
12. GE WITHOUT NOTICE IM213 Revision Number 0 November 2008 Copyright c 2008 ITT Corporation Engineered for life
13. ITT Commercial Water Goulds Pumps S Drive Constant Pressure Aquavar SPD Variable Speed Pump Control aa Installation Operation amp Maintenance Models Covered S Drive Aquavar SPD 5 30 HP C _ _ G GOULDS PUMPS Goulds Pumps is a brand of ITT Corporation www goulds com Engineered for life Index Important Safety Instructions 3 System Components 4 System DesIgn esses ated an ead En aaia Eaa BVa aaa EEA aa aiiai nadania 5 k ll E OA tl a 7 Mounting the Controller rrisnin aaa aaa a 8 Power Supply and Wiring niet eta 9 Starting the System Input Output Connections Switch Settings Motor Rotation 14 Input and Output Functions Control Terminals l ll I n nn 19 Troubleshooting rsin anaana gan iaaa SENE lee 20 Controller Dimensions l 25 Appendix Input Wire Sizing Chart 1 nsn 26 Goulds Pumps Limited Warranty l nn 28 Note Use Copper wire only e Suitable for use in a pollution degree 2 micro environment e Motor overload protection provided at 110 of full load current In order to maintain the environ
14. Pressure _ for piping requirements in your area All joints must be airtight Use Teflon tape or another type of pipe sealant to seal threaded connections Please be careful when using thread sealant as any excess that gets inside the pipe may plug the pressure sensor Galvanized fittings or pipe should never be connected directly to the stainless steel discharge head or casing as galvanic corrosion may occur Barb type connectors should always be double clamped Pressure Tank Pressure Relief Valve and Discharge Piping Use only pre charged tanks on this system Do not use galvanized tanks Select an area that is always above 34 F 1 1 C in which to install the tank pressure sensor and pressure relief valve If this is an area where water leak or pressure relief valve blow off may damage property connect a drain line to the pressure relief valve Run the drain line from the pressure relief valve to a suitable drain or to an area where water will not damage property Pressure Tank System Pressure Sizing A bladder tank not included is used to cushion the pressure system during start up and shut down It should be sized to at least 20 of the total capacity of your pump Example If your pump is sized for 100 GPM then size your tank for at least 20 gal total volume not draw down Pre charge your bladder tank to 10 15 PSI below your system pressure The controller is pre set for 50 PSI at the factory Therefore a 35 40 PSI pre
15. UMP END 10 SUBMERSIBLE MOTOR 3 PHASE 11 PRESSURE RELIEF VALVE NOTE FOR SINGLE PHASE INPUT CONNECT L1 AND L3 THEN SET MOTOR OVERLOAD SWITCHES TO 50 OF CONTROLLER RATING OR LOWER System Design Section 3 continued Diagram 2 shows a set up for municipal water connection v SPD CONTROLLER 2 FUSIBLE DISCONNECT CENTRIFUGAL PUMP 4 CHECK VALVE 5 PRESSURE TRANSDUCER CABLE ASSEMBLY NOTES 0 SUPPLY POWER l L1 L2 L3 GND 3 PHASE OUTPUT TO MOTOR SUCTION AIR DIAPHRAGM TANK 3 PHASE MOTOR GATE VALVE BALL VALVE PRESSURE GAUGE PRESSURE RELIEF VALVE For single phase input power use L1 and L3 terminals and adjust motor overload switches to 50 of controller rating or lower Section 4 General Note All plumbing work must be performed by a qualified technician Always follow all local state and provincial codes A proper installation requires a pressure relief valve a 1 4 female N PT threaded fitting for the pressure sensor and properly sized pipe Piping should be no smaller than the pump discharge and or suction connections Piping should be kept as short as possible Avoid the use of unnecessary fittings to minimize friction losses Some pump and motor combinations supplied with this system can create dangerous pressure Select pipe and fittings accordingly per your pipe suppliers recommendation Consult local codes
16. al Electrical Code or the Canadian Electrical Code CEC as well as all local state and provincial codes Code questions should be directed to your local electrical inspector or code enforcement agency Failure to follow electrical codes and OSHA safety standards may result in personal injury or equipment damage Failure to follow manufacturer s installation instructions may result in electrical shock fire hazard personal injury death damage to equipment unsatisfactory performance and may void manufacturer s warranty Controller Product Code Information SPD Y F F WITH OUTPUT FILTER BLANK NO OUTPUT FILTER 4 DIGITS FOR HP 5 0050 7 5 HP 0075 10 HP 0100 15 HP 0150 20 HP 0200 25 HP 0250 30 HP 0300 1 DIGIT FOR INPUT VOLTAGE 230 VOLT 2 460 VOLT 4 575 VOLT 5 SERIES System Design Section 3 Note Systems MUST be designed by qualified technicians only and meet all applicable state and local code requirements The following diagrams show a typical system using the S Drive Constant Pressure Controller Diagram 1 shows a typical set up for a submersible system L1 T1 L2 T2 L3 T3 GND GND O o A rw S DRIVE CONTROLLER 2 FUSIBLE DISCONNECT 17 3 PRESSURE GAUGE AIR DIAPHRAGM TANK PRESSURE TRANSDUCER 3 PHASE OUTPUT ALWAYS DISCHARGE CHECK VALVE GATE VALVE HIGHLY RECOMMENDED 9 SUBMERSIBLE P
17. ating instructions This manual is intended to assist in the installation operation and repair of the system and must be kept with the system Installation and maintenance MUST be performed by properly trained and qualified personnel Review all instructions and warnings prior to performing any work on the system Any safety decals MUST be left on the controller and or pump system The system MUST be disconnected from the main power supply before attempting any operation or maintenance on the electrical or mechanical part of the system Failure to disconnect electrical voltage power before attempting any operation or maintenance can result in electrical shock burns or death When in operation the motor and pump could start unexpectedly and cause serious injury Hazardous Pressure System Components Section 2 Please review the S Drive components and insure that you have all the parts and are familiar with their names Be sure to inspect all components Goulds Pumps supplies for shipping damage S Drive Variable Speed Controller 1 S Drive Controller 2 Pressure Transducer with Cable 3 Conduit Plate Caps Warning DO NOT power the unit or run the pump until all electrical and plumbing connec tions especially the pressure sensor connection are completed The pump should not be run dry All electrical work must be performed by a qualified technician Al ACAUTION ways follow the Nation
18. cally restart according to the No Water Restart Time switches Sensor Fault This fault can be caused by Disconnected sensor Disconnect sensor from sensor cable connector and reconnect to ensure a good connection Disconnected sensor cable lead inside the controller Check for loose wires where the sensor cable connects to the circuit board by tugging on each wire Broken wire in the sensor cable e Miswired sensor cable Check that the wires are connected to the correct terminals on the control terminal block Connect terminal 7 24VDCSUPPLY to the Brown wire Connect terminal 6 TRANSDUCER INPUT to the White wire Connect the drain wire to chassis e Failed sensor To diagnose this failure a meter capable of reading milliamperes mA and DC voltage VDC is required Set the meter to read DC voltage VDC Place the black lead on terminal 5 COM and the red lead on terminal 7 24VDC SUPPLY If functioning properly the DC voltage will be 24VDC 15 If this voltage is not present disconnect all control terminals and repeat the measurement If voltage does not recover replace controller Troubleshooting Red Light Codes continued Flashes Controller Status Description 3 Blinks contd Disconnect the White wire in the sensor cable from terminal 6 Set the meter to read DC current mA Connect the black lead from the meter to terminal 6 TRANSDUCER INPUT Connect the red lead from the meter to
19. e a motor overload setting that meets or is less than the motor s SFA rating For example if the full load output current rating of the controller is 37A and the motor SFA rating is 33A the motor overload setting should be set to 85 33A 37A 89 next lowest setting is 85 Co 115 BANK3 CARRIER z FREQ C o Ts NO WATER RESTART TIME BANK2 RESTART 3 4 TIME 0 o 2HOURS In applications where the pump and motor are not used to the full capacity the system may not draw current close to the motor s SFA rating In this case choose a motor overload setting that is close to the actual full load running current Note If single phase input power is used the motor overload switches must be set to 50 or lower or nuisance input phase loss errors can result The chart below shows the motor overload setting for each model Motor Overload Setting Supply Frame Model Voltage Size Number 100 95 90 85 80 70 50 40 1 2PD20030 17 8 16 9 16 0 15 1 14 2 12 5 8 9 7 1 SPD20050F ee 26 4 25 1 23 8 22 4 21 1 18 5 13 2 10 6 2 SPD20075F 37 0 35 2 33 3 31 5 29 6 25 9 18 5 14 8 SPD20100F 208 230 47 4 45 0 42 7 40 3 37 9 33 2 23 7 19 0 3 SPD20150F 60 6 57 6 54 5 51 5 48 5 42 4 30 3 24 2 SPD20200F 8 76 0 72 2 68 4 64 6 60 8 53 2 38 0 30 4 4 SPD20250F 94 0 89 3 84 6 79 9 75 2 65 8 47 0 37 6 SPD20300F 8 9 8 5
20. flow rate changes slowly or where fast changes in speed can cause water hammer or pressure surges Setting the No Water Restart Time Switches Switches 3 and 4 from bank 2 control the no water restart time The no water dry well restart time switches control the time between a no water dry well error and the restart of the system For example if the no water restart time switches are set to 30 minutes the system will restart 30 minutes after a no water dry well error has been detected For the 10 minute restart time the controller will not restart if 5 faults are detected within 60 minutes All other settings will continue to restart after the chosen restart time Note Failure to properly set the motor overload switches can result in nuisance no water dry well faults Setting the Minimum Frequency Switch Switch 1 from bank 3 controls the minimum frequency The minimum frequency switch controls the slowest speed that the motor will run For submersible pump motor applications these switches must always be set to 30Hz minimum speed For above ground applications with high suction pressure the 15Hz setting can be used to prevent pressure oscillation at low speeds In some cases the suction pressure may be high enough that the pump exceeds the pressure setting at 30Hz In this case the 15Hz setting can be used Caution Failure to properly set the minimum frequency switch can result in motor damage and will void the motor
21. ill restart automatically 5 times After 5 faults the power must be RED LIGHT CODES reset to clear the fault 5 Blinks Short Circuit Ground Fault Controller will not restart Power must be reset to clear the fault REPLACE CONTROLLER WATER LOSS OF PRIME SENSOR FAULT PUMP OR MOTOR BOUND SHORT CIRCUIT GROUND FAULT INPUT PHASE LOSS TEMPERATURE OVER VOLTAGE MOTOR OVERLOAD 2 BLINKS 3 BLINKS 4 BLINKS 5 BLINKS 6 BLINKS 7 BLINKS 8 BLINKS 9 BLINKS 6 Blinks Input Phase Loss Controller will restart automatically 5 times After 5 faults the power must be reset to clear the fault 7 Blinks Temperature Controller will restart automatically when temperature is within the operating range of the controller 8 BLINKS Over Voltage Controller will restart automatically when the input voltage is within the operating range of the controller Q z gt z 3 9 Blinks Motor Overload Controller will restart automatically Use the following table to help troubleshoot problems No Light Controller Status Low No Input Voltage Check the input voltage to the controller Measure the input voltage between phases using an AC Voltmeter This voltage should be greater than 140Vac for the status indicator light to turn on Green Light Codes Flashes Controller Status Constant Constant Green Light indicates the pump is off The system is in Standby mode when there is no flow in the s
22. ircuit breaker and wait 5 minutes before servicing Input and Output Functions Section 8 The control terminal strips allow for a variety of input and output functions Warning Turn off all power to the controller before wiring devices to the CLOSED RUN i CLOSED RU control terminals SIGNAL COMMON Warning Inputs RUN STOP HAND AUTO SP2 SP1 and PRESSURE DROP are Al CLOSED HAND OPEN AUTO switch inputs Do not connect power to these inputs or damage to the controller TRANSDUCER PUT Will result Only connect non powered switch contacts to these inputs 3 SVOG SUPPLY RUN STOP This input allows the pump motor to be turned on and off by an 5 SIGNAL COMMON external switch Connect the contacts of a non powered external switch to CLOSED SETPOINT2 terminals 1 COM and 2 RUN STOP When the switch is closed the controller OPEN SETPOINT1 12 PRESSURE DROP is in RUN mode output to motor is enabled When the switch is open the en os controller is in STOP mode output to motor is disabled MOTOR RUN STOP NC COM HAND AUTO This input allows the controller to run the motor at full speed ae without the use of a pressure transducer This input can be controlled by an OK NC ECOM external non powered switch Connect the contacts of a non powered external 18 RELAY2 COM FAULT NO switch to terminals 3 COM and 4 HAND AUTO When the switch is closed the controller is in HAND
23. mental rating integrity of the enclosure all openings must be closed by equipment rated 3 3R 35 4 4X 6 or 6P e Maximum Ambient temperature range 22 F to 122 F e Maximum Humidity 95 at 104 F non condensing Safety Instructions Section 1 Important Read all safety information prior to installation of the Controller Note This is a SAFETY ALERT SYMBOL When you see this symbol on the controller pump or in this manual look for one of the following signal words and be alert to the potential for personal injury or property damage Obey all messages that follow this symbol to avoid injury or death A DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a potentially hazardous situation which if not avoided may result in minor moderate injury CAUTION Used without a safety alert symbol indicates a potentially hazardous situation which if not avoided could result in property damage gt P 2 Indicates special instructions which are very important and must be followed All operating instructions must be read understood and followed by the operating personnel Goulds Pumps accepts no liability for damages or operating disorders which are the result of non compliance with the oper
24. mode While in HAND mode the RUN STOP input is used to start and stop the motor and the pressure transducer input is ignored When the switch is open the controller is in AUTO mode While in AUTO mode the controller uses the pressure transducer feedback to control the speed of the motor INPUT and 24V These terminals are the transducer feedback and transducer power supply Connect the white lead from the transducer cable to terminal 6 INPUT Connect the brown lead from the transducer cable to terminal 7 24V Connecting the drain bare wire to the chassis allows grounding of the case of the pressure transducer The controller is configured with a 300 PSI 4 20mA output pressure transducer ANALOG OUTPUT This output is a 4 20mA signal based on motor speed 4 0Hz 20mA 60 2 and be connected to external monitoring or external control devices Connect terminal 10 ANALOG OUTPUT to the 4 20mA input of the external device Connect terminal 9 COM to the negative side of the current loop on the external device The external device must an input resistance impedance in the range of 45Q to 2500 The maximum output voltage is 24V SP2 SP1 This input allows the system to operate at one of 2 pressure settings This input can be controlled by an external non powered switch Connect the contacts of a non powered external switch to terminals 5 COM and 11 SP2 SP1 When the switch is closed pressure set point 2 is enabled preset
25. nal block labeled T1 U T2 V T3 W GND Connect ground wire to the terminal labeled GND Connect the other phase leads to T1 U T2 V and T3 W For CentriPro Motors connecting T1 U to Red T2 V to Black and T3 W to Yellow will give the correct rotation Danger NYT The controller has high leakage current to ground The output terminals marked GND must be directly connected to the motor ground Failure to properly ground the controller or motor will create an electrical shock hazard Input Power Connections Make sure disconnect switches or circuit breakers are securely the OFF position before making this connection Run the input power wires from the fused disconnect through metal conduit to the bottom voltase _ of the controller Use metal conduit and metal conduit connectors Size the conduits according to the NEC CEC or local codes Use the wire sizing chart in the appendix to determine the size of the input power wires Connect the conduit and insert the wires into the far left opening on the controller Connect wires to the INPUT terminal block Connect the ground wire to the terminal labeled GND For three phase input connect the input phase wires to L1 L2 and L3 For single phase input connect the input wires to L1 and L3 If single phase input is used the motor overload switches must be set to 50 or lower Caution The wire used for input power connections on models 5
26. nd fans and do not set anything on the units Warning The controller access cover should always be securely fastened to the control box due Hazardous to the dangerous voltage shock hazard inside the unit A lock can be used to prevent unwanted entry Power Supply and Wiring Section 6 Power Supply Note Installation and maintenance MUST be performed by properly trained and qualified personnel Always follow the National Electrical Code NEC or Canadian Electric Code CEC as well as all state local and provincial codes when wiring the system The type of transformer and the connection configuration feeding a drive plays an important role in its performance and safety The following is a brief description of some of the more common configurations and a discussion of their virtues and shortcomings Always ask what type of power system the site has before sizing the drive Delta Wye with grounded Wye neutral This configuration is one of if not the most common It provides rebalancing of unbalanced voltage with a 30 degree phase shift Depending on the output connections from the drive to motor the grounded neutral may be a path for common mode current caused by the drive output Power Supply and Wiring Section 6 continued Delta Delta with grounded leg Another common configuration providing voltage rebalancing with no phase shift between input and output Again depending on the out
27. ntrollers For Frame Sizes 2 and 3 Controllers Connecting the Wye secondary neutral to ground through a resistor is an acceptable method of grounding Under a short circuit secondary condition any of the output phases to ground will not exceed the normal line to line voltage This is within the rating of the MOV input protection devices on the drive The resistor is often used to detect ground current by monitoring the associated voltage drop Since high frequency ground current can flow through this resistor care should be taken to properly connect the drive motor leads using the recommended cables and methods In some cases multiple drives on one transformer can produce a cumulative ground current that can trigger the ground fault interrupt circuit Open Delta consult factory This type of configuration is common on 230 volt systems From time to time it may be encountered where only single phase power is available and three phase power is required The technique uses two single phase transformers to derive a third phase When used to power a drive this configuration must be derated to about 70 of the single phase rating of one transformer This system provides poor regulation and it is possible that only the two line connected phases will provide power In this case the drive must be derated to 50 of its rating Ex A 20 HP 230 volt drive now becomes a 10 HP 230 volt drive Power Supply and Wiring Section 6 continued Single
28. or the minimum allowable wire size for each controller Note that these wire sizes are not adjusted for voltage drop due to long cable lengths Refer to the wire sizing chart in the appendix to determine the maximum length for the input cable Refer to the motor manual for maximum output cable length The maximum recommended voltage drop on both input and output cable combined is 5 Standard wire sizing charts give maximum cable lengths for only input or output cables Because of this the lengths given in the table must be adjusted so the total voltage drop does not exceed 5 For example if the input wire sizing chart in the appendix gives the maximum length of 400 and only 100 is used then only 25 of the total voltage drop 1 25 drop is used The maximum output cable length read from the motor s wire sizing chart must then be adjusted to 75 of its value so that the maximum voltage drop of 5 is not exceeded Use only fast acting class T fuses The wire used for the input power connections on models 5 020300 and SPD20300F must have a temperature rating of 90 C minimum All other wire must be rated 75 C minimum The chart below shows the recommended sizes for wire and fuses for each controller Note that the wire sizes were not adjusted for voltage drop due to long cable lengths Maximum Ambient Temperature gt 20 C
29. p was purchased and furnish complete details regarding the claim The distributor is authorized to adjust any warranty claims utilizing the Goulds Pumps Cus tomer Service Department The warranty excludes a Labor transportation and related costs incurred by the dealer b Reinstallation costs of repaired equipment Reinstallation costs of replacement equipment d Consequential damages of any kind and 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 Pumps and the dealer in purchases consignments or contracts for sale of the subject pumps 2 Dealer means any individual partnership corporation association or other legal relationship which engages in the business of selling or leasing pumps to customers 3 Customer means any entity who buys or leases the subject pumps 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 GOULDS PUMPS Goulds Pumps AquaBoost II and the ITT Engineered Blocks Symbol are registered trademarks and tradenames of ITT Corporation SPECIFICATIONS ARE SUBJECT TO CHAN
30. put connections from the drive to motor the grounded neutral may be a path for common mode current caused by the drive output Ungrounded secondary Grounding of the transformer secondary is essential to the safety of personnel as well as the safe operation of the drive Leaving the secondary floating can permit dangerously high voltages between the chassis of the drive and the internal power structure components In many cases this voltage could exceed the rating of the EMC filter and input MOV protection devices of the drive causing a catastrophic failure In all cases the input power to the drive should be referenced to ground If the transformer can not be grounded then an isolation transformer must be installed with the secondary of the transformer grounded Warning If a power system with an ungrounded secondary is used the line to ground EMC filter Hazardous components and line to ground MOV protection must be disconnected or damage to the controller can result To remove the line to ground EMC filter components locate the jumper shown below The jumper is on the left hand side of the controller on the main board Move to the disconnected position shown below Power Supply and Wiring Section 6 continued To remove the line to ground MOV protection locate the jumper shown below The jumper is located between the input and output terminal blocks on the main board Move to the position shown For Frame Size 1 Co
31. r the factory Before connecting power to the controller measure the line to line and line to ground voltage from the power source The line to line voltage must be in the range of 195Vac to 265Vac 230V 15 for 230V models and 391Vac to 529Vac 460V 15 for 460V models The maximum phase to phase imbalance is 3 If the phase to phase imbalance is greater than 3 then an isolation transformer may be necessary The line to ground voltage must be less than 110 of the nominal 230V or 460V line to line voltage If the line to ground voltage is not in this range the EMC filter and MOV components may need to be removed see section on Ungrounded secondary transformers or an isolation transformer with a grounded secondary may be necessary If an isolation transformer is used the best choice is ONE three phase six winding transformer A delta primary is best for third harmonic cancellation A wye secondary avoids circulating current problems and provides the very desirable option of grounding the secondary neutral for minimum voltage stress and ripple to ground The transformer should have a KVA rating at least 1 1 times the maximum connected HP A K factor of 6 is sufficient if transformer impedence is greater than 2 A K Factor of 5 is sufficient if transformer impedence is greater than 3 The transformer manufacturer may provide derating for non K Factor rated transformers to operate at the drive produced K Factor levels
32. set 7 Blinks Temperature This fault can be caused by e High ambient temperature The maximum ambient temperature rating is 122 F 50 C Low ambient temperature The minimum ambient temperature rating is 22 F 30 C This fault will be displayed if the ambient temperature is greater than 122 F 50 C or less than 22 F 30 C Do not install the controller where it will be exposed to direct sunlight Check for a fan failure The fans on the back of the controller will turn on only when needed The fans will turn on when the motor is running and the heatsink temperature reaches 104 F 40 C Troubleshooting Red Light Codes continued Flashes Controller Status 8 Blinks Over Voltage This fault can be caused by e High input voltage This fault will be displayed if the phase to phase input voltage is greater than 275V for 230V units and 560V for 460V units 9 Blinks Motor Overload This fault can be caused by e Mechanical binding from debris in pump Electrical failure of the motor Incorrect setting of Motor Overload Setting switches e Incorrect rotation The controller will protect the motor from over current by limiting the current applied to the motor The current limit is set according to the Motor Overload Setting switches This fault is displayed if the output frequency is reduced to limit the current to the motor by more than 10Hz for 5 minutes Controller Dimensions
33. terminal 18 RELAY2 COM When the system is faulted terminal 16 RELAY2 NO will be connected to terminal 18 RELAY2 COM and terminal 17 RELAY 2 NC will be open The relay rating is 250Vac 5 amps maximum Troubleshooting Section 9 General The S Drive and Aquavar SPD drive are self diagnosing controllers If a problem occurs observe the Status Code Indicator Light on the front of the unit No Status Code Indicator Light means either no or low input voltage less than 140Vac Danger NOTAT Status Code Indicator Light is not a voltage indicator Always turn off disconnect switch and circuit breaker and wait 5 minutes before servicing High voltage may still remain on controller Refer to the status code label on the side of the controller access cover to diagnose system errors See the following diagram STATUS CODES GREEN LIGHT CODES Red Flashes Fault Code Restart Action Constant Replace Controller Controller will not restart Power must be reset to clear the fault 2 Blinks No Water Loss of Prime Controller will restart automatically according to the No Water Restart Time switches switches 3 amp 4 of bank 2 3 Blinks Sensor Fault Controller will restart automatically when the sensor signal is within the valid operating range STANDBY BLINKING PUMP RUNNING z n 4 gt 2 ORANGE LIGHT CODES CONSTANT UNDER VOLTAGE 4 Blinks Pump or Motor Bound Controller w
34. w or the system is indicating Motor Overload error check the motor rotation direction Turn the breaker disconnect switch to the off position and wait 5 minutes Switch any two leads on the controller output T1 U T2 V or T3 W Turn the breaker disconnect switch to the on position Observe pressure and flow If the pressure or flow still seems low check plumbing For CentriPro Motors connecting T1 U to Red T2 V to Black and T3 W to Yellow will give the correct rotation Note It is possible for the pump to maintain constant pressure with a low flow a high suction head even if the pump is rotating backwards While the pump is running use an amp probe on one of the output power leads connected to the motor and compare the current draw between the two rotation directions The lowest current reading indicates the pump is running in the correct direction System Status The status indicator light displays the status of the controller A constant green status code indicates that the pump is in standby mode pump not running A blinking green status code indicates that the pump is running A constant orange light indicates the input voltage is low A blinking or constant red light indicates a problem with the controller or system Refer to the access cover side panel for a list of status codes See Section 9 for more details Danger MY The status code indicator light is not a voltage indicator Always turn off disconnect switch and c
35. warranty The minimum frequency must be set to 30Hz for submersible applications Setting the Carrier Frequency Switch Switch 2 from bank 3 controls the carrier frequency For model numbers without the F suffix the switch can be used to change the output carrier frequency to avoid audible noise issues in above ground applications For model numbers with the F suffix this switch is disabled and the carrier frequency is always set to 2 kHz Starting the System Section 7 continued Setting the Pressure When power is applied the pump will start and the system pressure will increase to the factory preset pressure 50 PSI if SP1 is enabled and a 300 PSI sensor is used or 75PSI if SP2 is enabled and a 300 PSI sensor is used After the pressure has stabilized use the increase INC or decrease DEC pressure adjust pushbuttons to adjust the pressure setting Push and Hold the increase or decrease pushbutton until the desired pressure setting is reached The new pressure setting will save when the system goes into standby mode solid green light pump off Pressure set point 1 will be adjusted and stored when the SP2 SP1 switch input is open Pressure set point 1 is preset to 50 PSI when used with a 300 PSI transducer Pressure set point 2 will be adjusted and stored when the SP2 SP1 switch input is closed Pressure set point 2 is preset to 75 PSI when used with a 300 PSI transducer Motor Rotation Direction If the pressure flow seems lo
36. yed if the output current exceeds 125 of the controller rating The controller will attempt to restart 5 times If the condition persists the controller will lock out and will need to be reset Verify the error by turning power to controller off for 5 minutes and then on Pump Motor Wiring must be checked if fault persists 5 Blinks Short Circuit This fault can be caused by Electrical failure of the motor e Electrical failure of wiring between controller and motor This fault will be displayed if the output current exceeds 150 of the controller rating Verify the error by turning power to controller off for 1 minute and then on If error persists motor and wiring between controller and motor must be checked Turn power off for 5 minutes Remove the three motor wires from the terminal block Check output wiring and motor for shorting phase to phase and phase to ground Refer to motor s manual for information on resistance readings and megger readings 6 Blinks Input Phase Loss This fault can be caused by Disconnected input power phase Incorrect Motor Overload Setting switches When using single phase input power the Motor Overload Setting switches must be set to 50 or lower For three phase input operation this fault will be displayed if the phase to phase input voltage is more than 25 lower than the nominal The controller will attempt to restart 5 times If the condition persists the controller will lock out and will need to be re
37. ystem and the pressure setting has been reached or the RUN STOP input is set to STOP open switch Blinking Pump Running Flashing Green Light indicates the pump is running Troubleshooting Orange Light Codes Flashes Controller Status Constant Low Input Voltage Constant orange light indicates the system input voltage is low For 230V units the orange light will be indicated when the input voltage is between 140Vac and 170Vac For 460V units the orange light will be displayed when the input voltage is between 140Vac and 310Vac x T Red tight codes Constant Controller Error Internal controller fault The controller may be internally damaged Red Verify the error by turning power off waiting 5 minutes then apply power If the error persists replace controller No Water Loss Of Prime This fault can be caused by Water supply level in well falls below suction inlet of pump e Plugged suction screen Restriction in pipe between pump and pressure sensor Air bound pump Deadheaded pump pump running against a closed valve Filling long irrigation lines on start up Incorrect setting of Motor Overload Setting switches In systems where the motor operates at less than Service Factor Amps the controller may show a false No Water Loss of Prime fault Reducing the motor overload setting will eliminate the false readings If problem persists please verify supply capacity The controller will automati
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